CONVEYING
similar or highly comparable project in the past. This enables it to draw upon real-world learning and examples to meet clients’ needs. Shipp:“ With a huge emphasis on reliability, longevity, and meeting the unique material requirements in the mining field, Wolf Point remains one of, if not the only, true full scope bulk system suppliers in the domestic US mining market.”
ABB completes GCDs for LKAB’ s Malmberget conveyor modernisation
In 2023, LKAB awarded ABB a contract to install two ABB Gearless Conveyor Drives( GCDs) on the existing conveyor belt system at its Malmberget mine, Gällivare, Sweden. As part of its commitment to operational excellence and sustainability, LKAB is modernising its conveyor system in the Malmberget iron ore mine in northern Sweden. This includes replacing conventional conveyor drives on a 25-yearold belt conveyor with gearless conveyor drives( GCDs) from ABB. This strategic shift aims to improve efficiency, reliability, and throughput.
The existing setup already carried up to 15 Mt of iron ore every year, using a 2,800 kW wound rotor induction motor( WRIM) with gearbox to drive the conveyor. It has now been replaced with ABB’ s latest GCD technology, two 1,600 kW models with permanent magnet motors( PMM) to enable an increase in annual production while reducing energy consumption per tonne.
ABB’ s mechanical and electrical engineers and project management team faced the challenge of working in a tight space at around 815 m underground to remove large pieces of equipment and replace them with the new units.
ABB says its GCDs are available for a motor power of between 0.2 MW and 10
MW, removing the need for a gearbox and thereby lowering maintenance costs while improving overall reliability and leading to greater uptime. A unique ABB innovation, a gearless drive using a permanent magnet motor, it says is the most energyefficient conveyor drive solution.
The GCD’ s permanent magnet motors( PMM) are directly coupled to the existing conveyor’ s drive pulley and can also adapted to meet the particular demands of this underground installation. The main advantages are energy savings, health and safety improvements, reduced maintenance costs and steady, solid production due to higher reliability and availability compared to geared drives.
In this case, the two new 1, m625 kW permanent magnet motors( PMMs), replaced an outdated 2,800 kW slip ring motor and planetary gearbox. The gearless design reduces space requirements, fire load, and noise, contributing to a safer work environment. As part of the modernisation, new system requirements were also made. The mass flow was to be increased by raising the belt speed. The new drive system was intended to meet the current state of the art and be optimised particularly in terms of energy efficiency, reliability and controllability.
The following parameters were defined for the new drive system: target mass flow 3,600 t / h; direct drive with low-voltage frequency converter; total drive power 3,250 kW; pulley speed 43 rpm; and belt speed: 3.6 m / s.
ABB GCD in place at LKAB Malmberget
ABB told IM that the commissioning of the two ABB GCDs was successfully carried out due to careful planning, excellent engineering and project management. Dismantling of the old and installation of the new drives took place during an annual twoweek general maintenance period.
“ Because of the precise engineering and preparation of this transition, all work could be completed on schedule and in time for the resumption of production. Drive optimisation was carried out in parallel with the ramp-up of ore production, and the conveyor began operating at the new production target,” says Ulf Richter, ABB Product Manager Conveyor Solutions.
The belt conveyor has been in operation with the new direct drive since May 2025 and allows for an increase of 20 % in production capacity for the conveyor.“ Here at Malmberget mine, Europe’ s largest iron ore mine, sustaining high productivity while
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International Mining | FEBRUARY 2025