At Schenck Process, we help mineral and mining processors maximize revenue, improve efficiencies and extract minerals in the most sustainable and economic manner.
Mining &Mineral Processing
» Trusted Reliability » Higher Performance » Maximum (I¿FLHQF\
02 Mining & Mineral Processing
Mining & Mineral Processing 03
CHALLENGES WE ADDRESS: SUSTAINABILITY EXPECTATIONS,
ENERGY CONSUMPTION, LOW GRADE DEPOSITS,
SITE DOWNTIME, RECOVERY RATES, REMOTE SITES
YOUR WORLDWIDE MINERAL PROCESSING PARTNER
HOW WE ADD EXTRA VALUE
SITE SUPPORT
Our highly experienced engineering teams, will travel far and wide to provide a variety of services, including: » On-site engineering » Support with installation and operation » Emergency breakdown call-out
At Schenck Process, we are a global engineering leader of material handling systems. We manufacture world-class solutions, high performing products and enable customer advancements through smarter technologies. Alongside mining, we support all material handling industries. Our mission is to Make Processes Work
MATERIAL TESTING We offer material and process testing in a number of global Technology Centres. Through many years of in-depth analysis, SAD=RAC=PDANA@=OECJEł?=JP=IKQJP of knowledge, which helps us optimize processes and customize the design of all our solutions, to suit client’s applications and desired outcomes. All test centres are equipped to allow for remote ‘digital’ involvement with customers, or you are welcome to visit and witness the testing LNK?AOOłNOPD=J@
OUR SOLUTIONS
» Truck and train loading » Vibrating screens with condition monitoring » Batch & continuous feeders » Weighing solutions » Continuous dense & dilute phase conveyor systems » Mechanical conveyors » Pulverising mills » Sifters, mills & mixers » Plant & logistical control systems » Bulk bag loading & unloading
» Repair and refurbishment » Upgrades and spare parts
EFFICIENT, RELIABLE PROCESSING
PROJECT MANAGEMENT For the supply of new equipment, our project management teams become an extension of your business. From start to łJEOD KQNPA=IO=NA@A@E?=PA@PKIAAPEJC your business goals.
We help mineral processors maximize NARAJQA EILNKRAABł?EAJ?EAO=J@ATPN=?P minerals in the most sustainable and economic manner. Our solutions combine decades of expertize and knowledge, to help clients overcome the challenges they face.
» Material and process testing » Extensive site services » Stress-free project management
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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Mining & Mineral Processing 05
“We see too often, the wrong feeder and
O?NAAJEJCIA@E=łPPA@EJPKKQN Vibrating Screens, which literally chews up their life-span. Through consultation, our Engineers can easily prevent that”. Paul Donovan,
Schenck Process Global Engineer
DIGITAL REMOTE AFTERMARKET SERVICES
ASSET MANAGEMENT
We’re here to help you achieve recovery of the highest purity. Economically, LNKłP=>HU=J@ABł?EAJPHU Partnering with a supplier of mineral processing equipment needs to be a long-term relationship. That’s why our teams are full entrenched into the belief that our solutions are an investment, which we must help clients to achieve the best possible results from, over the longest conceivable period. Through an extensive Asset Management Program, our mineral processing teams are trained to help you accomplish this.
PROGRAM BENEFITS
Digital support from our global Aftermarket team, means that no matter your location, an engineer can be available to help you. To contact one our team please call: +49 6151 1531 1531 , or email: service-eu@schenckprocess.com
» Extensive site support, for optimal KLAN=PEKJABł?EAJ?UKB=HH=OOAPO » Advice on integrating solutions & recommend processes which generate improved site performance » Maintenance planning on all relevant equipment » Feeder & screen pairing, for longstanding machine longevity
PHONE SUPPORT
REMOTE CONNECTION Remote in-depth analysis and support of your personnel
24/7 expert availability
» Support on monitoring AI algorithms shown through condition controls h0LA?Eł?=PEKJKBPDA?KNNA?PHU sized, robust screening media & other spare parts
VIDEO SUPPORT Consultation including video streaming and desktop access
MIXED REALITY INTERACTION Access to devices including augmented reality information exchange
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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Mining & Mineral Processing 7
MINERAL PROCESSING CAPABILITIES
MINERAL PROCESSING SOLUTIONS
INCREASED EFFICIENCY » Improved quality & throughput » Increased uptime HIGHER PERFORMANCE » Designed for volume » Durability; long-life performance » Bespoke for each project
» VIBRATING SCREENS Read more >> » CONDITION MONITORING Read more >> » FEEDERS Read more >> » WEIGHING Read more >> » TRAIN LOADING Read more >> » RAIL WEIGHING & AUTOMATION Read more >> » SPARES Read more >> » SERVICES Read more >>
For mineral processing, Schenck Process solutions will maximize recovery, generate ABł?EAJ?EAO=J@DAHLKLPEIEVAOEPANARAJQA Through adopting smarter and more ABł?EAJPPA?DJKHKCEAO SAAJ@A=RKQNPK enable the successful recovery of a variety of minerals, including:
Designed to achieve the best results, our extensive solutions for mineral processors, ?KRANA=?DOP=CA OP=NPPKłJEOD4DAPDAN it be a full system, stand-alone equipment or machine upgrade, Schenck Process can support you through all these options.
RELIABILITY » Lowmaintenance with real-time remote monitoring » Less wear and high availability SUSTAINABILITY » Lower energy consumption » Solutions enabling a lower Co 2 footprint
» GOLD
» LIMESTONE Read more >> » COPPER Read more >>
Read more >>
» IRON ORE
Read more >>
» COAL
SAFETY » Operator-safety-features » Low noise emissions
Read more >>
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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Mining & Mineral Processing 9
GOLD
GOLD
1DACKH@IEJEJCEJ@QOPNUD=OOAAJOECJEł?=JPCNKSPDEJNA?AJPUA=NO L=NPHU@QAPKPDA variability of what gold is now used for, as well as changes in exploration.
Schenck Process vibrating screens and feeders are core to our offering for the extraction and recovery of gold and applications:
The preferred process for modern gold >AJAł?E=PEKJEO?=N>KJHA=?DEJCCKH@ extraction. It involves adding activated carbon to the pulp, leaching and adsorbing gold at the same time. Critical to these processes are a number of Schenck Process solutions.
1DAR=HQAKBCKH@NACQH=NHUŃQ?PQ=PAO This presents mining companies with OECJEł?=JPLNAOOQNAPKAJOQNAKLAN=PEKJ and energy consumption costs are continually minimized and production is optimized. The solutions we provide for the extraction of gold from ores, are designed to enable maximummineral recovery, across both wet and dry mining OEPAOSKNH@SE@A =OABł?EAJPHU=J@ economically as possible.
This exceptional range is also supported by: » Condition monitoring, which detects faults or wear on screens and feeders, before they break-down and become a costly problem. Read more >> » Weighing technologies which control R=NE=>HAŃKSN=PAO SEPDRANUA=OU maintenance. Read more >> » Precise, controlled systems for train loading. Read more >> » Rail weighing and automation solutions that specialize in weighing and monitoring, such as for rail track and load weighing. Read more >>
WET PLANTS » SAG mill discharge screen » Pebble crusher feeder » Trash screen » Loaded carbon screen » Carbon sizing screen » Carbon screens » Gravity concentrate screen
GOLDING MINING PLANTS WE SUPPORT:
DRY PLANTS » Primary crusher vibrating grizzly screen » Secondary and tertiary crusher screens » Secondary and tertiary screen feeders Read more on screens >> feeders >>
» SAG mills » Ball mills » Heap leach
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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GOLD (SAG MILL) PROCESSING
Pebble crusher ore bin
Vibrating feeder
Ore from pit
Gyratory crusher
Pebble crusher
Crushed ore
Primary cyclones
Trash screen
Secondary cyclones
Apron feeder
Apron feeders
To waste dump
MULTIBELT ® belt weigher
Stacker
Conveyor
Gravity screen
MULTIBELT ® belt weigher
Conveyor
Pre-leech thickener
Gravity separators
SAG mill
Barren carbon kiln screen
SAG mill screen
Intensive leach
Kiln
Ball mill
Loaded carbon screen
Ball mill discharge pump box
Gravity tailings pump box
Carbon sizing screen
Loaded carbon bin
Carbon safety screen
Carbon fines
Carb
on-in-leach
Electrowinning
Induction furnace
Acid wash vessel
Gold bar
Pregnant solution tank
Carbon strip vessel
Barren solution tank
Mill reclaim water
Tailings pond
Fresh water pond
Pump
Process step supplied by Schenk Process Group Green arrows denote PDA?=N>KJŃKS
Effiuent treatment plant
Treated water discharge
Gray arrows denote PDAKNAOHQNNUŃKS
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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GOLD (BALL MILL) PROCESSING
Crushed ore
Dump hopper
Top deck oversize
Primary jaw crusher
Apron feeder
Bottom deck oversize
Gri scr
zzly een
Screen
MULTIBELT ® belt weigher
Secondary cone crusher
Tertiary cone crusher
Ore bin
Carbon kiln screen
Trash screen
To waste dump
Kiln
Vibrating feeder
Loaded carbon screen
Pre-leech thickener
Carbon sizing screen
MULTIBELT ® belt weigher
Gravity screen
Milling circuit
Loaded carbon bin
Carbon safety screen
Captured carbon
Carbon-in-leach
Ele
ctrowinning
Induction furnace
Acid wash vessel
Knelson concentrator
Gold bar
Pregnant solution tank
ACACIA reactor
Hydro cyclone
Carbon strip vessel
Gold room
Barren solution tank
Gold bullion
Tailings pond
Fresh water pond
Pump
Mill reclaim water
Effiuent treatment plant
Treated water discharge
Process step supplied by Schenk Process Group Green arrows denote PDA?=N>KJŃKS
Gray arrows denote PDAKNAOHQNNUŃKS
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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IRON ORE
IRON ORE
Schenck Process mineral processing solutions prevail where others give up. Our systems and products for the recovery of iron ore are durable, indestructible and extremely reliable, ARAJQJ@ANPDAIKOP@EBł?QHP?KJ@EPEKJO&J?NA=OEJCLNKłP=>EHEPU=J@LNK@Q?PEREPUEOI=@A possible with Schenck Process:
Our unparalleled knowledge and experience in iron ore recovery, has seen many of the world’s largest producers rely on us for the design and engineering of mineral processing OUOPAIO PD=P@AHERANPDAIEJ?NA=OA@ABł?EAJ?EAO=J@DECDANLNK@Q?PEKJ
Before the ores are ready to be sent for processing into iron and steel making, =?KI>EJ=PEKJKB?NQODEJC=J@>AJAł?E=PEKJ P=GAOLH=?A PKAJOQNAPDAłJ=HI=PANE=H consists of the highest concentrates possible. These stages are where Schenck Process screens, feeders and weighing systems are crucial towards successful output.
Iron ore mining is imperative towards sourcing the primary rawmaterial used to make steel – a material that it used across many worldwide industries such as construction. Steel is strong, long-lasting =J@?KOPABł?EAJPPKLNK@Q?AI=GEJC it perfect for everyday products such as vehicles, bridges, utility machines, tools and more. It also means that demand and our requirement for it, remains high.
» Heavy duty vibrating screens for material separation, that also include crushing and de-watering capabilities. Read more >> » Condition monitoring for vibrating machines. Enabling the very best, long- term performance of screens and feeders, combined with remote performance analysis for planned maintenance. Read more >> » Vibrating feeders, that offer a variety of feed rates and reliable material weighing abilities. Read more >>
» Precise weighing equipment, such as belt weighers. Read more >> » Train loaders that offer either gravimetric
and volumetric capabilities, with outstanding, trusted performance. Read more >>
» Rail technologies that optimize the loading and transport of iron ore, to correctly and safely meet set weights and requirements. Read more >>
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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IRON ORE PROCESSING
Rock breaker
ROM bin
Fan
Vibrating feeder
Fan
Apron feeder
Vibrating feeder
Filter
Filter
MULTIBELT ® beltweigher
Dust extraction hood
Secondary crusher*
Dust extraction hood
Vibrating grizzly screen
Scalping screens
MULTIBELT ® beltweigher
MULTIBELT ® beltweigher
Fan
Vibrating feeder
MULTIBELT ® beltweigher
Filter
Rock breaker
Dust extraction hood
Product screens
MULTIBELT ® beltweigher
Primary crusher*
Sample vibrating feeders
MULTIBELT ® beltweigher
Sample vibrating feeders
Filter
MULTIBELT ® beltweigher
MULTIBELT ® beltweigher
Train load out (TLO)
Lump stockpiles
Fines stockpiles
Train
MULTIRAIL ® weighbridge
Process step supplied by Schenk Process Group Process step not covered by Schenk Process Group
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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COAL
COAL
Preparation in coal mining requires technologies capable of withstanding harsh and unclean conditions. Coal is valued not just due to its energy properties but also as a component of steel and cement production – both of these are also two core industries for Schenck Process and therefore help add to our expert knowledge. &J?NA=OEJCLNKłP=>EHEPU=J@LNK@Q?PEREPUEJ?K=H preparation is made possible with Schenck Process, through a variety of solutions. High performing, reliable screens for: » Dry sizing » De-sliming and wet sizing (coal washery) » Media drain and rinse (coal washery) Read more >>
Coal preparation plants allow for cleaner burning processes, enhanced value and cleaner emissions. Our solutions in these plants ensure their processes are QJ@ANP=GAJABł?EAJPHU=J@I=TEIEVALNKłP Every year, Schenck Process help clients free around 10 million tonnes of raw coal in preparation plants, from impurities – a crucial process that contributes towards environmentally- friendly energy production.
» Condition monitoring for screens and feeders. Designed to allow long- term performance, avoid downtime and instead enable simple, planned maintenance. Read more >> » Heavy duty vibrating feeders that can work in conjunction with our screens or as stand-alone. They offer variable feed rates with trusted performance. Read more >> » Dynamic, durable weighing solutions, such as belt weighers. Read more >> » Train loading systems, that are seen across many of the globe’s mining sites. Read more >> » Rail weighing and automation technologies that optimize the loading =J@PN=JOLKNPKB?K=H PKABł?EAJP=J@ safe levels. Read more >>
CAPABLE FOR EVERY COAL PREPARATION APPLICATION » We cater to the requirements of various coal categories, including steam, coking and anthracitic coal » Have successfully proven and met the requirements of washery capacities ranging from 0.6 M tons/year to 31 M tons/year » Offer innovative design techniques, that meet the needs of multiple products and cover all advanced techniques, such as coarse coal bath separation, cyclone
łJA?K=HOAL=N=PEKJ ?K=NOAOHQNNU OAL=N=PEKJ=J@łJAOHQNNUŃKP=PEKJ
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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COAL PROCESSING
Raw coal
ROM bin
Apron feeder
Raw coal screen
LinaClass ® SLO desliming screen
Roll crusher
Conveyor
DMS cyclone
LinaClass ® SLO product drain & rinse screen
Deslime cyclone
LinaClass ® SLO reject drain & rinse screen
Coal thickener
Vacuum disc filter
Flotation cell
Sieve bend
Coarse coal centrifuge
Tailings thickener
Fine coal
Coarse coal
Product
Reflux classifier
Belt press filter
Fine coal centrifuge
Reject bin
Reject
LinaClass ® SLO reject dewatering screen
Process step supplied by Schenk Process Group Process step not covered by Schenk Process Group
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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LIMESTONE
LIMESTONE Through state-of-the-art technology and hands-on experience, our teams at Schenck Process have built-up a number of years in optimizing systems, PD=PABł?EAJPHU=J@?KOPABBA?PERAHU handle sand and gravel. These include: Extremely reliable vibrating screens that handle the largest quantities of materials and classify them to a very high level of accuracy. Read more >> Condition monitoring for vibrating screens, as well as feeders. Unique to Schenck Process, the technology makes avoiding break-downs possible and instead enables simpler, routine maintenance. Read more >>
Schenck Process solutions play an important role towards extracting the material that helps make these products, which is reinforced by our in-depth experiences and understanding of limestone processing. Limestone quarries are typically open- air and require only the best and robust equipment and systems – which is why SA=NA=JE@A=HłP
Limestone is a key component of many construction materials and one of the main elements for cement production, making it an important mineral resource. Limestone is also used to make many household products that include plastic, glass, paint, steel and is used in water PNA=PIAJP=J@LQNEł?=PEKJLH=JPO =OSAHH as in the processing of many foods.
Vibrating feeders, capable of handling even abrasive materials. They operate at different feed rates and come available with weighing capabilities. Read more >> Reliable and highly accurate weighing equipment, such as belt weighers. Read more >> Speedy gravimetric or volumetric train loading, that allows for consistent and easy material loading. Read more >> Dynamic and precise rail technologies for weighing rail carriages and monitoring transport. Read more >>
LIMESTONE IS A FUNDAMENTAL BASIC COMPONENT, FOR MANY OF TODAY’S COMMONLY USED PRODUCTS.
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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LIMESTONE PROCESSING
Raw limestone transporter
Screen
Fan
Filter
Dust extraction hood
Crusher
CONiQ Monitor
®
SRC vibrating feeder
CONiQ Cloud
®
Apron feeder
CONiQ Monitor
®
Ship
Fan
® MULTIBELT belt weigher
LinaClass SLR Crusher relief vibrating screen
Filter
Dust extraction hood
Crusher
CONiQ Monitor
®
Filter
SRC vibrating feeder
® MULTIBELT belt weigher
CONiQ Cloud
®
Bartlett Snow rotary dryer ®
Train
CONiQ Monitor
®
MULTIRAIL weighbridge
®
LinaClass SLR Crusher relief vibrating screen
Crusher
Truck
Raymond ultra fine mill ®
® Raymond roller mill
® MULTIBELT belt weigher
Weighbridge
Schenck Process packages
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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COPPER
COPPER Only around 2% of mined ores contain copper. As often seen in Ball Mills, Schenck Process solutions form part of the extraction process, to maximize recovery rates to the highest possible level. After the concentrate is recovered, copper then goes through many other stages, as such Smelting – which are other areas we can help with. For more information on these later processes, click here >>
4DAPDANEPOH=NCAHQILOKNłJAL=NPE?HAO the extraction of NF Metals, such as Copper, is another core speciality for Schenck Process. Copper is a critical material that is used in many sectors including construction, power, water supply and transport. While it’s properties, such as recyclability are extraordinary, the resource is limited; I=GEJCABł?EAJPNA?KRANU?NQ?E=H
For the recovery of concentrate, our core solutions include:
Vibrating screens that robustly handle =R=NEAPUKBI=PANE=HOBKNOEVA?H=OOEł?=PEKJ The range is recognized for their superior reliability. Read more >> Condition monitoring for vibrating screens and feeders. The CONiQ Monitor technology provides a warning of impending failures and allows for planned maintenance. Read more >> Vibrating feeders, that offer varying feed rates and are available with weighing capabilities. Read more >>
Highly accurate weighing solutions, such as belt weighers, which are known for their longevity and reliability. Read more >> Gravimetric or volumetric train loading solutions, for controlled and accurate loading. Read more >> Rail technologies for controlling the weighing of materials, such as those handled in rail carriages and for further optimizing loading. Read more >>
COPPER IS A MAJOR INDUSTRIAL METAL, BUT IS ALSO AN ESSENTIAL NUTRIENT IN OUR DAILY DIET AND OFFERS ANTIMICROBIAL PROPERTIES.
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
Mining & Mineral Processing 29
WE PROVIDE PACKAGES, NOT JUST EQUIPMENT… …FOR A WHOLE-LIFE RETURN ON INVESTMENT ROBUST, RELIABLE SOLUTIONS
SITE SOLUTIONS. NOT JUST EQUIPMENT
One of our core aims for mineral processors is to help make their processes work. This is partly achieved through the integration of packages which include not only the central machine, but also all additional accessories or process parts. Working with our Schenck Process team as a single trusted source, not KJHUOEILHEłAOOQLLHU?D=EJ >QPIKOP importantly provides peace of mind that all components are engineered to work seamlessly together. We offer full end-to-end solutions, not just a machine!
CUSTOMIZED PACKAGES
Our packages are bespoke to meet project needs and ensure you get the DECDAOPBQJ?PEKJ=HEPU=J@ABł?EAJ?U from their overall performance. In addition to the main equipment, packages can include many elements, such as: » Screening media » Chutes » Belt weighers » Gates » Hoppers » Much more
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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Feed end
Exciters
Drive assembly with guards
Body
Back plate Side plate
Dust housing
Cross beams Exciter beam Pipe lift beam
ISO frame
Dampers
Springs
Discharge end
VIBRATING SCREENS
VIBRATING SCREENS
Schenck Process linear LinaClass ® vibrating screens easily handle the largest quantities of materials and classify them SEPD=OECJEł?=JPHARAHKB=??QN=?U!NERAJ by robust exciters, they are specially customized for the widest range of onsite requirements and optimally operate, even under extreme weather constraints. Recognized for their reliability and outstanding performance, LinaClass screens have decades of experience and enhancements engineered into them. Used in conjunction with the UNIQUE CONiQ Monitor, they become the most dynamic, dependable screens available.
KEY BENEFITS
KEY BENEFITS:
SAFETY » Rubber encapsulated screen springs, that prevent accidents/tampering » Low noise impact » Dust control and covers REDUCED MAINTENANCE » Designed to withstand higher stresses » Shorter, less frequent maintenance » Quick change-out hydraulic systems » Screen panels are manufactured and available globally, for a quick turnaround
INCREASED EFFICIENCY » Improved quality and throughput » Lower energy and water consumption » Lower CO2 foot-print » Larger open area HIGHER PERFORMANCE » Higher reliability; increased uptime » Durability; longer service life CUSTOMIZED » Customized screens and screening media to suit material
WE’LL HELP YOU ACHIEVE UP TO 97% OPERATIONAL AVAILABILITY.
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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VIBRATING SCREENS
VIBRATING SCREENS
MODELS FLAT-DECK LINEAR
MODELS DRAINAGE & DEWATERING LINEAR » Used for washing, drainage, ?HA=JEJC LNAHEIEJ=NU?H=OOEł?=PEKJ and wet screening or for screening out foreign bodies » Reverse incline or reverse banana style » Reliable directional force exciters or vibrator motor driven options » Widths up to 3.0m (10 ft) and lengths up to 8.0 m (26 ft) » High capacities for a wide range of materials
SCALPING » For automatic loading and unloading of crushers
BANANA LINEAR Features a banana-like arrangement, enabling a larger quantity of feed, with DECDłJAOOAO >QPOPEHHQOEJCPDAO=IA screen area. » Large capacities for a wide range of materials » Multi-slope designs for maximum łJAONA?KRANU » Widths up to 4,500 mm, lengths up to 10,800 mm » Reliable directional force exciters » Single and double deck designs
?H=OOE?O?NAAJ BKNPDA?H=OOEł?=PEKJKB=HH bulk solids that are suitable for screening. » Widths up to 4,500 mm and lengths up to 11,500 mm » Reliable directional force exciters » Single, double and triple deck designs
Our screens are manufactured for strength
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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Mining & Mineral Processing 35
VIBRATING SCREENS
VIBRATING SCREENS
DESIGN FEATURES SCREEN BODY
DESIGN FEATURES DIRECTIONAL FORCE EXCITERS » Economic and powerful exciters up to one mega newton force for high screening performance » Range of exciters, speed and plug weight settings to generate required ‘g’ force » Long-life and extremely calm operation » Minimummaintenance requirements » Low operation noise level » Drive system allows smooth adaption of speed, for optimum performance
ISOLATON FRAME Robust isolation frames ensure the maximum level of vibration isolation. This minimizes noise emissions and reduces the dynamic loads; resulting in less material needed in the support structure, a lower plant cost and fewer emissions. » Reduces dynamic forces transmitted to the structure » Increase isolation of up to 99.9% » Saves cost on structural supports in steel SPRING SUSPENSION » Low dynamic foundation loads » Allows constant ratio between load =J@OLNEJC@AŃA?PEKJ » ‘Safety spring’ design to avoid injury
» Maintenance-free shafts between exciters, for higher production and less downtime » No welding on side plates, avoiding stresses » All stiffeners and attachments are bolted to side plates » Integrated feed box, removing extra cost for a bolt-on unit » Can be supplied with matched vibrating feeders to optimize material withdrawal from bins and feed » Wide range of high-quality screen deck options; resistant to wear
» Larger open area. Using fewer yet larger machines, reduces plant build costs, lowers emissions and power consumption » Fully bolted construction with corrosion and erosion resistant designs, for long- life performance » Stress relieved cross members, ensuring maximum rigidity, optimal force transmission and minimumweight-load » Thicker deck rails for ultra-heavy media; resulting in longer service life, less maintenance and a lower production cost per tonne
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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CUSTOMER CASE: THE WORLD’S BEAST OF A SCREEN
VIBRATING SCREENS
SCREENING MEDIA As the market leader in screen panel supply, our teams understand the importance of the relationship between the design of our vibrating screens and correct screening media selection, in order to obtain optimum performance. Through our range of screening media we can ensure your system is designed to best satisfy individual project requirements, and PKLNKRE@ALNK?AOOABł?EAJ?U OPNQ?PQN=H integrity and high service life. OUR MEDIA DESIGN: » Large open area » Allow extended service life; reduced wear » Modular screen panel design h3ANO=PEHAłTEJCOUOPAIO » Enable noise reduction » Range of material and surface features » Assured quality
OUR MEDIA SERVICES: » Process optimization » Recommendations for deck and aperture selection
Meet the BEAST - at over 72 tonne in body mass, using twin exciter beams, four one- mega newton force exciters and processing around 10,000 t/hr of slurry in a metal’s extraction process, our BEAST Vibrating Screen, may well be the largest ever built.
» Audit of screen surfaces to identify wear patterns and corrective actions » Development of customized solutions » Installation of new systems and components » On-site technical support » Replacing existing alternative supplier screening systems » Extensive knowledge and experience h&0,?ANPEłA@ More information >>
remote or planned maintenance, with no unexpected downtime In fact, it enabled less maintenance requirements. This BEAST screen is around 5.5 mwide, 10.5 m long and 6.5 m high; featuring almost every available design option possible. A typical project needing a screen of this size includes large open-pit copper and gold mines. Learn more on the CONiQ Monitor >>
The BEAST was made for wet processing the highest possible mine throughputs, with extreme fatigue strength and ability to handle huge loads. The project goal was to supply screens that withstood a SAG mill discharge of 6000 t/hr, in addition to 4000 m³/hr of water. Designed with a robust isolation frame ensured that structural vibration is effectively absorbed, It was supplied equipped with the CONiQ Monitor – to regularly update operators on screen performance and allow
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
Mining & Mineral Processing 39
VIBRATING MACHINES WITH CONDITION MONITORING
ENABLING SHORTER AND LESS FREQUENT MAINTENANCE
CONiQ ® MONITOR Using artificial intelligence , the latest sensor technology and analytical software, the intelligent CONiQ ® will in ‘real-time’ enable processors to avoid the costly downtime caused by failing screens or feeders and instead allow better performance, higher LNKłP=>EHEPU=J@HKJCANI=?DEJAHEBAOL=J
KEY BENEFITS
» Improves the lifespan of your machines » Improvessafetythroughremotemonitoring » Lowers Co ² footprint by sending less operators to site » Accessing data remotely, enables OEM technical expert support to assist site » Implementation and user support is readily available » Availability of long- termmonitoring service
» Provides early warnings of impending failures
» Maximizes revenue by avoiding LNKłPOHKOPBNKIOEPA@KSJPEIA h&J?NA=OAOKQPLQP=J@ABł?EAJ?U » Avoids unexpected downtime and instead enables forward planning » Enables greater process control » Allows predictive and planned maintenance
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
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Mining & Mineral Processing 41
CONIQ® IS A ‘HANDS-ON’ EXPERT, MONITORING YOUR SCREEN ALL DAY, EVERY DAY.
CONiQ ® MONITOR CONiQ ® will pay for itself immediately, when just one occurrence of unplanned downtime takes place. Inspection and maintenance accounts for up to a third of indirect site costs. Our unique condition monitoring system enables companies to realign their maintenance strategies around fault @APA?PEKJ LNARAJPEKJ=J@EJ?NA=OA@LNKłPO The real-time monitoring of critical variables, also delivers additional peace of IEJ@=J@AJOQNAOIKNAAJANCUABł?EAJPOEPA operation. With many built-in parameters, the CONiQ ® EOOLA?Eł?=HHUKLPEIEVA@BKN vibratory equipment and outperforms any other solutions on the market.
CONiQ ® MONITOR
CONiQ ® consists of three main elements - to measure, to analyze and to interpret.
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MEASURES: » FULL machine, with a 6 dimensional microelectromechanical system, including detection of any motion changes » Cracks or defects » Exciter performance » Oil temperature » Wireless and non-wireless set-up: AJOQNAOŃATE>EHEPUKBOAJOKN mounting, stability and security in data transmission and synchronicity to detect out-of-phase vibrations
ANALYZES : h2OAO NPEł?E=H&JPAHHECAJ?A OAJOKNO and other measurement devices; sending data to the processing unit located beside each machine » Data is also held centrally and available remotely, through a secure interface » Data is compared against previous DEOPKNU=J@LNA?KJłCQNA@R=HQAO INTERPRETS : » Overall machine condition is automatically interpreted » Warnings on impending failures or maintenance requirements
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
42 Mining & Mineral Processing
Mining & Mineral Processing 43
CONiQ ® MONITOR
CONiQ ® MONITOR
VIEW OUR DIGITAL CONiQ CATALOGUE FOR MORE TECHNICAL INFORMATION >>
EASY DETECTION AND ACCESS OF EARLY TRENDS
» Remote access to fault trends means a faster expert response to evaluate performance or potential problems » Centralized monitoring of a plant-wide viewminimizes demands on operational and maintenance staff » Quality performance data means faster understanding and optimization of machine performance Contact our team for an assessment of your requirements and a demonstration of the CONiQ ® solution. >>
The CONiQ ® enables a complete plant overview, consolidating information about all monitored vibrating screens or feeders. Data is sent to CONiQ ® software on a PC or other device, for interpretation of long- PANIPNAJ@O AJ=>HEJCA=NHUE@AJPEł?=PEKJ of any potential risks. This also means that trend data can be analyzed remotely, for example at corporate or regional head quarters; thereby reducing the demands on local operational staff and making access to data for isolated sites much easier.
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
44 Mining & Mineral Processing
Mining & Mineral Processing 45
VIBRATING FEEDERS
VIBRATING FEEDERS
Schenck Process vibratory feeders easily discharge heavy, highly abrasive material in a controlled and reliable manner, even QJ@ANPDAIKOP@EBł?QHP?KJ@EPEKJO1DAU can also be used to convey material over a variety of distances. This robust range of feeders are engineered PKIAAPOLA?Eł?OEPANAMQENAIAJPO=J@ are truly optimized to work alongside Schenck Process vibrating screens. Our feeder options include trim gates, magnetic exciters, unbalance exciters or force exciters; all depending on the application.
Our vibrating feeders are designed as combinations of riveted and welded constructions. ,JOLA?Eł?IK@AHO =PNKQCDEO>KHPA@EJLH=?A=J@EOPDANABKNAA=OUPKNALH=?A"=?DPNKQCD plate offers a range of plate thicknesses and materials, depending on the application. 1DARE>N=PEJCO?NAAJO?=J=HOK>AAMQELLA@SEPDSA=NHEJEJCOKND=N@OQNB=?A@łJEODAO=J@?KIA available with robust coil springs. Machines can be suspended depending on requirements.
KEY FEATURES
» Straight or diverging pan designs » Include directed-force exciters OR » Unbalance motors/magnetic exciters » Reliable and proven designs » Work seamlessly with Schenck Process vibrating screens » Can include condition monitoring control, for break-down prevention » Optional wear protection » Trough or lip sealing capabilities » Several models available
DESIGN FEATURES
Wear Protection » Optional wear lining can be rubber, ceramic or hard-surfaced plates Trough Sealing » Include optional rubber lip-sealing, or any seal required
Spring Suspension and Isolation Frame » Coil springs with linear spring characteristic » Optional isolation frames with hydraulic shock absorbers for larger machines
Directed Force Exciter » Minimal service required; just regular lubrication
Unbalanced Motor » Long motor lifetime and satisfying motor quietness
PAIRING A POOR OR WRONG FEEDER WITH YOUR SCREEN, WILL RESULT IN BREAKDOWNS.
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
46 Mining & Mineral Processing
Mining & Mineral Processing 47
WEIGHING
WEIGHING
The MULTIBELT range includes single-idler belt weighers and multi-idler options, with variants for bandwidths from 400mm, up to 2000mm – depending on the application. h#KNŃKSN=PAOQLPKPD » Robust design ensures high operational reliability » Accuracies of up to +/- 0.25% to the =?PQ=HŃKSN=PA » Legal for trade application » Calibration class 2 to 0.5 according to OIMLR50 » Flexible use in new and existing conveyors » Lowmaintenance required » Maintenance-free load cell(s) with high protection class » Optional speed transducer with friction wheel or for shaft mounting » ATEX versions for use above ground For mineral processing applications that require dosing, the MULTIDOS weighfeeders are an ideal solution. Applications can include: » Belt weighfeeders used in mill feeding for optimized operation » Apron weighfeeders for the feeding of large, edged grain material DOSING
Designed for high feed rates and satisfying accuracy, MULTIBELT ® provides exact performance for ?KJPNKHHEJCŃKSN=PAO=J@?KJOQILPEKJ ?KQLHA@SEPDŃATE>HAEJPACN=PEKJ=O well as very simple, fast maintenance. We have the right belt weigher solution for every application. Suitable for large belt widths and high speed belt conveyors, MULTIBELT is often EJOP=HHA@EJPK@EBł?QHPPK=??AOO=NA=OKB= site, making its reliable performance and A=OUI=EJPAJ=J?ABA=PQNAO =OECJEł?=JP >AJAłPPKIEJEJC=J@LNK?AOOEJCOEPAO
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
48 Mining & Mineral Processing
Mining & Mineral Processing 49
TRAINLOADING
TRAINLOADING
MAINTENANCE » Less maintenance through well engineered quality components » Easy to repair and inspect » Reliable OEM Aftersales support
Accurate, high-speed loading systems for any application.
OPERATION » High process safety, availability and operational reliability » High level of automation » Safety features for rail system compliance » Controls adaptable to process changes
PERFORMANCE » High automation control » High accuracy wagon load measurements » Consistent high accuracy and fast loading » Prevents spillages CAPABILITIES » Extensive experience globally, for all commodities » Process knowledge and implementation » Fully automatic volumetric or gravimetric systems » Full train load out system solutions
Schenck Process train loaders are designed to operate reliably in the harshest mining environments - even when facing high =J@HKSPAILAN=PQNAO @QOP=J@OECJEł?=JP rainfall. Our train loading systems require only routine maintenance, coupled with quick loading performance.
Featuring high quality corrosion resistant paints, environmentally sealed electrical equipment and high quality hydraulic components – our train loading systems are engineered to enable minimal maintenance and easy repair.
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
50 Mining & Mineral Processing
TRAINLOADING WITH WEIGHING & AUTOMATION TECHNOLOGIES – MULTIRAIL
THE PERFECT PAIR
TRAINLOADING
We have proudly been involved in a significant portion of all global train load out operations, for over 30 years. Our train loading experts have extensive know-how in materials handling and stockpile reclaim systems. We can support you with full-system design, thereby optimizing operation of the reclaim system and train loader, while at the same time considering capital expenditure constraints.
KEY BENEFITS: ADDING VALUE
» Development of tailor-made projects » End-to-end project management » In-house design and R&D » OEM for all train load out technology » Over 30 years’ experience in train loading
Email: info@schenckprocess.com
52 Mining & Mineral Processing
Mining & Mineral Processing 53
RAIL WEIGHING & AUTOMATION
RAIL WEIGHING & AUTOMATION
FUNCTIONALITY: MULTIRAIL includes the following basic functions: » Calculating and showing weights » Stop-and-go operation » Storing data » Issuing results on-line » Transmitting data to the PLC by OPC server Other optional functions are available: h/=EH?=NE@AJPEł?=PEKJSEPD/#&!KNKPDAN equipment » Monitoring the rail car centre of gravity » EDP / BDE system interfacing
INBOUND AND OUTBOUND SCALES – TRAINLOADOUT Train loading combinedwith our world-class rail weighing technology –MULTIRAIL ® TrainLoadOut, offers complete control and automationwith accuracies of ±0.5%of the total trainweight. MULTIRAIL provides data controlled, truly optimized and accurate train loading – all froma systemwhich is simple to integrate and operate. Weighing rail cars before and after loading provides a complete picture of axle loads and total train weight, as well as any material hang-up that can overload a rail car. Integration into on-site ERP systems ensures that operations run smoothly and ABł?EAJPHU#QHHU=QPKI=PE?N=EH?=NHK=@EJC software enables remote train loading, without the need for operators.
KEY BENEFITS: DYNAMIC WEIGHING
» Increased average rail car load » Optimized loading performance – no overload h&ILNKRA@N=EHHKCEOPE?OABł?EAJ?U » Management of roll back and data transmission » Train loader interface » Calculating the front / rear and right / left load distribution in the rail car » Tare and gross rail car weights to ±0.5 % accuracy
Please Note: MULTIRAIL in the USA is designed and supplied as MultiTrain, BKNPD=POLA?Eł?NACEKJ
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
54 Mining & Mineral Processing
Mining & Mineral Processing 55
RAIL WEIGHING & AUTOMATION
RAIL WEIGHING & AUTOMATION
To automate and generate customers CNA=PANABł?EAJ?EAO=OSAHH=OO=BAPU for material handling over rail, Schenck Process also offer the following MULTIRAIL solutions: LEGAL-FOR-TRADE DYNAMIC WEIGHING OF RAIL CARS These systems are very quick to install and aim to reduce downtime and thereby improve revenue. MULTIRAIL train weighing solutions include reliable, automated force sensors and weigh tie technology – enabling real-time control.
WHEEL SCANNING RECOGNITION OF DAMAGE AND PEAK FORCES MULTIRAIL modular wayside train monitoring systems are capable of weighing in motion, detecting impact KBHK=@=J@NAREASEJCSDAAHLNKłHAO such as diameter. Using radio-frequency E@AJPEł?=PEKJ A=?DS=CKJEOO?=JJA@=J@ E@AJPEł=>HA0LAA@IKJEPKNEJCEO?=H?QH=PA@ ‘live’, whilst in-motion weighing detects any alterations in wagon weights.
WHEEL SCAN POR (PERIODIC OUT OF ROUND) The periodic out of round modular wayside train monitoring system, ensures continued analysis of train wheels for safe and secure performance. Designed to quickly identify wear in train wheels, also known as out of round, this systemmonitors the wheel tread polygonalization for radial irregularities. As a dynamic system, it also calculates axle loads and acoustic measurements.
WATCH ALL OUR LATEST INNOVATIONS FOR RAIL WEIGHING ON YOUTUBE >>
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
56 Mining & Mineral Processing
Mining & Mineral Processing 57
SPARES AND COMPONENTS
MINING & MINERAL PROCESSESING SERVICES
For all our core systems we offer mineral processors, readily available spare parts, media replacement and components – globally. Examples can include: » Components for design improvements » Screening media » Refurbishment & 3rd party spare parts » CONiQ Monitor upgrades » Belt weighers onto existing conveyors » Train loading spare chutes » Train loading ProLift chute exchange
Our extensive services include: » Industry experts with decades of experience
» Global centre of excellences » Dedicated application support » Product engineering design » Global manufacturing and engineering » Installation and commissioning » Global product and operation training » Remote, digital support services for testing and aftersales
Technology specific: » Remote data analysis for CONiQ Monitor installations » CONiQ Monitor performance checks » MULTIRAIL calibration services
Email: info@schenckprocess.com
Tel: +49 615 115 311 029
Your Partner Please contact Schenck Process where you will be directly connected to an engineering expert.
Schenck Process Europe GmbH (Global Head Office) Pallaswiesenstraße 100 64293 Darmstadt, Germany T: +49 615 115 311 029 E: info@schenckprocess.com W: www.schenckprocess.com
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