• +49 (0) 251 9793 0
  • info@haverniagara.com

Tag Archive mineral processing

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

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!

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.

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.

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.