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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.

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 %.

 

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.