IPCC
indurad's IPCC automation journey
indurad has been founded on the success of an R&D project starting in
2003 at RWTH-Aachen's Institute of Advanced Mining Technologies (AMT),
evaluating suited sensor technologies for the automation of IPCC and
other equipment. The research contained benchmarks of laser, radar, RTLS
and ultrasonic technology, and it turned out that radar technologies were
most suited for these mining applications due to dust and fog, however,
they were only available as 1D level gauge radar. indurad consequently
developed 2D radar under the iPosition system name and was granted the
first IPCC related order in 2008 from one of the world’s larger IPCC system
mining company operators RWE Power, which runs more than 15 bucket
wheel excavators and 15 spreaders, with single BWEs having a daily
capacity of up to 240,000 t of coal or overburden. The systems are spread
across three large lignite mines in Germany: Garzweiler, Hambach and
Inden.
RWE Power’s Senior Manager of electrical and mechanical maintenance
section at Inden mine Wilfried Gau comments: “We started with indurad´s
2D radar on the suspended hopper cars and based on the high availability
of the manless-automation mode we have been rolling out the concept on
the travelling hopper cars and on the spreader side where we replaced
existing laser solutions providing now a better machine availability.
Finally, we reduced wear on the machinery as of reducing steering
commands of about 20% .”
indurad’s iPosition technology can be now found worldwide, for
example in Chile with a focus on leach pad systems including bridge
systems from FAM at BHP Spence or a FAM reclaimer at Codelco's
Radomiro Tomic. Christian González, indurad’s Managing Director in Chile
and PLC expert states: “iPosition together with iBelt and iReclaimer
support robust control loops on the machines increasing the tonnage
rate by more than 15%, besides protecting the machine with 2D iSDR
radar crawler collision avoidance."
One of the latest projects was the implementation on a brand-new
thyssenkrupp Industrial Solutions (tkIS) Bucket Wheel Excavator (BWE)
together with a Mobile Belt Wagon (MBW) and Cable Reel Car (CRC) at
Huaneng Coal’s YiminHe coal mine in China. The mine is one of China's
pioneers in using modern IPCC technology and first used indurad´s
iPosition technology on a tkIS fully mobile crusher fed by a rope shovel
back in 2003 and specified this system based on its good experience for
the new YiminHe II project. “In China we installed the world’s most
advanced iPosition solution using all three technology layers: 2D iSDR
Radar, 3D iRTT RTLS relative local positioning and 3D iSMU GNSS global
positioning – it is fault-tolerant with ‘hot spares’ allowing a broken cable
spokesperson said. “Dump trucks are carrying ore
and overburden for about 5 km; by 2023 this will
increase to 7 km – hence the decision to build the
conveyor complex.” The project has the added
benefit of reducing emissions as there will be less
exhaust from the equipment in the pit, the
spokesperson added.
Mae Moh’s long standing use of sizer
technology
MMD is delivering another Semi-Mobile Sizing
Station and 500 t Atlas Transporter to the Mae
Moh coal mine in Lampang, Thailand. This crucial
asset feeds the neighbouring Mae Moh Power
Station, owned & operated by EGAT (the Electricity
Generating Authority of Thailand).
ITD (Italian-Thai Development Public Company
RWE Power's Inden mine excavator 275 was indurad´s first IPCC
automation project with 2D radar and RTLS sensors now being in
operation for over 10 years
or sensor to be replaced in the next shutdown without stopping
automation of both transfer points and repairs to be carried out at -30C°”
says Dr Reik Winkel, founder of indurad and foremost a Mining Engineer
understanding the need for rugged technology.
In Chile, the ore flow at the Chuquicamata Underground project (see
dedicated section) on TAKRAF and Metso equipment is also monitored
with indura’s advanced radar technology, comprising 50 sensors (a mix of
1D iLDR and 2D iSDR types) on the ore passes, feeders and crushers.
indurad technology use at YiminHe II transfer point showing operator
interface with triple technology transfer point automation between
BWE and MBW
Ltd), the mine operator for phase nine of the
project, has also requested MMD to undertake the
design of a far-reaching refurbishment of the four
Semi-Mobile Sizing
Stations supplied back in
2001 for phases five, six
and seven. After
installation of these new
and refurbished machines,
it will bring the total to
eight MMD Sizer Stations
and two MMD Atlas
Transporters operating at
Mae Moh coal mine. MMD
has had a long relationship
with the mine dating back to 1993, and delivered
true turnkey processing solutions to assist the
mine’s progress, from initial order through to final
commissioning and aftersales service and
support.
MMD is delivering another Semi-Mobile Sizing
Station and 500 t Atlas Transporter to the Mae
Moh coal mine in Lampang, Thailand
MAY 2020 | International Mining