SCREENING
stratification to ensure product specification . It also creates a dynamically balanced system that transmits virtually no vibration into the structure - or chassis - preserving the integrity of the structure while also allowing for multiple machine installations . The upgraded design retains the technical benefits the original F-Class is known for , such as enhanced material stratification and reducing blinding and pegging .
The company also exhibited Niagara Exciters , its company ’ s signature brand of vibrating screen exciters . “ They provide increased service life and reduced maintenance , coming standard on Haver & Boecker Niagara ’ s high-capacity exciter-driven vibrating screens - the XL-Class and L-Class . The company engineers Niagara Exciters to set the required stroke , frequency and exact static moment for each application for improved screening performance .”
Additionally , Haver & Boecker Niagara featured its Pulse Diagnostics portfolio , which monitors the health of vibrating screens and identifies issues before they become critical , improving operations ’ productivity and proficiency . The suite combines Pulse Vibration Analysis , Pulse Condition Monitoring and the Pulse Impact Test to give mining producers a more holistic view of their individual machines and allow them to maximise uptime and screening efficiency through planned maintenance .
Finally the OEM highlighted Rhino Hyde liners , a critical component in the mining setup process , offering superior abrasion resistance when installed on key wear areas of chutes , hoppers , vibrating screens and more . “ They are essential for reducing wear on equipment at each point of the operation , from hauling to screening and material handling .”
Back to screens and earlier this year Haver & Boecker Niagara custom-engineered the largest vibrating grizzly screen in the world . Manufactured with SSAB Hardox ® steel perforated plates and grizzly bars for an unnamed large Brazilian iron ore operation , the Niagara XL-Class vibrating grizzly screen boasts a capacity of 8,000 t / h and a cut size of 200 mm . IM understands the unit is set to be commissioned in Q4 2024 .
As the largest exciter-driven machine in the industry , the company says the XL-Class provides the operation with high-capacity screening while maximising uptime and production . Combined with the grizzly technology , the XL-Class has the ability to remove oversize rocks , relieving pressure on the primary crusher .
At 120 t , the machine ’ s size required a modular approach , so Haver & Boecker Niagara engineered the XL-Class vibrating grizzly screen as two bodies . The 1.3 m top particle size that the screen had to be able to handle did not allow for the normal placement of exciters , resulting in an adjustment of the design to place three exciters beneath each body rather than the standard overhead location .
“ We recognise that no two operations are the same , which is why Haver & Boecker Niagara takes the time to understand each of our customers and their needs for every new quarry or mine location ,” said Denilson Moreno , Sales Manager at Haver & Boecker Niagara . “ We have worked with this customer for many years , but as they began production at what is the largest iron ore operation in the world , we realised to truly maximise output , it would require a durable and extremely efficient primary screen . That ’ s what led us to engineer and manufacture this XL-Class , which is now the largest vibrating grizzly screen on the market .”
Haver & Boecker Niagara says it listened to the operation ’ s challenges and employed their signature NIAflow plant simulation software to address them . The software analysed the proposed plans , processes , goals and material for plant optimisation , providing information to the customer and Haver & Boecker Niagara to design and custom engineer the one-deck vibrating grizzly screen .
To maximise uptime , the customer opted to equip the XL-Class vibrating grizzly screen with Haver & Boecker Niagara ’ s signature Pulse condition monitoring ( Pulse CM ) system . The advanced technology provides the producer with 24 / 7 access to the health of its vibrating screen . Pulse CM includes up to 20 sensors placed on the bearings and bodies , which continually assess the acceleration of the machine and provide a forecast of the equipment ’ s dynamic condition in intervals of 48 hours , five days and four weeks .
Additionally , the sensors capture real-time information on the monitored equipment and send e-mail alerts to the producer at the first sign of system anomalies . The collected data provides insights into preventive maintenance opportunities , the ability to catch possible issues before they cause unplanned downtime and the peace of mind that the machine is running at peak efficiency .
“ Our goal is not only to provide our customers with top-tier equipment but to act as a true consultant and partner to them ,” said Clayton Carvalho , Managing Director of Haver & Boecker Niagara ’ s Brazil operation . “ With more than 150 years of experience in the mining and aggregates industry , we are proud of the equipment and technology that we can offer as well as the knowledge and expert service we bring to our customers .”
FLS highlights wear solutions at Electra Mining Africa
FLSmidth used the recent Electra Mining Africa event , in Johannesburg , South Africa , providing a good platform to launch a new solution for its wear product line .
The company is driving sustainable productivity through its solid and growing support and maintenance infrastructure , it says . According to Alistair McKay , Vice President Mining : Europe , Arabia and Africa at FLS , this includes engaging visitors at the event on the value of the company ’ s innovative digital solutions .
“ In addition to our market leading solutions for mining plants , we will be sharing our extensive foundation of expertise , technical services , spares and consumables to support customers ,” McKay says . “ The show gives us the opportunity to demonstrate how these resources can lower operating costs and drive profitability .”
Key to FLS ’ s success in doing this is its understanding of exactly how its solutions are performing in customers ’ processing facilities . As the original equipment manufacturer , he argues , the company is best placed to partner with mines to optimise performance and to maintain equipment health at the highest level .
“ There is a global shortage of skills to conduct this important work , making it essential that we continue to both replenish and enhance the necessary levels of expertise for our everadvancing equipment ,” he explains . “ This is why we invest so heavily in our training facilities and trainers – to upskill not only our own people but those of our customers .”
He highlights that there is “ nothing worse ” than for customers to invest in high quality , high production equipment , which then underperforms due to insufficient knowledge . The company is also leveraging digital solutions in this endeavour .
“ While there is a plethora of digital solutions in the market , we have focused our energies on creating solutions that meets strategic priorities ,” McKay says . “ This means being able to monitor and analyse the health of the asset , while leveraging this data to optimise the performance of that asset .”
Visitors at the exhibition were also able to see how FLS ’ s digital solutions integrate with its control centre , from which it can provide customers with 24 / 7 support . In terms of new offerings , FLS launched its NexGen Polyurethane formula for the company ’ s wear products . NexGen Polyurethane is relevant to screening media and mill trommels – particularly at the front-end of the concentrator where impact and abrasion is high .
FLS stated : “ Designed to meet all your screening needs , NexGen features exceptional abrasion and cut resistance , high elasticity , and low compression deformation . Compatible with screens and trommels across various processing
42 International Mining | OCTOBER 2024