Tenova Takraf is the business segment within Tenova S.p.A. that
Bulgaria).
loading/unloading.
terminals etc. Close association with the engineering and
operate, transfer) concessions.
other fertilizer products etc.
(Civitavecchia, Italy). The CSUs have a capacity of 1,500tph
from 50,000 to 150,000 tonnes. The two systems, equipped with
comply with the latest environmental regulations.
plant (Mexico).
operations and maintenance of the two unloaders.
Terminal, Australia.
QBH coal stacker installation located in Brisbane QLD.
Limited. Tenova SEMF contract was for design, fabrication,
expected to be completed by late 2010.
The stacker was successfully delivered three weeks ahead of
schedule; the nominally 100m-wide stacker has twin booms and
a capacity of 2,750tph. The stacker is rail mounted, travelling up
to 165m and will generate two 20m-high parallel coal stockpiles.
This machine represents a key component of the whole
expansion plan for the coal terminal.
3) Tenova TAKRAF surface miners TSM 300commissioned and released for production in Australian
iron ore mine
December 2009: Two Tenova TAKRAF surface miners TSM 300
supplied to HWE Mining Pty Limited, Australia have been
recently released for production at the Yandi Iron Ore Mine in
Western Australia.
During the initial start up and training period the cutting
capacity averaged from 480tph to 1,110tph depending on the
material’s compressive strength. The TSM 300 is the latest
development of Tenova TAKRAF surface miner. The machine
features the well-proven front cutting drum with its direct twin
drive. That allows for a cutting depth of 800mm, unmatched in
its class. Due to its specific cutting drum design with top down
cutting, the TSM 300 produces consistently a small product size,
without additional crushing, thus efficiently eliminating a number
of processing steps. Its standard features include a spacious
operator cabin with two full-size access ways and a trainer seat.
It’s advanced on-board machine monitoring and diagnostic
system with full size screen and clear text messaging allows for
easy control and adjustment of machine parameters for best
performance under changing ground conditions. The machine is
driven by a CAT C32 ACERT engine. The engine combines
state-of-the-art technology with proven design and is EPA TIER II
Non Road certified.
For the application in Australia the TSM 300’s service and
safety features have been further refined. An integrated falling
objects protection structure (FOPS) and roll over protection
structure (ROPS) acc. to ISO standards are installed above the
operator cabin. The operator cabin is equipped with a powerful
dual air conditioning. Service centres at ground level allow for
fast and save refuelling, water tank filling and oil change.
Tenova TAKRAF offers the surface miner as part of its
comprehensive product range for high efficiency continuous
mining — as a major supplier of opencast mining equipment
worldwide.
4) CPE Mengdong Energy Group (China) placed an
order for a Tenova TAKRAF SRs 2000 bucketwheel
excavator.December 2009: Tenova TAKRAF obtained the turnkey contract
for the supply of one bucketwheel excavator SRs2000 for the
coal mine extension operated by the Zhahanaoer branch of the
CPE Mengdong Energy Group.
Tenova TAKRAF has been selected either for the long-lasting
and sound operation experience with the mining equipment
comprising two bucket wheel excavators, the complete belt
conveyor system and a spreader, supplied by Tenova TAKRAF to
Yuan Bao Shan some years ago, due in great part to the
company’s reputation as a reliable supplier of bucketwheel
excavators, as well as for the excellent technical solution of this
particular project.
The Zhahanaoer coal field is located at the northwest end of
Togliao city in the Inner Mongolia Autonomous District. The
open pit mine is situated at the ridge of the southern part of the
Daxing’an mountain range. In this region the tough climate is
characterized by temperatures varying from +39°C down to
-39°C.
The coal mine covers an area of 31.36km² and holds an
estimated coal reserve of 827.93mt (million tonnes) of lignite
extracted at various levels from 85 to 356m depth. The recently
ordered bucket wheel excavator is designed to excavate up to
6,600m³ overburden per hour, which then will be transferred via
loading unit to the bench conveyor. Thus, the designed capacity
makes the bucket wheel excavator the largest bucket wheel
excavator of its kind in East Asia continent. With a boom length
of 44 metres the bucket wheel excavator will be able to mine a
step height of 30 metres and a block width of 50 metres. The
conveyor bridge connecting the bucket wheel excavator and the
discharge module will have an approximate length of 120 metres.
The commissioning of the equipment is planned to take place in
October 2013.
This bucket wheel excavator is the 56th machine of this type
supplied by Tenova TAKRAF so far, operating reliably under most
adverse climatic conditions. The SRs 2000 supplied by Tenova
TAKRAF some 30 years ago to mine hard coal in Ekibastus
(Kazakhstan) are still in operation all around the year at
temperatures even exceeding the levels in Zhahanaoer mine.
Some of those excavators in Ekibastus are just under
refurbishment, replacing the original bucket wheel drives with
the all-new developed extra heavy duty Tenova TAKRAF bucket
wheel gear boxes to make them fit for the next decades of
operation.
5) Tenova TAKRAF satisfactorily refurbished a big bucket
wheel excavator in KosovoMarch 2010: Tenova TAKRAF has recently accomplished the
refurbishment of a large bucket wheel excavator (BWE) SRs
1300, built more than 27 years ago by Tenova TAKRAF. The big
machine left the erection yard perfectly in accordance with the
budget and timing of the project, looking like a brand new
machine and it travelled on its all new crawler tracks to its
operating place in the Sibovc mine of KEK Kosovo, where it
began work immediately.
The complete mechanical and electrical revamping was
realized in less than two years by the consortium
TAKRAF/ABB/Vattenfall Mining Consulting and the local
partners. The whole machine, of more than 1,500t of weight,
was dismantled in big portions and then refurbished or replaced
in some parts to be finally reassembled and commissioned.
Under this EU financed project, ABB supplied all electrical
components and Tenova TAKRAF provided the crawler, the giant
slew bearing between upper and lower structure as well as the
belt pulley. All of those parts were manufactured in Tenova
TAKRAF’s own workshop in Lauchhammer (Germany), as well as
many more components to update the BWE to today’s
technological standards. In 2005 Tenova TAKRAF had already
replaced the bucket wheel excavator’s entire bucket wheel head
including all drive components and today only one frequency
control had to be modified. Local companies took care of the
new corrosion protection, crane employment, scaffolding and the
majority of the labour required for the works. This joint effort
well prepared the machine for the next decades of operation in
this huge coal deposit, containing more than 1 billion tonnes of
coal reserves.
The successful completion of this job is another proof of the
excellent collaboration between the coal miners in Kosovo and
Tenova TAKRAF’s engineers providing a valid support to the
European Union to stabilize the energy supplies in the region.
6) Pac for Tenova Takraf Grab Ship Unloader in TarantoApril 2010: The grab ship unloader built by Tenova TAKRAF for
the ILVA steelworks in Taranto received the Provisional
Acceptance Certificate (PAC) from the customer, the Riva group,
on 6 April 2010.
The Tenova TAKRAF system is one of the world’s largest
unloaders in terms of operating capacity — more than 3,000tph
of iron ore and coal — and size: it will unload ships up to
325,000dwt. The contract was signed in January 2008 and
delivery took place at the beginning of April 2010 after an
intensive test phase and seven days of continuous unloading
operations.
7) Tenova TAKRAF to supply a petcoke handling system
in Saudi Arabia.May 2010: Tenova TAKRAF has recently signed a contract for a
pet coke handling, storage and shiploading system for the new
Jubail Export refinery in Saudi Arabia. The customer, Gulf
Consolidated Contractors (GCC), is to build most of the new
refinery for new refinery named Sau Di Aramco Total Refining
And Petrochemical Company (SATORP) while Tenova TAKRAF
will supply the entire pet coke handling systems, which will be an
important ‘package’ of the refinery.
Tenova TAKRAF will be working in partnership with PHB
Weserhutte (Gijón — Spain) and will be responsible for the
design, supply and site delivery of a handling system comprising: a
conveyor belt system plus one scraper in the refinery area; an
overland conveyor covering a distance of 25km from the
refinery to the port; a system of conveyor belts plus two
scrapers and one shiploader in the port area. The system will be
used to store, transport and load petroleum coke (petcoke), a
solid residue obtained from petroleum refinement processes.
8) Tenova Takraf: a new contract in MauritaniaMay 2010: Tenova TAKRAF recently signed a contract for the
turnkey supply of a shiploader and a conveyor system to Société
Nationale Industrielle et Minière (SNIM), a state-owned company
in Mauritania. The new shiploader has an iron ore capacity of
12,000tph and is part of a project for the expansion of the
Zouerate mine. The extracted ore will be transported by rail
from the mine to the Nouadhibou terminal for export.
The loader will be constructed by Tenova TAKRAF Italy and
transported to the port, almost fully erected, on a special ship
equipped with the necessary hoisting equipment. The conveyor
system and ancillary equipment will be built by Tenova TAKRAF
Germany
The contract will involve close co-operation between the
teams from TAKRAF Germany be responsible for conveyor
system and TAKRAF Italy in charge of the design and
construction of the shiploader
9) Pac for Tenova Takraf Stacker at Vale terminal in S.
LuisMay 2010: the giant iron ore stacker (20,000tph capacity, 55m
boom length) built by Tenova TAKRAF for the Vale terminal at
Ponta de Madeira in Sao Luis do Maranhao, Brazil, received the
Provisional Acceptance Certificate (PAC) from the customer. The
fabrication of the steel structures has been carried out at TIMEC
plant, China, also part of Tenova group. Due to financial
problems of the erection partner, the final installation has been
performed directly by Tenova Italimpianti do Brazil organization.
This stacker was part of a contract which also included the
design and turnkey supply one bucket wheel reclaimer of
11,000tph capacity, 50m boom length at Vale terminal at Ponta
de Madeira and of two identical stackers of 16,000tph, 55m
boom length each at Carajas mine site, currently under final
installation.
10) Tenova Takraf, a new stacker for mining giant ValeJune 2010: Tenova TAKRAF brought financial year 2009/2010 to a
successful close with the signature at the end of June of an
important contract with Brazilian mining giant Vale.
Under the order, Tenova TAKRAF is to supply on a turnkey
basis a new giant iron ore stacker with a nominal capacity of
16,000tph and project capacity of 20,000tph, and a 55m boom.
The stacker will be installed in the stockyards of the Ponta de
Madeira terminal in São Luís (State of Maranhão, Brazil) as part
of Vale’s plans to expand the terminal to 130mt per year.
The stacker is scheduled for delivery 730 days after the
contract date. The project period includes two months of
“assisted operation” during which Tenova personnel will provide
24-hour assistance for machine operations. The contract covers
optional supply of an identical machine.
NEGRINI srl’s strength lies in skilled and experienced staff
MISSIONNEGRINI srl has as its primary objective the complete
satisfaction of its clients. It strives to achieve this through a
continuous and effective process of study and collaboration with
its clients and suppliers. Professionalism and versatility when
addressing the different needs of its customers: this is the
business philosophy of Negrini srl.
PRODUCTS OFFERED BY NEGRINI SRL:- hydraulic grab;
- mechanical grab;
- hydraulic clamshell;
- mechanical clamshell;
- auto-radio clamshell;
- ecological clamshell;
- clamshell bucket; and
- dragline bucket.
COMPANY PROFILEThe purpose of NEGRINI’s present business profile is to offer a
vision of the organization, the methods of production, the range
of its products and the services that it has to offer.
The continuous search for qualitative improvement,
expressed across the whole range of products marketed by the
Negrini brothers, has led to a dynamic development of
engineering that is innovative and cutting edge.
NEGRINI srl continuously reassesses the company’s main
objectives and general guidelines in the medium and long term.
These may include:
- the company’s commitment to quality
- customer satisfaction
- employee satisfaction
- the work environment
- reduction of non-compliance
- reducing the costs of non-quality
- the achievement of the objectives
- the adjustment to the requirements of international standards.
ACTIVITIESThe strength of NEGRINI srl lies in the skills and experience
gained by all working, highly skilled staff.
The company’s technical department is always ready to face
and solve any technical problem, explaining and justifying the
solutions adopted. As necessary, NEGRINI srl employs
engineers to solve the problems with more complex designs.
At present, the company has eight employees and makes use,
where appropriate, of external consultants.
The company has three warehouses of about 750 square
metres, fitted with two 6.3-tonne cranes.
PRODUCTIONEach request is evaluated and an assessment is made as to its
feasibility, in terms of both technical requirements and capacity.
All elements of the request, including drawings, are designed and
planned, in agreement with the department manager, in order to
guarantee delivery times, reliability and the best use of
resources.
The technical data, including drawings, are loaded into a
system of electronic processing three-dimensional solid CAD/
CAM and CAD, for better product management and rational
organization of the machines.
Product testing is performed by trained personnel, who are
sensitive to the needs of the customer. Before shipping, it is
standard practice for the production manager to perform a final
inspection under the supervision of the proprietor.
Supplies are fully compliant with the technical specifications
and drawings required, using reliable suppliers and historically
known. On request NEGRINI can provide individual certificates
and attestations.
WELDING PROCESSNEGRINI srl has EN 287-1-qualified welders to carry out the
welding process. They are regularly checked and active in the
activity known to them. The training makes use of external
technical certificates.
NON-DESTRUCTIVE TESTINGUpon request, tests are performed by suitably qualified external
staff. Control procedures are in accordance with current
European standards.
PRODUCT TESTINGAll products are subject to continuous control activities: in
acceptance and during production, before shipping the finished
product is screened and tested, in order to assess the
effectiveness of the processes used and to ensure the quality of
product to the customer.
Gambarotta bucket elevators
INTRODUCTIONFor more than 90 years, Gambarotta Gschwendt has been
developing and manufacturing bucket elevators for lifting any
type of bulk solid material writes Stefano Bisson. Thanks to its
patented research and development effort and to the quality of
its products, Gambarotta Gschwendt had a great success in
winning a leading position in the field of bucket elevators. With
more than 1,500 elevators currently in service worldwide, the
company’s core strengths lie in the reliability of its products,
which minimizes their maintenance costs.
Gambarotta Gschwendt can offer an extremely
large range of bucket elevators, covering all the
needs of the cement industry. The company
manufactures nine families of bucket elevators, many
of which have set world records in terms of grain
size (400mm and more), capacity (2,500tph [tonnes
per hour] and more) and chain life (80,000
operating hours).
RELIABILITY THROUGH TECHNOLOGYGambarotta bucket elevators are reliable products.
The general design and manufacturing approach is
aimed at minimizing their maintenance requirements
and ensuring a machine availability that is among the
highest in the industry.
Modularity and standardization are two key
advantages of Gambarotta bucket elevators: each
bucket profile is designed to maximize capacity
while ensuring an efficient material discharge,
minimizing recycle and dredging. Because a
standardized bucket profile is used for each elevator
family, bucket designs that have been field-proven for
years can be used in a variety of applications with
various throughput rates, ensuring the strictest
compliance with the production-related
requirements of the customers.
On chain bucket elevators, usually installed at key
stages of the production process, the chain wear is
the main reason for scheduled maintenance shutdowns,
which negatively affect the plant productivity.
Achieving the longest possible chain life is therefore
a critical success factor for Gambarotta’s products.
On chain bucket elevators most of the wear occurs
during the transit of the chain on the drive and idle wheels,
because of the chain-wheel contact and the relative rotation
between the chain elements. With some simplification,
Gambarotta can assume that the wear is proportional to the
number of transit cycles of the chains on the wheels and to the
specific loads on the chain elements. The use of manganesechromium
steel alloys on chain and sprockets, together with an
advanced deep-hardening of the surfaces, allow these
components to achieve a high tensile strength and a high surface
hardness, ensuring performance and long operating life to chains
and sprockets. However the shorter and the faster the elevator
is, the higher the number of wear cycles the components have
to go through. The Gambarotta design philosophy is to keep
speeds as low as possible to reduce the wear cycles and to
design elevators with some of the highest chain safety factors in
the industry, thus maximizing the operating life of all wear parts.
The quality of sub-components such as drive units, bearings,
and seals has a strong influence on the overall machine reliability.
One of the strengths of the Gambarotta design philosophy lies
in selecting only top quality components made in Western
Europe only.
The drive assembly is designed so that each element
downstream of the motor has a higher safety factor than the
element immediately upstream. This ensures an intrinsic
machine integrity that prevents the costly and time-consuming
failures that occur to other manufacturers when process
anomalies force their machine to operate beyond its physical
limits.
The self-aligning roller bearings installed on
the drive and idle shafts are placed outside the
casings and protected by an adjustable triple
gland-packing and grease labyrinths, ensuring a
long-lasting bearing integrity.
NINE CONFIGURATIONS FOR INFINITE
APPLICATIONSThe cement industry uses a large variety of
materials with a wide range of grain sizes and
temperatures. The Gambarotta approach is to
provide its customers with solutions designed
for each specific application. Therefore the
company developed nine different bucket
elevator families (represented in figure 1 on
p95), each optimized for a specific class of
materials. This approach enables Gambarotta
to offer every elevator the cement industry
requires, including extreme machines in terms
of grain size (over 400mm), capacity (over
2,500tph), height (over 100m), etc.
Gambarotta classifies its elevators
according to how they discharge the transported material:
centrifugal discharge (or high-speed) elevators, gravity discharge
(or low-speed) elevators, and hybrid discharge (or mid-speed)
elevators.
HIGH-SPEED BUCKET ELEVATORSThe elevators in this class are fast enough to discharge the
material by means of the sole centrifugal force. Bucket profile,
drive wheels diameter and speed are calculated to provide -
with the density and the dynamic properties of the conveyed
material — optimal discharge and minimum recycle on each
specific application. This class of machines is well suited to
transporting materials with a moderate and
uniformly distributed grain size, such as raw
meal, clinker, cement, additives, etc.
Gambarotta manufactures five families of
high-speed elevators, each available in all sizes
foreseen by the DIN norms, providing a wide
capacity range for each family.
EVD (DOUBLE ROUND LINK CHAIN BUCKET
ELEVATOR)This type of elevator is equipped with double
chains and shackles and is built according to
the main guidelines of the DIN 15251
standard. Drive and idle wheels are smooth,
buckets are guided around the wheels for an
excellent chain stability. Gambarotta advises
clients to employ this type of elevator to
transport fine and granulated materials up to
30¸60mm, such as raw meal, additives, gypsum,
cement, clinker, etc. up to a centre distance of
40 metres.
EVR (DOUBLE ROUND LINK CHAIN BUCKET
ELEVATOR)This type of elevator is similar to the EVD
family, however drive
wheels are toothed with
components in special
alloyed steel, surface
hardened and highly wear
resistant. The chain is
continuous, calibrated to
match the toothing and
certified. This elevator
type is well suited to lifting
clinker or moderately
granulated materials to
centre distances above
40m when temperature,
grain size or type of
material do not allow the
use of a belt bucket
elevator.
EVN (BELT BUCKET ELEVATOR)The belt bucket elevator is typically employed to lift
fine and cold to moderately warm materials, with centre
distances over 100 metres. A distinctive feature of Gambarotta
belt elevators is the belt design: while most elevator belts on the
market have only a warp steel carcass, Gambarotta belts have
both a warp and weft steel carcass, which ensures an optimum
distribution of the concentrated loads from the buckets.
ESP-C (CENTRAL BUSHED CHAIN BUCKET ELEVATOR)Gambarotta recommends the use of its central chain bucket
elevator for fine and granulated materials up to 30–60mm, such
as clinker, raw meal, additives, coal, ashes, etc. Its bushed chain is
built in manganese-chromium alloyed steel, deep-hardened on all
surfaces. The use of a smooth drive wheel forces most
manufacturers to employ an expensive forged chain on their
machines to withstand the 3-axial chain stress and skidding
induced by the smooth wheel. Gambarotta uses a replaceable
sprocket wheel to drive the chain, concentrating the loads and
the wear on the hardest components (pin and bush) loading the
chain links with a simple tensile stress in one direction. This
optimizes the chain load, reducing its cost and increasing its
operational life.
ESP-LV (LATERAL DOUBLE BUSHED CHAIN BUCKET ELEVATOR)These bushed-chain elevators are born to provide large
capacities (up to 2,500m3 per hour) in a compact configuration.
Modern mills can deliver such high throughputs that recycle
capacities of 1,500–2000tph of clinker and additives are often
required. Gambarotta ESP-LV elevators have a continuous
sequence of buckets with lateral chains. This space-saving
configuration drastically reduces the overall installation costs and
ensures large lifting capacities at moderate speeds, thus
combining the price/capacity ratio of a high-speed machine with
the robustness and long life of a low-speed one. The double
bushed chains enable this elevator to withstand the accidental
intake of large grains of material much better than central chain
elevators, sometimes used at the mill recycle.
LOW-SPEED BUCKET ELEVATORS
The greatest limit of high-speed elevators is the maximum grain
size they can handle. Lifting hard materials, such as limestone,
with a grain size of 50–80mm would start to cause some serious
trouble to centrifugal elevators due to the high impact speed of
the material on buckets at the loading end. Gambarotta has
developed three families of low-speed elevators, which are
capable of lifting the hardest materials with grain sizes exceeding
400mm. The speed is kept below 0.3m/s, enabling the armoured
buckets to dredge large grained materials. Because the speed is
too low for a centrifugal unloading, these elevators discharge the
material centrally by gravity.
ELD / ELR (DOUBLE ROUND LINK CHAIN BUCKET ELEVATOR)These elevators are the heavy-duty, low-speed versions of
the EVD/EVR described above. The buckets are designed to
tolerate dredging of large grained material, the chains are
fixed to the bucket sides to allow the gravity discharge.
Typically these elevators are used to feed secondary
crushers or wherever it is necessary to handle materials
with grain sizes up to 150mm.
ETR (DOUBLE ROUND LINK CHAIN BUCKET ELEVATOR)This elevator is designed to handle large and abrasive materials
with grain sizes reaching 400mm. This machine has a continuous
sequence of buckets and a central loading hopper, ensuring
continuous feeding and preventing any dredging at the loading
end.
MID-SPEED BUCKET ELEVATOR: ESP (DOUBLE BUSHED CHAIN
BUCKET ELEVATOR)Closing the gap between low- and high-speed elevators, the midspeed
elevators are used when the material the grain size is
large enough to trouble high-speed elevators and yet not large
enough to justify the use of a low speed elevator: the typical
application, field-proven now for over 20 years, is the handling of
coarse gypsum, friable lime, clinker and blast furnace slag.
Because the speed, typically about 0.7m/s, is not high enough
for a complete centrifugal discharge, the buckets are shaped so
that the fraction of material that is not centrifugally discharged
can slide on the preceding bucket’s back and reach the outlet.
GLOBAL PRESENCEWith over 1,500 elevators currently in service worldwide
Gambarotta can offer great expertise in terms of bucket
elevator solutions and one of the highest quality/price ratios in
the industry.
The worldwide activities of Gambarotta continue to develop.
A wide network of agents and a global service team take
Gambarotta one step closer to its customers, providing a
prompt commercial, technical and after-sales support in any part
of the world.
RULMECA’s commitment to quality
THE COMPANY
Rulli Rulmeca Spa is a family owned company, based in Almè
(Bergamo) Italy, and is the headquarters of RULMECA
worldwide group, specializing in the development, production
and sales of belt conveyor rollers/idlers, motorized pulleys,
fabricated pulleys and other components for the worldwide bulk
handling industry.
Rulli Rulmeca has been working since
1962 with conveyor components for the bulk
handling industries and today Rulmeca is
working internationally with leading OEMs,
engineering companies and end users in the
major applications within the handling of bulk
materials such as; coal and lignite mining,
cement, quarries, tunnelling, power plants
installation, ports, salt and fertilizers, sugar
plants, recycling and demolition, crushing and
screening etc.
THE MARKET AND RULMECA’S
COMMITMENTMarket demands of improved efficiency and
higher throughput simply do not allow for
maintenance stops or breakdowns.
The selection of quality rollers and
motorized pulleys are more vital than ever to
ensure a long trouble-free life of the
conveyors.
From research and development to the
final product quality control the Rulmeca
Group’s commitment to quality is always
evident and present.
This choice has led to a group-wide policy
oriented toward continual investment in
manufacturing and technology, in the quality
of the materials used and in research and
development.
This unwavering commitment has received a positive
response from the market.
With an ongoing focus on market demands and customer
requirements the Rulmeca Group offers:
- a close partnership and consultancy to its customers for the correct selection of its products;
- a range of products designed to last;
- its own Rulmeca company or distribution in all major countries with a strong tradition in bulk handling activities;
- a market leading product range within rollers and motorized pulleys distributed globally;
- a group-wide implemented quality system helps to ensure Rulmeca is meeting and exceeding customer expectations;
- a continuously expanding and evolving product range;
- constant improvement in technical, design, and service; and
- a global market reach thanks to ten manufacturing sales companies and nine sales companies.