Answers for industry.

SIMINE for conveyorsThe information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the prod- ucts. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

Subject to change without prior notice 09/12 Order No.: E20001-A230-T195-X-7600 DISPO 21662 SCHÖ26136 GD.LD.VM.MIMI.52.2.02 GB 120265 WS 06122.0 Printed in Germany © Siemens AG 2012

Siemens AG Industry Sector Drive Technologies Mining Technologies Schuhstraße 60 91052 ERLANGEN GERMANY

More information:www.siemens.com/mining

Contact:mining@siemens.com

For more information and technical descriptions, click on the “Support” navigation point on our Website.

siemens.com/mining

2 3

SIMINE for conveyors generates:

• High system availability

• Low operating and energy costs

• Low maintenance costs

Your challenge:Moving mountains reliably and efficiently

To meet worldwide demands for raw materials, under-ground mines and open pit mines are being established in increasingly remote areas. Every year, billions of tons of bulk materials such as ore, coal, copper ore, and min-ing waste have to be moved – powerfully, reliably, and efficiently.

Comprehensive requirementsBelt conveyors operate under the harsh-est conditions, often far removed from centers that provide replacement and spare parts. To operate efficiently, it is essential that these conveyors remain failure-free, a factor that in turn depends on high availability and reliability. High availability coupled with ease of main-tenance must ensure a long service life, which is possible only if all the electro-tech nical components and mechanical elements are perfectly coordinated.

More than just technologyBesides production-oriented concerns, mine operators must increasingly consider ecological aspects as well, including compliance with emissions guidelines and maximum energy effi-ciency wherever possible. The appropri-ate fuel-efficient drives not only reduce energy costs but also reduce the carbon footprint.

Mines subsist on moving raw and bulk material. This makes conveyor solutions business critical in terms of performance and availability.

4 5

Our solution:Comprehensive belt conveyor expertise from a single source

Where it all fits togetherModern belt conveyor systems place high demands on the equipment used. Seamless interaction between the indi-vidual components – above all between electrical and mechanical components – is a basic requirement for the safe, opti-mal operation of a belt conveyor. Based on our many years of experience in these areas Siemens developed SIMINE as a comprehensive concept for belt convey-ors. Combined with SIMINE, we cover the entire life cycle of the belt conveyor and its components, offering a complete, broadly based range of belt conveyor products.

Customized solutionsSiemens specialists are available to assist you from the planning phase, construc-tion, and commissioning to service and maintenance.

On the following pages the most impor-tant products, systems, and solutions for belt conveyors will be presented. Of course, this can be no more than a brief introduction, but we’ll naturally be glad to meet with you individually at any time to discuss your own particular on-site requirements.

Siemens provides belt conveyor solutions for the mining industry from electrical drives to instrumentation. And we are one of the few international companies with sufficient know-how to combine all the relevant compo-nents into a truly integrated over-all concept.

With its comprehensive portfolio, Siemens covers the entire life cycle of conveyors, thus ensuring produc-tivity at all times.

SIMINE

Sensors, measurementCommunication

Power distribution

Converter technology

Motors

Automation/control

Mechanical drive components and

systems

Service

6 7

Drive systemsThe right power for every application

Each mine is different. The demands on belt conveyors also differ depend-ing on the material being conveyed and the particular landscape. Drives must be sufficiently versatile. Siemens offers both conventional constant-speed drives and variable-speed drives.

Conventional drives – quickly up to speedIn the case of conventional drive sys-tems, the belt conveyer is operated at a constant speed. Asychronous motors executed as slip ring motors or squirrel-cage motor.

In connection with a gear unit, they deliver the necessary speed and the necessary torque to the belt conveyor.

The slip ring motor’s start up behaviour is determined by the starting resistors, which are switched on in stages until the motor and belt conveyor reach their rated speeds, or with liquid starters.

Drive systems with a squirrel-cage motor use modern hydraulic couplings. At start up, the motor is practically load-free and achieves its rated speed very rapidly.

As the coupling halves slowly fill, the belt conveyor accelerates until it reaches its rated speed.

Modern drives – flexible and efficientModern drive systems use variable-speed (speed-controlled) drives. Asynchronous motors executed as squirrel-cage motor are combined with a gear unit.

For belt conveyors that require several megawatts of power, drive systems without gear units – that are, direct drives with synchronous motors – are also used.

Both drive systems employ frequency converters that can adapt drive behav-iour to various operating conditions. Proven control options make it possible to adjust the interaction between a drive system and belt conveyor precisely as needed. Such control algorithms permit:

• Simultaneous starts and stops of the entire conveying routes

• Load sharing for multi motor and multi pulley belt conveyors

• Reduced slip between drive pulleys and belt during starting and stopping

• Smooth starts and stops to reduce wear and tear on mechanical components

Whether you are looking for con-stant or variable speed drives, Sie-mens offers the right solutions.

Conventional drive systems,fixed speed

Modern drive systems,speed-controlled

Asynchronous motorResistance starter

Asynchronous motorHydraulic coupling

Asynchronous motorFrequency converter

Synchronous motorGearless drive

Brake

VFC

Transformer

Synch. motor

Belt drive

pulley

CouplingBrake

VFC

Transformer

Asynch. motor

Coupling

Gear box

Belt drive

pulley

Resistor

CouplingBrake

Starter

Asynch. motor SRM

Coupling

Gear box

Belt drive

pulley

Hydraulic Coupling

Brake

Starter

Asynch. motor

Coupling

Gear box

Belt drive

pulley

SRM VFC

Slip Ring Motor Variable Frequency Converter

8 9

MotorThe heart of your belt conveyor solutions

Thanks to our various type series, you can select the right motor for each operating mode required, whether constant speed, variable, or direct drive. Our robust, reliable motors are the perfect basis for your customized belt conveyor as well as for moderniz-ing existing systems.

For maximum availabilityIn addition to tried-and-tested geared drives, Siemens also produces gearless synchronous motors, which, when inter-acting with a corresponding converter, generate the requisite speed and torque and transfer it to the belt conveyor’s drive drum. Our direct drive systems are individually configured for each applica-tion in terms of speed, torque, and other requirements.

Economically attractiveIn addition to providing a solution that is optimally matched to individual require-ments, our direct drives also offer con-crete economic advantages. Elimination of the gear unit means elimination of the majority of moving parts, thereby sig-nificantly reducing wear, extending the service life, lowering maintenance costs, and increasing overall availability and productivity.

We offer our customers all the com-ponents needed for an efficient trans-mission of power from the motor to the drive shaft of the belt conveyor, either as individual elements or as a complete drive system.

Gear unitsProven FLENDER gear units are ideally suited to the requirements of belt con-veyors and guarantee the reliable opera-tion of the drive system.

Drive unit for belt conveyor with gearbox B3SH26, with external oil cooler OLGE 09/V2, operation torque 439.220 Nm, power rating 2052 kW, input speed 980 rpm, transmission ratio 22,4

The right gear unit is available for every drive task. Thanks to extensive standard-ization, all the components are perfectly coordinated, which not only increases reliability but also improves efficiency – with distinct cost advantages compared to solutions that are not coordinated.

CouplingsCouplings form the link between motors and gear units, and often between gear units and drive drums as well. The con-nection permits a reliable transmission of speed and torque, and can also – for example, by means of hydraulic cou-plings – influence the start up behavior of the entire drive system.

We supply high-quality FLENDER cou-plings and offer a wide range of flex-ible, highly flexible, torsionally rigid and hydrodynamic couplings in a number of different sizes and versions. Some FLENDER coupling series are mainte-nance-free, while others have long maintenance intervals. Wearing parts can be easily replaced and are available worldwide, thus reducing downtimes to a minimum.

Geared motorsGeared motors combine motors and gear units in an extremely compact structure. For power ranges up to 200 kW and torques up to 20,000 Nm, versions are available with helical, flat, or bevel heli-cal gear units.

Complete drive systemThe individual components are combined into complete drive systems for belt con-veyors. Our complete solutions are con-figured to meet your exact requirements for the specific application. Thanks to the high quality of our components, we build reliable, efficient, economical drive systems.

Conveyor Drive – FLENDER Self Aligning SystemTM as integrated drive train with SIEMENS Motor, input coupling, gearbox and ouput flange

Mechanical componentsEverything for the efficient transmission of power

The heart of every conveyor is its motor. Siemens makes it beat

reliably.

With its comprehensive portfolio Siemens ensures the efficient power transmission.

Series Power Voltage Type Operating typekW

N-Compact IEC Standard

200 – 1,000 400 V – 690 V asynchronous drive – squirrel-

cage rotor

for controlled drive systems

H-Compact IEC

200 – 3,000 690 V – 11 kV asynchronous drive – squirrel-

cage rotor

for constant speed as well as for controlled drive systems

Vario 315 – 1,900 400 V – 11 kV asynchronous drive – slip ring

rotor

for constant speed

Low speed synchron motor

2,000 – 10,000 690 V – 13.2 kV synchronous motor

for speed controlled drive systems

10 11

Converter technologyConverters for variable drive systems

For variable-speed drives to oper-ate at maximum efficiency, they must have the right frequency con-verter. Siemens’ SINAMICS family offers proven converter technology

for a variety of tasks. Depending on requirements, services range from the simple movement of a machine to open- and closed-loop control of com-plex motion sequences.

Efficiency is always a question of control. SINAMICS is our answer.

Medium-voltage converters from the world market leader As the undisputed number-one supplier of MV drives, Siemens sets worldwide standards in terms of installed capacity, market share, and breadth and depth of offerings. For belt conveyor solutions, we offer various voltage source convert-ers, load-commutated inverters, and cycloconverters. In addition to simple air-cooled converters, also water-cooled models for the higher power ranges are available.

Low-voltage converters for maximum flexibilityOur low-voltage converters are suitable for all performance levels and feature maximum flexibility, functionality, and engineering comfort. Converters in this range can operate in two- and four-quadrant mode.

Whether medium or low voltage – Siemens delivers the converter that meets your needs.

Converter LV Converter MV

Type Power Voltage Type Apparent power Voltage

kW V MVA kV

G130 75 – 800 380 – 690 GM150 0.8 – 21 2.3 – 4.16

G150 75 – 1,500 380 – 690 SM150 3.4 – 31.5 3.3 – 4.16

S120 1.6 – 4,500 380 – 690 ROBICON Perfect Harmony 0.15 – 120 2.3 – 13.8

Dynavert T 2.2 – 6,600 230 – 690 SL150 3 – 25 1 – 4

Convert types and functional range (power, voltage) specialized for mining

12 13

Power distributionOver 160 years of power know-how

Every belt conveyor needs power, which includes the corresponding infrastructure of medium- to low-volt-age power distribution. As the world’s leading provider in the area of power distribution and with over 160 years of experience, we contribute to the

sustainable and responsible use of electrical energy. Our comprehensive portfolio for medium- and low-voltage power distribution makes it possible to implement intelligent power networks and thus lay the foundation for indus-trial applications.

Reliable switchgear for every situationThis includes reliable connection on every distribution level, for every per-formance range, for every type of appli-cation, and for every system type.

Siemens has developed product series that are exactly in line with the specific requirements. Our SIVACON models, for example, have stood the test at the low-voltage level. With a switching capacity of up to 7,000 A, they offer sufficient reserves to guarantee a safe, flexible, and cost- effective power supply.

On the medium-voltage level, the SIV-ACON models are supplemented by our NXPLUS C and 8DA10 switchgear.

Our unique transformer portfolioFor over 100 years and in more than 100 countries, Siemens transformers have been synonymous with top quality. Our expertise as a technology leader enables us to provide the right trans-former for every task, from large power transformers to compact distribution transformers. Above all, our GEAFOL cast-resin transformers have seen decades of successful use wherever com-pact designs are required that also meet the highest safety standards. GEAFOL has none of the limitations of liquid-immersed transformers while retaining their operational reliability and long ser-vice life.

The switchgear and transformer solutions from Siemens meet the needs of mine operators at any point.

When it comes to power distribu-tion there is hardly any competitor with a comparable track record like

Siemens.

Siemens medium voltage switchgear NXPLUS CGEAFOL transformers

14 15

SIMINE Automation is the result of Siemens’ unique experience in both automation technology and conveyor expertise. Its reliability and efficiency has been proven in numerous installa-tions around the world.

Minerals Automation StandardThe Minerals Automation Standard pro-vides a comprehensive library focused on mining-specific requirements and is highly scalable from single equipment like conveyors up to automation of com-plete mine operations. With its modern architecture based on SIMATIC PCS 7 the Minerals Automation Standard is the ideal basis for future-proof and economi-cal solutions for the mining industry. Open communication standards such as ethernet and industrial WLAN are the basis for easy communication to the cen-tral control level.

Sensors and communicationsA wide range of instrumentation, sensors and communication solutions include high precision belt scales, flow meters, level instruments, industrial switches, and WLAN products that meet the indus-trial requirements to operate in harsh mining conditions.

Maintenance and diagnosticOur standardized solutions offer enhanced diagnostic features to reduce unplanned shut down times to a mini-mum. Siemens’ devices are available with intelligent diagnostics and condi-tion monitoring. The valuable informa-tion is available for local diagnostics and Plant Asset Management via remote connection.

Industrial automationSiemens offers a complete range of auto-mation products for the mining industry starting with the world market leading PLC SIMATIC S7, a comprehensive solu-tion for a plant wide DCS with SIMATIC PCS7 and the library Minerals Automa-tion Standard, Industrial PC, and SIMATIC IT the MES solution from Siemens.

Belt weighingWith Milltronics, Siemens offers systems for belt weighing, which feature simple mounting and low maintenance require-ments – isolated from lateral forces, with minimal hysteresis and maximum linear-ity. Together with our high-resolution speed sensors you can achieve a high measuring accuracy and repeatability.

Siemens Automation for conveyors:

• A complete field instrumentation and automation portfolio for mining

• Automation for vendor packages inclu-ding seamless integration into the automation of a complete mine

• Advanced control packages for speed and volume control from single convey-ors to complex conveyor systems

• Advanced stockyard management sys-tems from precise material tracking to 3D stockpile management including au-tonomous operation solutions

Siemens Automation products and solutions for conveyors are designed

• to increase through-put and product quality,

• to minimize maintenance and wear and tear,

• to protect man and conveyor during continuous operation,

• for operation under harsh environmen-tal conditions,

• to comply with environmental regulati-ons, and

• to control and minimize energy consumption.

AutomationBrings intelligence and connectivity to your conveyor

SIMINE Automation products and solutions for conveyors help you to

engineer, operate, and maintain your conveyor efficiently and

reduce the project risk due to stan-dardized and out of the box

solutions.

16 17

InstrumentationKnow what’s happening

Technology-based servicesFor a greater competitive edge

Optimal conveyance of bulk materi-als depends on having the very latest information. A comprehensive net-work of measuring points and sensors is required to ensure the necessary information density and quantity.

Siemens offers a comprehensive port-folio of Process Instrumentation. Our solutions cover the most diverse appli-cations and requirements.

With a track record for consistent performance in harsh environments, Milltronics conveyor belt scales combine simple, drop-in installation, low maintenance and repeatable accuracy for pro-ductive operations.

Belt weighingSiemens offers systems for belt weigh-ing, which feature simple mounting and low maintenance requirements – iso-lated from lateral forces, with minimal hysteresis and maximum linearity.Together with a high-resolution speed sensor high accuracy and repeatability are achieved. The belt scale data can be collected in a stand-alone integrator or seamlessly integrated in SIMATIC S7 with a SIWAREX weighing module.

Point level measurement for all applicationsSiemens level switches are built to resist the most demanding conditions in the mining industry. Various technologies, such as non-contacting ultrasonics, vibrating forks, paddle switches, tilt switches and capacitance technol-ogy allow the best solution for every application.

Continuous level measurementContinuous level measurement monitors dynamic processes. These measurements are transmitted as an analogue signal or digital value. For this purpose, Siemens is a world leader in solids level measure-ment and offers numerous solutions based on ultrasonic, radar, capacitance, gravimetric, and hydrostatic technolo-gies.

SITRANS LR560 2-wire, 78 GHz FMCW radar level transmitter for continuous monitoring of solids in silos to a range of 100 m (328 ft.)

Robust motion sensorsMonitoring moving equipment in a mine is essential for safe operation of the process. Siemens motion sensors are developed for the most demanding conditions and can monitor over-speed, under-speed or zero-speed of all kinds of conveyors. With a sensing distance of 100 mm, they can be installed in the most challenging installations.

Intelligent mine operation needs information. Siemens provides the

necessary measuring equipment.

Minimum downtime and the optimum use of staff and resources are key to sustainable success in industry. Siemens provides the basis for greater productiv-ity, flexibility, and efficiency with tech-nology-based services throughout the life cycle of an industrial plant – reliably, globally, and around the clock. In-depth technology and product knowledge as well as industry expertise within Sie-mens’ global network of experts ensure a considerable competitive edge.

Siemens offers far more than just prod-ucts and systems: A comprehensive range of services is available for the min-ing industry worldwide.

From the start-up, to the mine operation across the entire lifecycle for products and systems, Siemens provides industry services tailored to the mining needs.

Engineering support and technical con-sulting from Siemens assist customers with specialist expertise right from the beginning. In the start up phase of a mine operation, Siemens provides ser-vices and solutions, such as online and technical support.

For mining operations, the available operational support and maintenance services can be enhanced, e.g. by repair and spare parts services as well as field services. Furthermore, Siemens supports mine operators to face new challenges and changing conditions – with the necessary know-how and experience providing mine-specific technologies for modernization and optimization require-ments as well as energy and environ-mental features.

18 19

2010/2011 – 26 belt conveyorsfor Çöllolar Lignite Open Pit Mine, Turkey

Conveyor characteristics

Total length: 26 conveyors, 17.4 km

Capacity: 6,900 t/h and 9,350 t/h

Belt width: 1,800 mm

SolutionTotal installed power: 46,300 kW

Installation of drive systems consisting of Siemens motors, Fludex turbo couplings and Siemens-Flender gear boxes

1985 – Belt conveyor with gearless drive Solution Prosper Haniel Coal Mine, Germany

Conveyor characteristics

Length: 3.8 km

Capacity: 2,800 t/h

Belt speed: 5.5 m/s

Lifting height: 800 m

Solution 2 x 3,100 kW gearless drive systems, each consisting of a low-speed synchronous motor with cycloconverter

Gearless tandem drive located at the head

2010 – Coal conveyorLignite Open Cast Mine Reichwalde, Germany

Conveyor characteristics

Length: 13.5 km

Capacity: 6,000 t/h

Solution6 single belt conveyors consisting of totally 9 x 1,250 kW drive units and 9 x 900 kW drive units

Conveyor speed adjustable according to load requirements

1998 – Coarse ore conveyor systemMinera Los Pelambres, Chile

Conveyor characteristics

Length: 12.7 km

Capacity: 8,700 t/h

Solution3 single belt conveyors consisting of 10 x 2,500 kW drive units, each comprising of 1 squirrel-cage motor fed by 1 SIMOVERT ML voltage source converter 3,3 kV

Downhill conveyor, permanent generating

Our referencesMeasure us by what we do

2007 – 14 km conveyor linefor Neyveli Lignite Corporation, India

Conveyor characteristics

Total length: 8 conveyors, 14 km

Belt width: 2,000 mm

Belt speed: 5.4 m/s

SolutionThe conveyor system consists of 4 x 630 kW drive units

Conveyors with slip ring motors with resistance starters

Asynchronous motorResistance starter

Asynchronous motorFrequency converter

Synchronous motorGearless drive

Asynchronous motorHydraulic coupling

Brake

VFC

Transformer

Synch. motor

Belt drive

pulley

CouplingBrake

VFC

Transformer

Asynch. motor

Coupling

Gear box

Belt drive

pulley

Resistor

CouplingBrake

Starter

Asynch. motor SRM

Coupling

Gear box

Belt drive

pulley

Hydraulic coupling

Brake

Starter

Asynch. motor

Coupling

Gear box

Belt drive

pulley