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Enhancement of recycling of steelworks remnants by the SCARABAEUS®

The experts from HAVER & BOECKER NIAGARA: Project & Sales Manager Dr. Metodi Zlatev and pelletizing expert Dr. Jan Lampke about recycling of steelworks remnants by the SCARABAEUS®


 

Most metallurgical processes are characterized by a gas flow through the material bed. Thus fine particles are carried away and have to been filtert after the metallurgical devise. Every modern metallurgical plant, no matter if based on blast furnace process, oxygen steelmaking process, electric arc furnace or direct reduction process consists of filters and wet separation for the exhaust gases. In the past these dusts and sludges had been landfilled. Since several decades different extraction processes for special reasons are in industrial use and only little amounts of the remains were discarded as dumps. Most recycling-processes are faced with very small particle sizes of the steel work remnants. Thus agglomeration is necessary in order to improve transport, storage and utilisation properties, especially the reintroduce into the metallurgical process.

The pelletizing disc SCARABAEUS® is perfectly suitable and in multible use for the transmission of fine-grained particles into larger agglomerates with defined particle size distribution with smooth surface. [1]

As an example of the use of the SCARABAEUS® in the recycling of steelworks remnants, such as blast furnace dust and sludge, converter dust and sludge, electric arc furnace dust, metallurgical debris, mill scale, mill scale sludge and various slags will be focused in the following. Since these metallurgical waste materials contain impurities such as zinc and lead, the reuse of these residual materials in the blast furnace or direct reduction plant may be problematic. Some of these materials are landfilled, anyhow the very most proportion is recycled to zinc, nickel, molybdenum or chromium.

Worldwide approximately 6,750,000 t of electrical arc furnace dust are produced annually. These dusts contain 1.600.000 tpy of zinc. About 35 Waelz kilns with an average capacity of 75,000 tpy are installed worldwide. They process every year 3.400.000 tons of electric arc furnace dust [2].

In zinc recycling, zinc-containing residues are reduced by carbon carriers in rotary kilns. Zinc and lead sublimate and are re-oxidized in the air flow in counterflow and are transported and separated in downstream waste gas purification plants. In the production of Waelz oxide, lime is used for slag formation. Prior to the Waelz process, the zinc-containing components dust and sludge (approx. 74 wt.%), coal (approx. 19 wt.%) and lime (approx. 7 wt.%) are homogenized and pelletized.  In opposite to the dust, the pellets have got improved transport and storage properties and most important significantly enhanced utilisation properties.

As the Waelz kiln works in counterflow, the risk of discharging unprocessed materials and contamination of the product is high. Defined particle sizes of the steelworks remants pellets are a pre-requisite for Waelz kiln optimization. Typically the pellets have a moisture content of approx. 14 wt.%. The target size of the pellets is mostly approx. 4 to 8 mm. The capacity of the SCARABAEUS® in the recycling sector is approx. 50,000 to 150,000 t/a.

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Scheme of Waelz kiln [3]

As early as 2010 HAVER ENGINEERING GmbH developed a pelletizing prozess, wich was attapted to the individual particle size requirements of the Waelz kiln process [4]. One year later HAVER NIAGARA GmbH delivered a SCARABAEUS SC 4200 for this process optimizing project in Germany. The plant was running with a vertical intensive mixer to blend the feed materials and charge them directly into the rotary kiln. To optimize the kiln capacity and the Waelz oxide output, the customer decided to produce agglomerates in the SCARABAEUS (better reaction with the process gas in the kiln due to higher permeability of the pellets). It was possible to increase the zinc output significant using the combination of a mixer and a pelletizing disc with a capacity of approx. 17 tph instead of only using the vertical intensive mixer as they done before.

The target of the project was to increase the total throughput and optimize the Zinc recovery. Due to the pellet production the customer could not only achive the set targets they exceed them.

The basic idea of the customer was using an agglomerate with high porosity to have a fast gas diffusion through the agglomerates into the inner core. Comparing the nature of agglomerates generated in a mixer and in a disc a general difference is the density of the agglomerates. Usually pellets produced in a mixing process have a higher density due to relative high energy input into the material by the agitators and a more coarse particle size distribuion compared to the roll agglomeration in a SCARABAEUS® which is characterized by its segreation effect.

The process chamber of the SCARABAEUS® is made by an inclined, rotating, flat cylindrical pan. Due to rotation of the pan, the fine material is pulled along to the disc uppermost point and then rolling down onto a material bed. Caused by the special movement of the material itself and the addition of water onto the material, nucleation and growing occurs as a result of the settings of the pelletizing disc. Typically, final pellets with a very tight particle size distribution are discharged continuously over the board of the SCARABAEUS®.

Due to the good porosity of the pellets and the teight particle size distribution what leads to a high pellet bed / bulk permeabilty the capacity of the kiln and the Zinc recovery increase.

 

In the following years that process was adapted on similar or compareble processes. Pelletizing disc with diameters from 2.2 m to 5.2 m are to be found nowadays in recycling of steelworks remnants.

HAVER & BOECKER NIAGARA supports the customers to develop and optimize their processes, machines and plants. In the test facility of HAVER ENGINEERING are various tests equipment for pelletizing available. The objective of HAVER Process Engineering is to meet customers technical requirements and economic benefits. To achieve this, it is necessary to concentrate on the whole pelletizing process, starting with raw materials preparation, dosing and mixing and binder treatment. The core-components of pelletizing are focused in detail to minimize the efforts of final product classification, material circulation as well as de-dusting, safety and environmental protection. Applying recognized technical norms and standards with tailor-made processing leads to a production process that saves energy and resources.


Sources:
[1] Eberhard Gock et al; Verwertung von deponierten eisenreichen Filterstäuben der Stahlindustrie durch Pelletierung. Recycling und Rohstoffe. 2013
[2] Noël Masson, Pascal Briol, PBSIM & BFS Consulting Engineering; Zinc One Resources Inc.: A Brief Summary of Zinc Oxide Processing Methods Available for the Bongará Deposit. 2017
[3] Eckhard von Billerbeck et al; Verarbeitung von Filterstäuben aus der Elektrostahlerzeugung im Wälzprozess. Mineralische Nebenprodukte und Abfälle. 2014
 [4] Jan Lampke et al; Solid and compact. Aufbereitungstechnik 03/2011. 2011

 

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Die Chancen des Pelletierens für die Eisenerzaufbereitung

 

Die Technologie des Pelletierens von Eisenerzen wird seit Jahrzehnten angewendet. Die Grundprinzipien sind die Gleichen, aber es gibt noch Raum für Verbesserungen.

 

 

Die Experten der HAVER NIAGARA GmbH: Der Vertriebsleiter Dr. Metodi Zlatev und der Pelletierexperte Dr. Jan Lampke erläuterten diese Verbesserungen im exklusiven Experteninterview.


 

Wie populär ist das Pelletieren in der Eisenerzindustrie?

Der beständige Bedarf an Eisenerz führt zu der Notwendigkeit, auch minderwertige Lagerstätten abzubauen. Der verminderten Qualität der natürlichen Ressourcen stehen wirtschaftliche, ökologische und technologische Restriktionen gegenüber, die eine Aufbereitung des gewonnenen Eisenerzes erfordern. Eine Anreicherung des Eisenerzes kann durch die Abtrennung unerwünschter Bestandteile erreicht werden. Diese Anreicherung von Eisenerz stellt in der Stahlproduktion einen signifikanten Verfahrensschritt dar. Bei der Anreicherung wird der größte Teil der Nebengesteine abgetrennt. Dadurch werden Transportkosten reduziert und die Produktionsrate von Hochofen und Direktreduktionsanlage gesteigert. Da das bis zur Aufschlusskorngröße zerkleinerte und aufkonzentrierte Eisenerzkonzentrat weder transport- noch gebrauchsfähig ist, muss es agglomeriert werden. Die Aufbauagglomeration von Eisenerzkonzentrat im Pelletierteller ist daher ein unverzichtbarer Bestandteil der Aufbereitung von Eisenerz.

Wird diese Methode immer bekannter/beliebter? Und warum?

Die weltweite Roheisenproduktion entwickelte sich in den Jahren 2007 bis 2015 mit einer jährlichen Steigerung von ca. 3,5%. Die Eisenerzfördermenge im Jahr 2019 wird mit 2,850 Mrd. t angegeben, bis 2028 soll laut konservativen Prognosen eine globale Eisenerzfördermenge von 3,119 Mrd. t erreicht werden, was einem jährlichen Anstieg von nur noch 0,9 % entspricht. Demgegenüber steht eine bis 2025 erwartete Steigerung der globalen Pelletierkapazitäten von 5.5 % per annum. Diese Zahlen verdeutlichen eindrucksvoll, dass die Aufbauagglomeration im Pelletierteller nicht nur bekannter, sondern auch beliebter wird.

In den Jahren von 2005 bis 2015 konnte eine stabile weltweite Produktion von nur 56 Mio. t Eisenschwamm (DRI) beobachtet werden. Trotz vielfältiger Entwicklungen und moderner Technologien der Direktreduktionsverfahren zeigte sich noch immer eine deutliche Branchenfokussierung auf die konventionelle Hochofen-Konverter-Route. Neuste Bestrebungen zur Verringerung des weltweiten CO2-Ausstoßes zeigen jedoch eine Trendwende auf. Alleine von 2017 bis 2018 ist die globale DRI-Produktion um 11.6 % gestiegen, im Folgejahr nochmals um 7%. Moderne Direktreduktionsanlagen verwenden designte Eisenerzpellets, mit ganz speziellen Pelletgrößenverteilungen und Basizitäten. Diese können nur mit modernen Pelletiertellern wirtschaftlich sinnvoll produziert werden.

 

 

Welche Ausrüstung braucht man für die Vorbereitung des Materials für den Pelletierprozess?

Zur Anreicherung des Eisenerzes ist es notwendig, das Erz bis zur Aufschlusskorngröße zu zerkleinern und Sortierprozessen wie Magnetscheidung und Flotation zuzuführen. Das dadurch produzierte Eisenerzkonzentrat wird anschließend mit Bindemittel, z.B. Bentonit oder organischen Bindemitteln, wie Carboxymethylcellulose und Polyacrylamid vermengt.

Durch Wasseraufgabe im Pelletierteller wird ein Aufquellen des Bentonits erreicht. Dabei zerfällt das Bentonit in kleine Plättchen, welche sich mit den Eisenerzkonzentrat-Partikeln wie auch untereinander verbinden. Während des Trocknungsvorgangs der Pellets entstehen dadurch stoffliche Brücken zwischen den Eisenerzkonzentrat-Partikeln, welche die Trockenfestigkeit der Agglomerate deutlich steigern. Beim anschließenden Brennen bzw. Härten der Pellets wirken die Sodium- bzw. Kalzium-Komponenten als Fließmittel, wodurch die Schmelztemperatur der Grundsubstanz verringert und somit lokale Schmelzbrücken bei Temperaturen unterhalb der eigentlichen Schmelztemperatur des Eisenerzkonzentrates erzeugt werden. Da der Bentonit während des Agglomerationsprozesses einen Teil der Pelletierflüssigkeit bindet, stellt er ein robustes Bindemittel mit einem breiten Bereich der Einsatzgrenzen dar.

Problematisch stellt sich allerdings der Eintrag der Mineralkomponenten dar, wobei im Speziellen durch den erhöhten SiO2-Gehalt der Eisenerzkonzentrat-Pellets der Energiebedarf zur Reduktion und Schmelzung derer gesteigert wird. Zudem steigt der Anteil an auszutragender Schlacke bzw. Verunreinigung im DRI. Daher gibt es, speziell im Bereich der DR-Pellets immer intensivere Bestrebungen, dieses Bindemittel weitgehend durch organische Bindemittel zu ersetzten.

Wie entwickelt sich die Pelletiertechnologie allgemein?

Zur ressourcenschonenden Erzeugung von Roheisen und Eisenschwamm sind geeignete Pellets notwendig. Diese zeichnen sich neben metallurgischen Zielgrößen im Speziellen durch eine enge Partikelgrößenverteilung und ein hohes Rundheitsmaß aus. In der Praxis hat sich herausgestellt, dass die Betriebsbedingungen des Pelletiertellers die Pelletqualität stark beeinflussen. Daher sind Pelletierteller notwendig, mit denen unsere Kunden sowohl auf sich ändernde Materialeigenschaften wie auch auf geänderte Zielgrößen des Produktes reagieren können.

Gibt es regionale Unterschiede?

Wir verzeichnen ein globales Interesse an der multidimensionalen Automatisierung unserer Pelletierteller. Der osteuropäische Markt erscheint besonders interessiert an der HAVER SCARABAEUS-Technologie.

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Welche Firmen sind bereits mit Pelletiertellern ausgestattet und warum hat sich der Kunde gezielt für dem HAVER SCARABAEUS entschieden?

Metinvest und Ferrexpo sind bereits mit dem HAVER SCARABAEUS ausgestattet.  Beide Unternehmen haben festgestellt, dass zur Produktion enger Partikelgrößenverteilungen für Direktreduktionsprozesse innovative Technik notwendig ist, die den Anlagenbedienern vielfältige Möglichkeiten gibt, den Pelletierprozess zu stabilisieren und ein optimales Ausbringen zu erreichen. Die moderne SCARABAEUS-Technologie, bestehend aus dem Pelletierteller HAVER SCARABAEUS, einer Partikelgrößenanalyse der Pellets mit der HAVER Momentum und das HAVER Process Management System bietet die Möglichkeit, die Erfahrung der Anlagenbediener für die Zukunft zu konservieren und mit innovativer Technologie zu optimieren. Nur so können ideale DR-Pellets produziert werden.

Welchen Service / Unterstützung bietet HAVER NIAGARA dem Kunden beim Entscheidungs- / Ausarbeitungsprozess?

HAVER & BOECKER Niagara unterstützt Sie bei der Entwicklung und Optimierung Ihrer Prozesse, Maschinen und Anlagen. In unserem Technikum stehen verschiedene Prüfgeräte zur Pelletierung zur Verfügung. Das Ziel des HAVER Process Engineering ist es, Ihre technischen Anforderungen und wirtschaftlichen Ansprüche zu erfüllen. Um dies zu erreichen, ist es notwendig, sich auf den gesamten Pelletierprozess zu konzentrieren, beginnend mit der Rohstoffaufbereitung, Dosier-, Misch- und Bindemittelbehandlung. Die Kernkomponenten der Pelletierung werden im Detail fokussiert, um den notwendigen Aufwand der Endproduktklassierung, des Materialumlaufes sowie der Entstaubung zu minimieren und dabei höchsten Standards der Prozess- und Mitarbeitersicherheit sowie des Umweltschutzes zu erfüllen.

PM-275-Titel

Im HAVER INSTITUT, einem An-Institut der TU BERGAKADEMIE FREIBERG werden maßgeschneiderte Aufbereitungsprozesse unter Anwendung anerkannter technischer Normen und Standards erarbeitet, um Einsparungen im gesamten Ressourceneinsatz unserer Kunden zu erzielen.

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Covid 19

How HAVER & BOECKER NIAGARA is handling the Covid-19 pandemic?

Dear colleagues, customers, business partners, dear friends,

The Corona virus is spreading worldwide: As an international company, we have already taken all the recommended precautions set out by the World Health Organization and we comply with all the government regulations to ensure the smooth running of our business. Our main priority is the safety of our employees and communities during this unprecedented time and we are doing everything we can to protect them. We created Corona Preventive Task Forces at the end of February 2020 and built Corona prevention teams, thus being updated in a very fast and regular way. Based on this, we have taken a large number of precautionary measures ranging from digital meetings to avoiding travel to increased information about hygiene to keeping daily contact logs. Thanks to the efforts of our IT team and our crisis management, we are still available for you.

 

What does this mean for our customers?

 

You can contact us

We are open and operational. Part of our colleagues are working mobile. To enable face-to-face meetings without travel, we use modern chat and video conferencing tools.

Service

With the increasing number of travel restrictions, we are offering remote service tools as a way to access the expertise of our service technicians. Our goal is to help keep your machines in production. We have increased our capacities accordingly. Installations and commissioning of new machines will be arranged in close cooperation with our respective customers.

Contact

HAVER NIAGARA GmbH: +49 (0) 251 9793 0
info(at)haverniagara(dot)com

Follow us also on LinkedIn, Facebook & Instagram

In addition, we are supporting DR-Process with Haver & Boecker pelletizing disc THE SCARABAEUS 7500. Find out more on our new landing page: haverniagara.de/pelletizing/ 


Delivery of spare parts

Supporting our customers’ ability to remain in production is our top priority. Our spare parts department is prepared. Most of our original spare parts are available as inventory. Due to closed border and longer waiting times, in some cases we will coordinate with our customers to determine the quickest way for ordered parts to reach them.

 

Please find below an overview of our most important measures

 

  • Travel has been limited to urgent business only.
  • Travel to areas of risk (according to the German Robert-Koch-Institut) and visits from these regions have been prohibited.
  • A travel history is required from all visitors.
  • Participation in large events such as symposiums, annual meetings, etc. is not allowed.
  • Cancellation of trade shows in risk areas or those with several participants and exhibitors from risk areas.
  • Internal and external meetings conducted primarily via video conference.
  • Daily contact log required from all Haver & Boecker Niagara employees.
  • Communication about proper hygiene and availability of disinfectants.
  • Temporary mobile office and voluntary self-quarantine rules in place for possible cases.

 

Thank you for your continued trust in us! Together we will cope with this challenge and we will get stronger! We wish you and your families all the health, patience and strength! We will see us in person again! Take care of yourself!

 

Peter Grotjohann

CEO of Haver Niagara GmbH

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Sustainable and efficient production of iron ore pellets with HAVER & BOECKER NIAGARA: Visit the new landing page http: //haverniagara.de/pelletizing/ to learn how!

Haver & Boecker Niagara is launching a new landing page: www.haverniagara.de/pelletizing/ presenting an innovative pelletizing technology: The SCARABAEUS® 7500 pelletizing disc, which aims to apply the own understanding of the company for sustainable and efficient iron ore production. The new page and the new technology as well are a part of the mission Planet Blue making an impact of the more careful use of resources and materials and contributing to the environmental protection.

The new landing page convinces with a powerful design and shares important information about iron ore & pelletizing technology. Scrolling through the different sections, the users quickly find out detailed overview of improvement of resource efficiency using the innovative HAVER & BOECKER NIAGARA pelletizing disc SCARABAEUS® 7500 and come across information about pelletizing service of HAVER Engineering GmbH. They discover how pelletizing process makes the distribution of very tight particle size possible and learn why pelletizing technology is so important for the enrichment of iron ore.

“The SCARABAEUS® 7500 with its unique SCARABAEUS process control is a strong tool for the operators to achieve specification of tomorrow by use of long term practical expertise. The experience of more than 50 years of common pelletizing of iron ores is the basis for Industry 4.0 in harsh industrial environments“ emphasized Dr. Jan Lampke, Head of sales at HAVER ENGINEERING GmbH.

The landing page presents SCARABAEUS®7500 – pelletizing discs used for agglomerating iron ore concentrates into pellets with very tight particle size distribution (target size of 10 to 14 mm) and supporting DRI-Process (processing method for sustainable and efficient production of iron ore):

“It is the direct iron ore reduction process, enabled by those uniform size pellets, which finally leads to the tremendous reduction in greenhouse gases. This innovative pellet based solution avoids the traditional blast furnace route and, hence, the energy intensive smelting of the ore and ensures the production of 97% pure iron at the end. This is such a great contribution to protect our climate through technology innovation”, said Prof. Holger Lieberwirth, Director of Institute of Mineral Processing Machines at Technical University BERGAKADEMIE Freiberg.

The optimum operating parameters of the disc can be set by automatic adjustment of the inclination, the rotational speed, the mass flow rate, and now also the rim height thanks to the innovative automatic pelletizing disc control system. The quality of the product is ensured thought the integrated camera system: because you can only manage what you can measure. In order to determine which process is the best for the customers iron ore and pellets requirements and to provide the possibility of achieving the desired parameters HAVER & BOECKER NIAGARA conducts iron ore tests in their Associated-Institute of TU BERGAKADEMIE Freiberg – HAVER ENGINEERING GmbH. All technical details, product advantages and also information about the mission of Planet Blue are briefly listed on the new page.

We are sure that on the new landing page you will find all the inspiring information about the sustainable and efficient production of iron ore that you need. The site contains also an integrated social media buttons for Blog, Facebook, Instagram and Linkedin to foster improved communication with the customers. Do not forget: “Power is gained by sharing knowledge, not hoarding it” (Maria Khan)! Let this knowledge reach as many people as possible! Share it, the innovation of HAVER & BOECKER NIAGARA: http://haverniagara.de/pelletizing/  & make your small but sure contribution to the mission Planet Blue: “Together to more careful use of resources and materials”.

Be one of the first visitors of the landing page http://haverniagara.de/pelletizing/ to find out the three main benefits for you choosing pelletizing disc The SCARABAEUS® 7500 for processing iron ore!

P.S.: If you would like to send us your feedback about your experience with the page, please send us an email: pelletizing@haverniagara.com

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HAVER NIAGARA strengthens the link between industry and university

When thinking about developing new technologies, universities bring valuable resources to the table and  HAVER NIAGARA GmbH always uses every chance to strengthen the link between industry and university. Last week our expert in fine screening Markus Löher gave an interesting lecture to the students at TU Bergakademie Freiberg. He shared with them insights and trends in the industry, answered question about our innovation in fine screening – the ultrasonic technology U-Class, supported the students by bridging the gap between theory and practice and gave them a look behind the scenes of his work life.

After the lecture, Prof. Holger Lieberwirt expressed his impressions: “The lecture was a perfect mix of revisions of different basics in mineral processing for our students shortly before the exam. You imparted exciting information about the latest developments in the magnificent field of fine screening and you have managed to show our students once again that Haver Niagara is a significant lead, when it comes to innovation in mechanical engineering. Thank you, Mr. Löher! You’ve made a great job!”.

Appreciating these kind words, we are sure that these students will be the experts of tomorrow and we have to support them. We can hardly wait to welcome one of them to our staff! Good luck!

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Haver & Boecker Niagara and Metinvest have met: Together for a future with more CO2-efficient ironmaking processing

The iron and steel industries are indispensable components of economy. Our world is built by using steel. We need even more steel for the improvement of infrastructure of our cities. Owing to this increasing steel demands we consider significantly growth of the iron ore production in recent years.

On the other hand, there are many environmental effects from the iron industry. Iron ore and steelmaking are the largest energy consumer of electricity and fossil fuels, being responsible for over 25% of hazardous atmospheric emissions and over 30% of carbon dioxide emissions. That’s why we need to think about sustainable solutions that minimize the CO2 emissions and energy use by iron ore production; solutions that deliver higher performance in terms of energy efficiency, resource efficiency and better process and product performance. We need CO2-efficient ironmaking processes.

One of the possible solutions could be direct reduction process like Midrex- or HYL, Corex process. 1

In this light, the transformation of iron ore into steel requires several process stages. First at all, we need to become H2 and iron ore pellets. Iron ore pellets produced from the iron ore concentrate by pelletizing and sintering. At the same time, the quality requirements of pellets, such as size distribution, physical, chemical and metallurgical specifications are higher and should be guaranteed by very innovative pelletizing technology that is able to ensure the perfect flow for our blue planet.

As a world’s leading supplier for customized screening, washing, pelletizing machines and plants solutions, we are feeling responsible to take actions into the protection of our environment by developing systems, which use fewer resources, fulfill the needed higher quality of the pellets and care for the health of the mother Earth.

Тhe result of our efforts we developed the SCARABAEUS pelletizing disc. The pelletizing disc fulfills the specification deeds for the processes of direct reduction and saves up to 5% energy by reduced recycling rate. The production capacity can be up to 150 t/h.

Those characteristics convinced experts from Eastern Europe in the potential of our innovative pelletizing technology for the production of iron ore pellets with a very narrow particle size distribution (10 to 12,5 mm) and high product rate (up to 70 %). Subsequently we got the great opportunity to work with one of the international steal and mining groups in east Europe: Metinvest. Аfter conducting iron ore tests in Haver Engineering in Freiburg and proving the possibility of achieving the desired parameters, a contract for the supply of the necessary equipment was signed. The pelletizing disc SCARABAEUS 7500 was delivered in combination with completely automatic control system.

In order to satisfy the higher needs of the pellets, an automatic pelletizing disc control system was introduced for the first time, incorporating three machine parameters: rotation speed, tilt angle, and board height.

In the end of July the CEOs of Haver Niagara GmbH (Peter Grotjohann) and Metinvest (Yuriy Ryzhenkov) have met in the manufactory of Metinvest in Ukraine. They inspected our powerful and reliable pelletizing technology and discussed the future course of our business relationship. The managers have dealt with all the advantages that our technology ensures to Metinvest and put heads together into developing the best strategy that is able to become fully aware of their common vision for the future: to live in a stronger, lighter and more sustainable world, where technology guarantees the care for the health of the mother Earth using highest environmental protection standards.

We are very happy that starting working together with Metinvest opened new doors to more CO2-efficient ironmaking processes and we have the unique opportunity to lay the first foundation stone of the future to green iron ore processing.

Metinvest, we would like to express our huge thanks for the trust, which you have placed in us. It is such a pleasure working together!

 

 

1 https://www.tec-science.com/de/werkstofftechnik/stahl-erzeugung-herstellung/direktreduktionsverfahren/

https://de.wikipedia.org/wiki/Stahlerzeugung

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Geheimrezept hoher Druck und wenig Wasser: Der Hydro-Clean reinigt Körnungen von Schad- und Störstoffen bei geringem Ressourceneinsatz.

Die Hydro-Clean Waschanlage HC aus dem Programm von Haver & Boecker Niagara befreit in effektiver Weise Nutzkorn von Schad- und Störstoffen. Dabei soll der Wasserbedarf im Vergleich zu traditionellen Waschsystemen um bis zu 75 % niedriger liegen bei ebenfalls um bis zu 15 % geringeren Energiekosten. Dieser Spareffekt ist der kompakten Baugröße und dem geringeren Gewicht gegenüber traditionellen Waschsystemen, die zudem eine größere Aufstellfläche haben und mehr Ausrüstung benötigen, zu verdanken. Das wartungsfreundliche Design ermöglicht im Bedarfsfall den einfachen Austausch der wenigen Standardkomponenten, wobei der HC laut Hersteller wenig verschleißanfällig sein soll.

Zur Reinigung von Aufgabematerialien bis zu einer Größe von 150 mm in einer vertikalen Trommel sprühen Hydro-Clean-Hochdruckdüsen Wasser mit Drücken bis zu 140 bar bei einer Drehzahl von 90 UpM auf das Material. Das Waschsystem entfernt auf diese Weise Schlamm- und Lehmpartikel bis zu 63 Mikron aus Mineralgemischen.

Die Waschanlage ist in vier Modellgrößen erhältlich, die 18 bis 400 t Material pro Stunde aufbereiten, je nach Typ und Anwendung. Der Wasserverbrauch reicht dabei je nach Anwendung und Modellgröße von 102 bis 798 l/min.

Das System funktioniert folgendermaßen: Verunreinigtes Material wird über einen Trichter in die vertikale Trommel des Hydro-Clean aufgegeben, woraufhin die oben montierten Hochdruckdüsen rotieren und das Material mit Wasser besprühen. Die Turbulenzen in der Trommel erzeugen zusätzliche Scheuer- und Schleifkräfte, die den Reinigungsprozess verstärken, während das Material den Trommelzylinder passiert. Am Ende des Reinigungsprozesses wird die Aufgabe über einen Abzugsförderer ausgeleitet, der zu einem Waschsieb führt. Dieses ist für eine Nachwäsche zuständig, während es gleichzeitig das Material fraktioniert.

Lesen Sie den Beitrag in Ausgabe 4/2019 von Gesteinsperspektiven

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Haver & Boecker Niagara visited the magnificent gravel and split plant in Saxony

The customer Steinbruch Schelmberg GmbH & Co. KG is completely satisfied with the perfect flow of our screening machines

We are always pleased, when our products provide added value for our customers. We developed this amazing gravel and split plant for medium-hard and hard rock for Steinbruch Schelmberg in Oelsnitz/Vogtland. There we implemented three of our free-vibrating screening  machines type T-Class in heavy duty design for regular and high loads, one Fine-Line especially for fine particle natural moisture screening and two Haver Niagara Feeder. They support our customer to classify his material of the secondary crushing stage by specific sizes, to re-crush the coarse excess material to a minimum size and finally to transport the classified material to the heap.

A modern robust built of this installation allows the processing of more than 200 t/h and crushes the feed material up to 90 mm. The processed material is used to satisfy the needs of asphalt and concrete industry whereby we also could contribute to the development of sustainable infrastructure for our cities.

Few months after processing start we visited our customer ‘‘Steinbruch Schelmberg GmbH & Co. KG” ones again. He is completely satisfied with the perfect flow of our screening machines, feeder, fine line and the whole process as well. He is impressed how fluently works the classifying of fillers from fine material and he find out that with our innovative processing technology he spares resources, increases his productivity and reduces his costs.

We highly appreciate hearing such fantastic impressions from our customers.

 

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Haver & Boecker Niagara N-Class Scalper Excels in Heavy-Duty Applications

Haver & Boecker Niagara offers the rugged, efficiency-enhancing N-Class vibrating screen to optimize crushing plants and screening operations through its ability to screen as much as 5,000 tons per hour. The Niagara N-Class is ideal for tough jobs, such as scalping and classifying ores, minerals, stones, sand and gravel in aggregates and mining applications. Haver & Boecker Niagara builds the equipment with an advanced four-bearing design that minimizes structural vibration and maintains constant g-force even through fluctuating material feed rates.

“The Niagara N-Class is a one of a kind machine with the ability to productively accomplish screening tasks other vibrating screens have difficulty with,” said Peter Grotjohann, managing director of the German facility. “The machine offers our customers an ideal solution for improving crushing plant efficiency and classifying coarse materials, therefore improving profits.”

Haver & Boecker Niagara’s N-Class offers one to threescreen decks and features an advanced single-eccentric shaft design that’s supported by four high-performance, double-spherical roller bearings. It is dynamically balanced to minimize dynamic loads transferred into the structure and allows multiple screens to be placed side by side in the same building. The N-Class maximizes screening efficiency and virtually eliminates blinding and pegging by providing a consistent g-force in all operational modes regardless of load consistency. A heavy-duty body design handles heavy loads in applications with extreme material sizes up to 2 x 1 x 1 meter. The screens offer a self-cleaning action to minimize common problems encountered with traditional grizzly feeders.

The N-Class is ideal for reducing loads and energy demands for a crushing plant by providing more consistently-sized material to improve crushing efficiency. The use of the vibrating screen in the process before the crusher increases the crusher capacity and maximizes the quality of the crushed product.

Each N-Class comes equipped with Haver & Boecker’s signature Ty-Rail System, which cuts media replacement time by about 50 percent by simplifying the process.

Haver & Boecker Niagara builds the N-Class for quick and easy re-balancing. It includes long-life bearings and a maintenance-friendly, modular machine design. The vibrating screen is equipped with buffers between the screen box and support frame for improved process reliability.

It is recommended to equip the machine with Haver & Boecker Niagara’s patented crossbeam abrasion protection system, Snap-Guard®. Snap-Guard is made from polyurethane and protects crossbeams from harsh materials, extending maintenance intervals, reducing operating costs and increasing profits.

About Haver & Boecker Niagara

Haver & Boecker Niagara is a leading provider in screening, washing, pelletizing and primary crushing systems. The company’s mission is to deliver the best of these technologies to customers in the aggregates, mining, mineral processing, chemical and food industries. With deep roots and years of experience in these industries, Haver & Boecker Niagara uses its innovative and shared technologies to effectively meet the needs of customers around the world.

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Haver & Boecker Niagara Offers Turnkey Solutions for Primary Crushing Plant Systems

MÜNSTER, Germany (June 5, 2019) — Haver & Boecker Niagara offers rugged primary crushing plants in a wide variety of configurations for pre-crushing, secondary and tertiary crushing in the mining and aggregates industries. From design to installation, the manufacturer uses its extensive industry experience and knowledge to provide turnkey systems engineered and built to individual specifications. Haver & Boecker Niagara will work with any crusher and peripheral component manufacturers to ensure customers receive the best plant matched to their requirements.

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“We’re entrenched in the mining and aggregates industries and are dedicated to each customer’s profitability and success,” said Peter Grotjohann, managing director of the German facility. “We use our industry experience and work closely with each operation to design comprehensive primary crushing plant systems with the highest level of durability, service and flexible design so each customer can find the best plant for their operation.”

Haver & Boecker Niagara offers turnkey primary crushing plant solutions through customer-oriented project support, from initial concept to the production phase. In addition to coordinating the physical plant, Haver & Boecker Niagara offers structural building engineering at the start, including verifiable statics calculation. The company features transportation management, supervision or the complete package: from assembly and electrical installation to plant start-up and optimization. Haver & Boecker Niagara also offers project management, on-site services, operating supplies, components or plant control. Operations also benefit from service and spare parts planning and service contracts.

Haver & Boecker Niagara provides crushing plant systems with a variety of components, including impact, jaw, cone or roller crushers, Haver screens or rolling screens, push feeders, apron conveyors and Haver vibrating feeders. The plant systems work with all peripheral components such as maintenance cranes, de-dusting systems, compressed air systems, hydraulics and hammers.

Customers choose from two types of systems, basic or master. Basic is the classic pre-crushing plant that uses a Haver & Boecker Niagara N-Class eccentric screening machine to relieve the primary crusher. It includes a feeder, vibrating screen, crusher and several conveyors. If needed, an additional screen deck screens stony earth either to be screened away or to be fed to production.

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The master system allows customers to get the most production and profitability out of their natural mineral deposit. The system provides increased flexibility for primary crushing stages, especially with non-homogeneous natural deposits. For high quality natural deposits, the operations can use the master system to feed extracted material completely to the production. The system can screen stony soil off to a second vibrating screen for moderate natural material deposits. The system can be configured to completely remove stony soil from difficult natural material deposits.

Both systems work with the Haver & Boecker Niagara N-Class vibrating screen. The screen is perfect for scalping thanks to its smooth operation and heavy-duty design making it capable of screening as much as 5,000 tons per hour. Haver & Boecker Niagara builds the equipment with an advanced four-bearing design that minimizes structural vibration and maintains constant g-force even through fluctuating material feed rates.

Haver & Boecker Niagara primary crushing plant systems feature rugged steel construction and a robust design incorporating a durable, optimum flow, low wear and maintenance friendly chute system and integrated custom conveyor technology. Accessibility is easy thanks to engineered work platforms, walkways and stairway systems. Integrated plant control systems and data management ensure intuitive operation.

Also included is comprehensive plant documentation on CE requirements and beyond and declaration of conforming with EC directives for machines 2006/42/EG (CE). Haver & Boecker Niagara gives extensive consideration of requirements for personal safety and the environment.

About Haver & Boecker Niagara

Haver & Boecker Niagara is a leading provider in screening, washing, pelletizing and primary crushing systems. The company’s mission is to deliver the best of these technologies to customers in the aggregates, mining, mineral processing, chemical and food industries. With deep roots and years of experience in these industries, Haver & Boecker Niagara uses its innovative and shared technologies to effectively meet the needs of customers around the world.

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Haver & Boecker Features Ty-Rail™, an Industry-Changing Tension Rail System for Vibrating Screens

Haver & Boecker features the Ty-Rail™ quick-tensioning system. The patented Ty-Rail system solves an age-old problem of time intensive screen media change-outs. Replacing tension rails is typically time consuming and requires removing and replacing many pieces of hardware per screen section. Washers or bolts are often dropped or lost in the process, which adds to downtime and parts costs. The Ty-Rail system provides a fast return on investment, and cuts screen change-out time in half.

Haver & Boecker will feature Ty-Rail in Hall B2, Booth 149 at bauma 2019 in Munich.

“As a whole, Haver & Boecker is committed to innovation that’s focused on improving efficiency,” said Florian Festge, Haver & Boecker managing director. “Our engineers’ invention of the Ty-Rail system solves the long-time problem of lost parts and difficult, time-consuming screen panel change-outs. Without a doubt, once implemented, our customers will see increased uptime and, as a result, profits.”

Each Ty-Rail package includes two tension rails, eight angle boxes and eight bolts; all the hardware required to change one screen section. Once installed, each rail becomes a singular, removable piece since the bolts remain attached to the rail, and the angle boxes remain attached to the vibrating screen. To remove the tension rails, an operator simply loosens the bolts on each, shifts the angle boxes up, and lifts the rail and bolts out as one piece. This reduces screen media change-out times by about 50 percent. Additionally, the innovation can take the task of changing tensioned screen media panels from two people down to one.

The system is designed specifically for Haver & Boecker’s vibrating screens.

About Haver & Boecker

Haver & Boecker, is a leading provider in processing, storage, mixing, packing, filling, palletizing and loading systems. The company’s mission is to deliver the best of these technologies to the marketplace. With deep roots and years of experience in these industries, Haver & Boecker uses its innovative and shared technologies to effectively meets the needs of customers around the world.

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Underground processing plant for fluorspar

The opening up of a new mine in Germany’s Erzgebirge (Ore Mountains) in late 2013 marked a milestone for German mining, continuing the tradition in this region, following decades of stasis. The reasons for the extraction of fluorspar and baryte are closely tied to steadily rising raw material prices on the world market. The operator, the Erzgebirgische Fluss- und Schwerspatwerke, chose HAVER NIAGARA GmbH when it came to designing and installing an underground processing plant for the mine in the Erzgebirge. HAVER NIAGARA GmbH took on the challenge to set up a flexible and economically viable processing plant (Fig. 1). Despite the limited space and the high requirements to be met by the processing plant, a tailored plant was designed (Fig. 2) that fulfils the high expectations of the operator to full satisfaction.

Fig. 1: Production line installed by HAVER NIAGARA GmbH

Fig.2: The space restrictions made it necessary to speciallytailor the plant to the conditionsin one of the two underground chambers

 

 

 

 

 

 

 

 

 

 

 

 

The processing plant roughly consists of two independent production lines, which were installed in two parallel underground caverns. In the first process stage, the blasted raw material is removed from the feed bin by means of reciprocating feeders and fed to a NIAGARA scalper (Fig. 3). This reduces the load to be processed in the downstream jaw crusher. The material from the primary crusher is conveyed on a troughed belt conveyor to a NIAGARA screen, which as well as screening off the ultrafine material, splits the material into two sub-streams to feed an X-ray sorting plant. This sorter separates the raw spar from the “dead rock” on the basis of the atomic density. The raw spar obtained in this way is crushed in a cone crusher to the necessary finished grain. The crusher discharge is sent via a downstream NIAGARA screen to a loading silo, there the raw spar is loaded onto road trucks.

Fig. 3: NIAGARA scalper in the first stage of the process

From there, the material is conveyed to the processing plant above ground, where it is ground and enriched in a flotation plant and then separated into the main components baryte and fluorite. After drying, two high-grade raw materials are produced, which are then sold.

Over the next years, HAVER NIAGARA GmbH will be on hand providing services for our german customer to keep the complete plant at its best both economically and ecologically.

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Haver & Boecker offers the Pulse Vibration Analysis Service Program

Haver & Boecker  Niagara features its Pulse vibration analysis service program. This innovation in vibration analysis gives mining and aggregate customers a means to optimum vibrating screen performance.

Haver & Boecker will feature Pulse in Hall B2, Booth 149 at bauma 2019 in Munich.

Pulse is designed specifically to monitor the health of vibrating screens to ensure optimum screening performance and equipment durability. Understanding that small imbalances can lead to substantial and expensive problems, the program detects irregularities that could translate into diminished performance, decreased efficiency and increased operating costs for the vibrating screen. The reporting and historical tracking of the machine’s performance gives customers the information needed to minimize downtime and maximize productivity and profits.

The program was developed to be easy to operate. Components were specifically chosen and engineered for the harsh environments where screening takes place.

“Pulse has the potential to significantly impact our mineral processing customers as well as others in the processing chain,” said Florian Festge, Haver & Boecker managing director. “Customers that utilize the Pulse system have the tools they need to optimize screening efficiency on a daily basis. This helps improve their operation’s profitability through minimized downtime and lower maintenance costs.”

Pulse gives customers the hardware and software required to instantly record vibrations on their machine. That data is then transmitted to Haver & Boecker where the engineering team analyzes it. The team then issues a report back to the customer including an analysis of the machine’s performance and recommendations for improvement.

If the results are good, the customer has reassurance that the machine is healthy. If the results require a Haver technician to examine the machine in person, a service call is scheduled.

The Pulse system uses an industrial-grade tablet computer that connects wirelessly with eight tri-axial sensors. The sensors attach to key places on the equipment and send up to 24 channels of data to the tablet, which displays a real-time view of the machine’s orbit, acceleration, deviations and more.

Beyond the real-time view on the screen, all of the information from the sensors is electronically stored in the database for an easily-accessible historical overview of the machine. The information can be downloaded online in two report formats. The Orbit Report provides a visual of orbit and wave form, as well as data about acceleration, stroke, speed and phase angle. Fast Fourier transformation, or FFT, plots are processed by the software for values for three channels of data for each measuring point. The Tuning Report extrapolates deviations between measurement points while providing recommendations on balance, acceleration, stroke and speed. It provides feed and discharge analysis as well as diagonal measurements.

About Haver & Boecker

Haver & Boecker, is a leading provider in processing, storage, mixing, packing, filling, palletizing and loading systems. The company’s mission is to deliver the best of these technologies to the marketplace. With deep roots and years of experience in these industries, Haver & Boecker uses its innovative and shared technologies to effectively meets the needs of customers around the world.

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Hooked Engineered Screen Media as Alternative to Costly Deck Conversions

Haver & Boecker Niagara, a leading equipment manufacturer and solutions provider in aggregates and mining applications, offers its Tyler brand of hooked engineered screen media as a solution to the problem of expensive deck conversions. Tensioned screen media can be used on a cambered deck, eliminating the need for a deck conversion when switching from woven wire to polyurethane screen media. The media includes products such as Ty-Max and Ty-Wire.

Haver & Boecker will feature Tyler engineered screen media in Hall B2, Booth 149 at bauma 2019 in Munich.

Hooked screen media allows operations to easily switch from woven wire to modular polyurethane products without the expense of a deck conversion. Retrofitting a machine from a cambered deck to a flat deck can cost as much as $15,000 per deck. Tyler’s tensioned screen media is used on a cambered deck to eliminate the need for that conversion. This also allows operators to test the media on a vibrating screen with no additional cost or commitment.

Another benefit is that Ty-Max and Ty-Wire can be blended with woven wire or self-cleaning screens on cambered decks. In many applications, operators are looking for more wear life on the feed end of the screen. This can be accomplished by installing a section of Ty-Max at the feed end. Ty-Wire can be used in the middle of the deck, for example, where basic screening takes place to give operators the ideal combination of wear life and open area. Using woven wire or self-cleaning screens at the discharge end will provide maximum open area at the end of the deck.

The screen media is manufactured out of Haver & Boecker’s signature blend of polyurethane. It’s made in one of the only facilities that blends its own material, which is critical for quality control. Chemists developed the media to offer the best combination of open area and wear life for both wet and dry applications. Engineered screen media is poured open cast, resulting in 1.5 to 2 times longer wear life than injection-molded products sold at comparable prices. In addition, open cast polyurethane permanently hardens when cured to maintain its chemical properties, so it resists wear and tear. Injection-molded screens can soften when the temperature rises during screening, resulting in shorter wear life.

Haver & Boecker manufactures a variety of engineered screen media options to suit different operations’ applications, taking into consideration top sizes and opening requirements. Operators looking for high durability and strength choose Ty-Max, which Haver & Boecker reinforces with an internal wire grid as thick as 9.5 millimeters (3/8 inch). Ty-Wire combines woven wire with an engineered composite to achieve open area closer to wire cloth but with four to six times longer wear life. Ty-Wire weighs less than woven wire, making it safer to handle and easier to install.

Haver & Boecker also offers Ty-Deck modular panels, available in multiple configurations for flat deck setups. Ty-Deck’s lightweight design eases installation and sectional deck replacements

To find out more about the benefits of Haver & Boecker hooked engineered screen media, email info@haverniagara.com or call +49 (0) 251 9793-0.

About Haver & Boecker

Haver & Boecker, is a leading provider in processing, storage, mixing, packing, filling, palletizing and loading systems. The company’s mission is to deliver the best of these technologies to the marketplace. With deep roots and years of experience in these industries, Haver & Boecker uses its innovative and shared technologies to effectively meets the needs of customers around the world.

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More profit with the innovative washing technology Hydro-Clean®

Reduced water and energy use

Haver & Boecker Niagara advanced Hydro-Clean® washing technology is helping a gold producer looking to expand its operation in eastern Russia increase production, reduce water consumption and minimize wear. The producer currently uses a test washing drum and two bearing screen to separate the sand and clay from its mined gold ore. This method provides inadequate washing results, causes excessive equipment wear and consumes high volumes of water and energy. Working closely with the customer, the HSG set up the Hydro-Clean 700 unit (Fig. 1) and rinse screen as a separate test operation to prove it could successfully wash the operation’s three distinct products better than the current test equipment. Each product has varying degrees of impurities, ranging from easy-to-wash to sticky material that is nearly impossible to clean with the current washing system. Since installing this combination, the operation has increased production from 5 t/h to 25 t/h, reduced its water consumption by up to 70 % and saved up to 30 % energy for every ton of material.

In preparation for a large mine upgrade project, these positive results have led the operation to put the Hydro-Clean in its plans for all future mineral washing.
The Russian gold producer, who asked to remain unnamed due to the competitive advantage this equipment provides, first contacted the HSG about the Hydro-Clean in 2009 after seeing impressive results at a different gold operation using HSG equipment. The Hydro-Clean appealed to the producer because its current washing system, a traditional washing drum, was not removing enough sand and clay content to produce the required 2 mm to 120 mm gold product with clay content less than 2 %.

 

 

 

 

 

 

• Clay-heavy material on the conveyor

Ideal for use in clay-heavy material deposits (Figs. 2 and 3), the Hydro-Clean employs high-pressure nozzles, rotating at 90 rpm, to spray up to 90 % recycled water on the material with pressures up to 200 bars (2900 psi) to remove silt and clay particles as small as 63 μm from mineral mixtures. While the high-pressure nozzles mounted at the top rotate and spray the material with water, the turbulence in the drum creates additional scrubbing and abrasive forces that enhance the cleaning process to break up agglomerates and clean the particles of stubborn material. The Hydro-Clean also injects high-pressure streams of water into areas of the material (holes, cracks, etc.) that are difficult to reach with traditional cleaning methods. A UME 1200 x 4500 mm rinse screen follows and rinses away the loose sand and clay contaminants. The end result is a cleaner gold ore product with clay content less than 2 % (Fig. 4).

• Final product is a clean washed material

The Hydro-Clean consumes far less water and energy. The test washing drum and two bearing screen used by the Russian gold producer consumes up to 13 m3 (13 000 liters) of water to wash just one ton of material. With the Hydro- Clean and rinse screen, the producer only uses a maximum of 4 m3 (4000 liters) of water for each ton of material, reducing the operation’s water consumption by up to 70 %.

In addition to water savings, the Hydro-Clean 700 model used by the gold producer was able to save up to 1.8 kW of energy for every ton of cleaned material when compared to the washing drum system. The Hydro-Clean’s compact size and reduced weight keep overall operating and structural costs considerably lower than with traditional washing systems – which also require more equipment and a greater footprint. In addition, it experiences little wear with a low-maintenance design that allows for simple replacement of the few standard components that are subject to wear. This allows operations to save thousands of rubbles in yearly maintenance costs. Thanks to the success of the Hydro-Clean 700 test unit, the producer plans to authorize an investment program that will allow the installation of a larger washing operation with several HSG Hydro-Clean 1000 units.

This operation would be capable of washing up to 4 million t of auriferous ore a year. To make the adaption of this new, advanced washing technology easier, the HSG has provided easy-to-understand flow sheets on how the Hydro-Clean would fit into this new operation. If made part of the producer’s every day operation, the Hydro-Clean could reduce its total water usage by up to 70 % and energy costs by up to 30 %.

 

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Haver & Boecker Optimizes Mining Operations with NIAflow Software

Haver & Boecker offers NIAflow plant simulation software. NIAflow helps producers optimize quarry and mine operations by diagramming plant flow, machine placement, product pre-calculations and more.

Haver & Boecker will feature NIAflow in Hall B2, Booth 149 at bauma 2019 in Munich.

Developed by Haver & Boecker engineers, NIAflow instantly analyzes existing or proposed processes, records plant statuses, and recognizes potential for plant optimization. The software is available for download on Windows-based systems. NIAflow supports the user in every engineering phase, from drafting flow diagrams for product pre-calculation to plant start-up and simulating parameter changes. Its intuitive menu control makes it easy for all levels of experience, and Haver & Boecker provides several levels of training, if needed. These can be group, company or even individual training sessions.

“We are constantly developing innovative machines, programs and software to help optimize plant efficiency,”

said Florian Festge, Haver & Boecker managing director.

“NIAflow will serve as a cornerstone in the development of process engineering projects. When paired with other Haver & Boecker technology, such as Pulse vibration analysis software, our customers will hold all of the tools they need to optimize process flow and increase productivity and profits.”

NIAflow allows users to analyze more than 90 different process equipment pieces, from crushers and vibrating screens to material washers and conveyers. Beyond equipment, the system uses scientific-based methods to monitor the operation’s input, output and waste piles. The program calculates the mass and volumetric flow rates as well as the valuable content with machine-specific operating parameters to prevent plant bottlenecks before equipment is in place.

“NIAflow will significantly impact the efficiency and profitability of our mineral processing customers,”

said Joachim Hoppe, Haver & Boecker Mining general manager. “The thought process behind this software development was to give our partners tools to closely monitor their plant setup as a whole, allowing them to identify problems and plant bottlenecks. NIAflow helps producers discover the most efficient set up for existing equipment as well as determine equipment needed to enhance productivity and increase production.”

NIAflow is available for purchase for aggregates and mining. The NIAflow Aggregates version is the extensive, full version of the NIAflow simulation software that allows unlimited machine input. NIAflow Mining complements the Aggregates full version, but offers additional equipment options, such as classifying and sorting equipment.

A basic, complementary version of NIAflow is available for download at www.niaflow.com.

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Successful project ‘Organic Fertilizer’

Fertilizer production with the HAVER pelletizing disc SCARABAEUS

In view of the increasing food requirements of the world’s population and the continuing eluviation of the soil due to intensive agriculture as well as the loss of arable land following sealing of surfaces in urban environments, the exploitation of raw materials and the contamination with pollutants, fertilizers are becoming more and more important in the production of foodstuff.

Plant growth and harvest quality generally depend on how much of the required nutrients there is in the soil. The nutrient of which there is least defines the success of the cultivation. It follows that fertilizers are needed to make up for any deficits. Today, great demands are made on the fertilizers used to increase the yield of crops, for example regarding the mineral combination which supplies the plants with nutrients, or regarding the structure and shape of the fertilizer pellets to improve the flight behaviour when the pellets are spread.

The company “Australian Mineral Fertilisers“ produces fertilizers under the brand name ‘GrowSafe®‘ in Tenterden, West Australia. The biological mineral fertilizer is a material mix. Every pellet contains all combinations of minerals. The pellets are suitable for spreading with standardized sowing and fertilizer distributors. They are sold in Big Bags, 25 kg bags, or as bulk material.

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In recent years, the company was faced with the question whether a 10-year old pelletizing drum could be safely replaced by a pelletizing disc to increase production capacity and product quality.

Owing to the complexity of the processes, the production of mineral fertilizers by means of the pelletizing drum proved to be increasingly complicated and highly inefficient due to the high volume of undersized and oversized pellets beyond the specified product range. The requirements made on a pelletizing disc were very high: In addition to a significant capacity increase from 7 to 20 t/h, it was to improve product homogeneity as well as product quality.

Australian Mineral Fertilisers directly contacted HAVER NIAGARA in Münster. Both sides quickly agreed that test runs were required to provide a basis for further discussion and for dimensioning the system components. In cooperation with HAVER ENGINEERING, a test concept was generated to investigate the suitability for pelletizing, which drew the interest of the project owners at AMF’s.

An AMF associate together with the Plant Manager came to the site of HAVER NIAGARA to gain a personal impression of the manufacturing capacities. They also visited the R&D Center of HAVER ENGINEERING in Freiberg, to learn more about the results of the research. A presentation of detailed results and the demonstration of agglomeration tests with AMF fertilizers convinced the customers of the capabilities of HAVER SCARABAEUS. With up to 80 M.-%, the share of usable fertilizer pellets, produced in the tests under laboratory conditions, exceeded the expectations.

Based on the results of the test runs, the decision was made to replace the pelletizing drum by a pelletizing disc of the HAVER SCARABAEUS® series.

The features that made AMF decide on the HAVER SCARABAEUS 4200 were the robust design, the energy-efficient and low-maintenance drive unit with two asynchronous motors, which allow for start-up even under full load and ensure continued operation if one of the motors fails, as well as the system’s high flexibility, such as the possibility to adjust inclination and speed during ongoing operation.

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Around the time this decision was made, HAVER AUSTRALIA was established in Perth West Australia. This means that the parameters for designing and dimensioning the system could be coordinated quickly, reliably and at low costs between the customers and HAVER NIAGARA.

In addition to the pelletizing disc HAVER SCARABAEUS SC4200 complete with its control system, a HAVER NIAGARA T-Class 1500×5000 for product grading and a Computer Particle Analyzer CPA 2.1 of our wire weaving company for continuous determination of product quality was sold. Other machines from the extensive product portfolio of HAVER NIAGARA are already operating successfully in the chemical fertilizer industry (MAP, DAP, NPK).

With 61 M.-%, the share of usable pellets in the product was above the level of the previously used drum already during the commissioning phase of the pelletizing disc in autumn of 2013. Today, after completed commissioning and some months’ worth of experience, the rate of yield for AMF is up to 80 M.-%. Even the solidity and roundness of the pellets improved significantly. The Plant Manager confirmed that his customers had registered this distinct improvement in quality and said that they were very satisfied. Such success stories not only guarantee the good image of the HAVER group in the eyes of the customers but also provide for sustainable growth of the customer, who can continue to rely on the services of the HAVER Group as a technological partner.

After the completion of commissioning, HAVER Australia took over customer service. They will carry out the regular maintenance of the machines and support the customer in future process optimization.

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Primary crushing plant and processing of riprap in the Sauerland region

 

HAVER NIAGARA GmbH: after one and a half year new operators came to a positive result

The quarry for greywacke “Kleinhammer” is situated among a wooded mountainous region in Sauerland, sixhundred meters in south-east direction to the town Werdohl-Kleinhammer. Since the change of ownership in January 2015, Holcim, a manufacturer of construction material, has operated the quarry. Ownership changes did not result in a change of personnel.

In close collaboration with the previous operator HAVER NIAGARA GmbH designed a new primary crushing plant with subsequent processing of riprap. Besides the primary crushing plant and processing of riprap the scope of supply also included the complete conveying system, the intermediate silo and the dust silo as well as the planning of concrete works and the overall assembly.

The main challenge in this project were great demands of the customer on quality specifications, emission and environmental standards as well as the tight schedule for finalization. Furthermore, the installation should secure a safe and flexible production for the next decades. By means of the designed concept HAVER NIAGARA provided an innovative solution for the fulfilment of these requirements.

An example of the flexible production is the processing plant for riprap. The weight classes 540 kg and 10-60 kg can be processed separately or simultaneously on request by means of two heavy duty screening machines. Soundproofed building facades, energy saving electrical components and the dedusting unit are the main objective with regard to emission and environmental protection.

The period for the realization from the start of project until commissioning took 12 months. Due to the onset of winter at the beginning of 2013 concrete works had to be stopped for several weeks. Therefore, the planned start of production was endangered. The specialist in  from Münster took up that challenge and modified the assembly process, so that contrary to the initial plan the building for the processing of riprap was installed at first. The concrete works on the building for the primary crushing plant have been continued at the same time. As a result of the measures taken, the scheduled start of production was at the beginning of September 2013. On the occasion of the opening celebration on 27 September the installation was formally inaugurated with a spectacular firework.

The successful realization of the project has been achieved by long-term and close cooperation between the previous operator and the experts from HAVER NIAGARA. This is the pooling result of years of experience and the technical know-how of both companies.

The precise realization on the basis of prescriptions is an impressive example for the problem-solving expertise of HAVER NIAGARA – particularly with regard to an efficient conception of primary crushing plants and its precise implementation.

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