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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

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.

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.

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.

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.