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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.

 

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.

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.

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 %.

 

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.