Digitalization is key – industry

trends and challenges

Mining

The next generation

of direct drives

Cement

A holistic approach

for cement plants

01.2016 | siemens.com/magazine

The Magazine

for the mining and cement industries

Contents

Editorial |

Imprint |

News

Onboard energy storage systems are significantly

improving hauling operations

Mining for productivity and profit

at the Sentinel copper mine

Cong Thanh cement plant benefits

from an integrated automation and drive system

Digitalization is key to remaining competitive

in the global mining industry

Cover story

Digitalization is key

Industry trends and challenges

Mining

The next generation

Direct conveyor drive systems

A major overhaul

Energy efficiency

Pit perfect!

Conveyor systems

Mining for productivity and profit

Kalumbila Minerals Ltd., Zambia

Steep challenge

Conventional mill drives

Coming full circle

Process instrumentation

Powering the gold rush

Horizontal mills

Service

Retrofits raise profits

Integrated Drive Systems

Cement

A holistic approach

Cong Thanh Cement Joint Stock Company,

Vietnam

Smart move

Control system migration

A greener brownfield

Plant modernization

Siemens AG

siemens.com/magazine/industry | 01.2016

Over the last three years in the mining industry, we have seen substantial

changes – from the all-time high prices of gold, copper, and iron ore in

2011 to the historic lows of today’s commodity prices. When asked when the

market will recover, experts are hesitant to make precise predictions – but as

Deloitte’s 2016 trend outlook for mining suggests, we may not be there yet.

Instead of hoping for the best, operators, engineering companies, and equip-

ment suppliers should focus on exploiting synergies and optimization poten-

tial in order to remain competitive in an increasingly challenging and volatile

market.

Digitalization can provide several levers for this. From improved asset man-

agement to smart sourcing and efficient global collaboration, software and

data can help companies streamline their processes. For example, simulation

tools can help increase the output of existing equipment, such as gearless

drives (see page 18). Another area for operational improvement is energy

efficiency. As mining operations expand and the grades that can be mined

deteriorate, the amount of material that needs to be transported and the

transport distances increase – resulting in higher emissions and costs. Our

experts have devised several solutions that address this issue, for example,

energy-storage systems for small trucks (see page 14) and an efficient drive

solution for a new pipe conveyor system for open-pit mining (see page 16).

As a trusted partner to the mining and cement industries, we support opera-

tional excellence first and foremost with our proven products, systems, and

solutions for electrification and automation: robust, reliable, and efficient

integrated drive systems and integrated automation solutions that provide

both the control and the data needed to optimize operations, including sourc-

ing and maintenance. These solutions are complemented by our digitalization

portfolio. Tools such as Comos for integrated engineering and highly-efficient

operations can help streamline the design and implementation of new proj-

ects, and our operations intelligence software XHQ can help operators collate

and assess data from various sources for informed decision making.

With this issue of our customer magazine, we want to provide you with some

insights into how companies can improve their operations with our solutions.

For a more detailed and hands-on experience of our products, systems, and

services, come visit us at the BAUMA 2016 exhibition (booth 325 in hall C2) in

Munich, April 11–17. We look forward to seeing you there!

Kind regards,

Mikael Leksell,

CEO, Process Industries and Drives - Process Solutions

Success is a matter

of drive and partnership

01.2016 | siemens.com/magazine/industry

Imprint

Order from B2Gold, Canada

Siemens supplies drive systems

for two gold mills

Siemens project partner FLSmidth was commissioned

by Canadian gold producer B2Gold at the end of 2015

to supply two mills for grinding the ore in its new plant

in Mali. FLSmidth will be supplying a semi-autogenous

grinding (SAG) mill as well as a ball mill. Both mills will

be equipped with Siemens Integrated Drive Systems that

will help B2Gold reduce its capital investment and save

up to 50% on spare parts.

By using converter technology for regulating the

rated speed of the SAG mill motors so that the four large

Flender gears all work with the same transmission ratio,

both mill types can operate with the same gear size and

design. This reduces capital investment for the mechan-

ical drives by 17%

and spare parts costs

by up to 50%.

The SAG mill is driven

by two 7,500-kW, air-

cooled asynchronous

motors from the

Simotics HV series;

oil-filled drive isolation

transformers; and two

water-cooled Sinamics

GM150 frequency

converters. For the

dual-pinion ball mill,

Siemens USA is supply-

ing two 5,250-kW

slip-ring motors,

liquid starters, and

the frozen charge

protection package. The gears, couplings, and lubri

cation units for the two mills will be supplied by

Siemens Flender in Illinois. The frozen charge protec-

tion function developed by Siemens protects mills

during start-up by ensuring that the charge that has

become firmly attached to the mill wall does not detach

rapidly and damage the mill. Different operating modes

of the mills, such as controlled ramp-up, load balanc-

ing, creeping, and inching, all serve to reduce the load

on the mechanical components, significantly extending

the service life and preventing damage. Additionally,

a controlled load balancing function is provided to help

minimize mill downtime.

siemens.com/mining

Published by:

Siemens AG

Communications and Government Affairs

Wittelsbacherplatz 2

80333 Munich, Germany

magazine@siemens.com

Responsible for content:

Winfried Wittmann

(in accordance with the German press law)

Edzard Lübben

Thomas Walther

Concept, coordination:

Daniela Michel-Fracci, Cornelia Dürrfeld

Editorial committee:

Thomas Walther

Karen Chong

Daniel Schmid

Publishing house

Publicis Pixelpark

P.O. Box 32 40, 91050 Erlangen, Germany

Editorial staff:

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Art direction:

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Layout:

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Copy editors:

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DTP:

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Print:

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Circulation:

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Munich and Berlin.

Article number:

VRMI-M10007-00-7600

The following products are registered trademarks

of Siemens AG:

BIPEX, CALOMAT, COMOS, DRIVE-CLiQ, ET 200, LOGO!,

MAXUM, MicroSAM, OXYMAT, PCS 7, S7-300, S7-400,

S7-410, S7-1200, S7-1500, SCALANCE, SILYZER,

SIMATIC, SIMATIC HMI, SIMATIC IPC, SIMATIC IT, SIMATIC

RF, SIMIT, SIMOTICS, SIMOTION, SINAMICS, SINAUT,

SINEMA, SIPART, SIPAT, SIPEX, SIPLUS, SIPROCESS,

SIRIUS, SITOP, SITRAIN, SITRANS, STEP, TIA, TIA Portal,

ULTRAMAT, WinCC

If there is no special mention of trademarks, trade names,

technical solutions, or similar items, this does not mean

that these items are not protected.

The information in this magazine contains only general

descriptions and performance features which do not

always apply in the described form in the actual application

or which may be subject to change in the course of further

development of the product. The specific performance

features are only binding if they were agreed expressly in

the contract.

carbon neutral

natureOffice.com | DE-217-445643

print production

Siemens AG

siemens.com/magazine/industry | 01.2016

News

thyssenkrupp Industrial Solutions and Siemens have

extended their successful collaboration for mining

conveying system solutions for another five years,

which ensures that the mining industry will continue

to profit from innovative and reliable transport sys-

tems and solutions.

The mining industry is faced with falling grades

and new mines in remote locations, both leading to the

need to transport more material over longer distances.

“Conveying technology must keep up with the com

plex requirements of the modern mining industry. We

want to continue offering our customers reliable and

highly-efficient conveyor systems,” says Jens Michael

Wegmann, Chairman of the Management Board of the

Industrial Solutions business area of thyssenkrupp.

“It is only possible to optimize modern mechatronic

belt drive systems like this by working in close colla

boration with a partner because the mechanics and

the motor form a self-contained unit. That’s why we

are continuing the tried and tested collaboration with

Siemens,” Wegmann continues.

In mining, robust, reliable, and easy-maintenance

drive technology is a key component of conveyor sys-

tems. “We are happy to be able to keep on supporting

thyssenkrupp with our well-proven direct drive sys-

tems featuring Sinamics cycloconverters and rugged

synchronous motors that have undergone continuous

development in recent years,” says Jürgen Brandes,

CEO, Siemens Process Industries and Drives. Both

Together with the well-established engineering

service provider and Siemens Solution Partner CESA

Cement Engineering SA, renowned for excellence in

engineering and consultancy services for industrial,

mining, and cement plant projects, from feasibility

studies to commissioning to start-up, Siemens has

recently successfully implemented several inter

national cement projects, meeting tight schedules

and overcoming challenging conditions.

One particular project to benefit from the smooth

cooperation between Siemens and CESA is NOCIBE,

owned by Les Ciments du Sahel, currently the largest

cement plant in Benin. But CESA and Siemens also

collaborated on a new CMS Cement plant in Kuching,

Malaysia, and a new cement factory for Germany’s

Schwenk Group in Ohorongo, Namibia. In every case

CESA served as a very reliable consultant and engi-

neering services provider to the end customer, and

Siemens is looking forward to future projects with

CESA Cement Engineering.

siemens.com/cement

Mining technology

thyssenkrupp Industrial

Solutions and Siemens

continue partnership

CESA Cement Engineering SA

Successful collaboration based on a trusted partnership

Siemens AG

thyssenkrupp and Siemens have many years of experi-

ence in mining and lead the sector in their respective

technological fields. The two companies have success-

fully implemented a number of joint projects in recent

years. thyssenkrupp provided the conveyor system

for Xstrata Copper in the Antapaccay and Las Bambas

copper mines in Peru, for example. And Siemens

provided thyssenkrupp with the direct drive for

the world’s largest conveyor belt. The belt conveyor

system is being erected in the Peruvian Cuajone

mine belonging to the Mexican Southern Copper

Corporation mining company.

siemens.com/mining

Jürgen Brandes (left), CEO Siemens Process Industries and Drives,

and Jens Michael Wegmann, Chairman of the Management Board

of thyssenkrupp Industrial Solutions, after signing the contract

Siemens AG

01.2016 | siemens.com/magazine/industry

News

siemens.com/magazine/industry | 01.2016

Digitalization

is key

From tumbling commodity prices and declining global

demand to growing safety and security risks, the

global mining industry faces major challenges as well as

mounting stakeholder expectations. In order to stay

competitive, companies must become leaner, stronger,

and more innovative. Digitalization is key to achieving

these goals.

Cover

Cover

01.2016 | siemens.com/magazine/industry

he main elements of com

petitiveness are productivity

and operational excellence.

This reality has not changed over

the centuries. What has changed,

however, are the possibilities mod-

ern technology offers – especially

to those who are open to rethink-

ing the entire mining process. In

this context, digitalization plays

a crucial role.

Operational excellence today

In the past, enhancing operational

excellence in the mining industry

often meant nothing more than

simply cutting costs. But now, mod-

ern technology is opening up new

ways to achieve breakthroughs in

productivity. Leading mining com-

panies all over the world are con-

tinually investing in state-of-the-

art automation, energy, and drill-

ing systems in order to increase

mining intensity with lower per

sonnel and energy costs. Some

companies are able to achieve

energy savings of 10% to 40%

through renewable energy instal

lations, innovative energy tech

nologies, and highly automated

mining processes.

Advanced distributed control

systems (DCSs), such as Simatic

PCS 7, are critical here. The open,

flexible, and scalable architecture

of PCS 7 ensures maximum pro-

ductivity and reliability. Thanks to

its integration with safety, indus-

trial security, and energy man

agement systems, it helps protect

personnel, machinery, and the

environment – and lays the foun-

dation for the digital enterprise.

Its integrated Advanced Process

Library (APL) provides the best

Cover

siemens.com/magazine/industry | 01.2016

Siemens offers

a wide range

of products and

solutions for

digitalization

Discovering the

potential of

digitalization: The

intelligent use of

process data can

help improve asset

utilization, logistics,

and maintenance,

contributing to

overall operational

excellence

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153.4 kWh

22° 16' 47''S

68° 54' 2'' W

5,263 MTPH

43.6 mm/s

How much

Where

am I?

What’s my

capacity?

What about

my vibrations?

do I consume?

Cover

01.2016 | siemens.com/magazine/industry

route to higher efficiency in opera-

tion and engineering. In addition,

Siemens has released the Minerals

Automation Standard, a tailor-

made solution that is designed to

meet all mining requirements and

that ensures the highest levels of

efficiency and reliability.

On track to support the future

energy mix

As the global energy mix shifts and

technology advances, companies in

the mining sector can benefit from

emerging opportunities to control

their energy costs. The sector’s best

partner in pursuing these op

portunities is Siemens – for exam-

ple, through the substitution of

thermal coal with renewables,

or through the identification of

energy savings potential with

Simatic B.Data. This holistic and

proven state-of-the-art energy

management solution covers all

relevant business areas, from pur-

chasing to controlling, and thereby

ensures efficient energy and cost

controlling. Innovative Siemens

solutions also contribute to maxi-

mum vehicle operating efficiency,

which minimizes the cost per ton

Virtual team, real benefits

Anglo American Platinum Limited is the world’s lead-

ing primary producer of platinum group metals and

accounts for about 40% of the world’s newly mined

platinum. Anglo American mining operations consist

of managed mines, joint-venture mines, and asso

ciate mines across South Africa and in Zimbabwe.

Recently, Anglo American contracted Siemens to

migrate the company’s piping and instrumentation

diagrams (P&IDs) and process flow diagrams (PFDs)

into Comos. For this project, Siemens chose a virtual

team approach in which the Siemens engineers in

India worked with the teams of the project owner

in South Africa using the working layer of Comos.

This reduced travel expenses and ensured efficient

and timely project execution. With Comos, Anglo

American benefits from a consistent database for its

PI&Ds and PFDs that always reflects the as-is state,

facilitating maintenance and process improvements.

of hauled material by improving

overall system efficiency and

reducing maintenance. A good

example of this technology is an

onboard energy storage system

that allows for the reuse of stored

regenerative energy at low-effi

ciency operating points. This

significantly reduces emissions.

Driven to perform

Implementing innovations in the

mining industry always demands

a certain degree of openness, as

innovation goes hand in hand with

a change in tradition and culture.

Today it is no longer enough to

optimize existing equipment and

possibly outdated technology.

Any mining company striving for

better and more economical ex-

traction must embrace innovation.

Many of today’s game-changing

technologies are highly automated

or even entirely autonomous. The

spectrum includes robotic and

GPS-supported mining systems, as

well as autonomous rail systems,

among others. With its expertise in

Some companies are able to achieve

energy savings of

10% to 40%

through renewable energy installations,

innovative energy technologies, and

highly automated mining processes

Cover

siemens.com/magazine/industry | 01.2016

automation and robotics, Siemens

can help deploy these technologies

in mining.

Another innovation issue that

must be addressed is improving

asset management so that it can

help mining companies look past

tomorrow. Enhanced asset manage-

ment is key for the implementation

of smart repair and maintenance

strategies – and therefore contrib-

utes to maximum availability and

productivity with minimum effort.

Among the most valuable assets in

the mining industry are the drive

systems. They must meet ever ris-

ing demands in extraction, trans-

portation, and beneficiation. Gear-

less drives; perfect interaction be-

tween sensors, IT, and mechanics;

and intelligent service strategies

are key here – and with Siemens,

mining companies always benefit

from cutting-edge technology.

Siemens offers the world’s first

true one-stop solution for entire

drivetrains, setting new standards

with Integrated Drive Systems (IDS).

IDS ensure perfect interaction of all

components, reduced engineering

effort, maximum investment secu-

rity, and lower operating costs.

Digitalization also paves the way

for enhanced efficiency in employ-

ees’ daily routines by providing the

right information to the right per-

XHQ Operations Intelligence in mining

XHQ Operations Intelligence solutions deliver

real-time, actionable views based on real-

time operational and business data. In mining

operations, there are several areas in which

this can help improve operations:

◾

Real-time energy management using both

leading and lagging indicators helps reduce

energy consumption and costs, provides

faster access to critical information for plan-

ning and production tuning, and enables the

exploitation of opportunities to capitalize on

energy spot market price fluctuations for buy/

sell.

◾

Integrated equipment monitoring for fixed

(rock crushers, conveyors, etc.) and mobile

(excavators, bucket wheels, draglines, haul-

ers, etc.) assets helps reduce incidents and

equipment downtime and facilitates main

tenance.

◾

Asset management dashboards help com

panies improve reliability, plan and control

maintenance budgets, and manage assets by

exception.

◾

An equipment and work order browser

solution can bridge the gap between engi-

neering and maintenance information sys-

tems and processes, improve work processes,

and reduce equipment lifecycle costs.

◾

Fleet management enables real-time over-

sight of mobile equipment, enhances site

safety by reducing incident risk, and enables

faster access to information for incident pre-

vention and remediation.

◾

Real-time performance management pro-

vides a global data aggregation and presen

tation context for fast access to critical infor-

mation for decision making and a reduced

risk of operational incidents and losses.

Cover

01.2016 | siemens.com/magazine/industry

siemens.com/mining

thomas.walther@siemens.com

son at the right time. With its

unified data platform, the Comos

engineering and collaboration soft-

ware provides all involved parties

with a continuous flow of data that

meets their specific needs across

all project phases.

Data. Mining. Industrie 4.0

With global trends such as digitali-

zation and Industrie 4.0 becoming

more and more relevant to the

mining industry, companies need

solutions that not only collect and

visualize operational data but also

manage them across different

sites. The good news is that today’s

systems already offer most of the

functionality that is needed: they

make it possible to share valuable

experience and insights with

other sites via a seamless data

transfer – and thereby not only

help solve problems but also allow

for company-wide process and

plant performance comparison

and optimization.

Innovative Siemens

solutions also contribute

to maximum vehicle

operating efficiency,

which minimizes the

cost per ton of hauled

material by improving

overall system

efficiency and reducing

maintenance.

Siemens AG

siemens.com/magazine/industry | 01.2016

direct conveyor drive system

comprises a low-speed syn-

chronous motor, a cyclocon-

verter or voltage source converter,

drive control, power distribution,

an E-House, and a cooling system.

Eliminating various components of

the drivetrain reduces maintenance

effort and spare parts inventories

and allows the system to offer uni

quely high availability. Even in chal-

lenging applications, direct con-

veyor drives can achieve a bench-

mark availability of more than 99%

– as confirmed by real-world data

from the Antapaccay mine in Peru.

There, the belt system transports

approximately 5,260 tons of ore

per hour from the mine to the pro-

cessing plant over a distance of

around 6.5 km. The Siemens drive

system for the belt conveyor con-

sists of two low-speed synchronous

motors, each with a power rating

of 3,800 kW, and the associated

Sinamics SL150 cycloconverters,

E-House, cooling system, and con-

vertor transformers.

Triple challenge

In 2015, Siemens commissioned di-

rect conveyor drive systems for two

additional copper mines. One was

for one of the largest copper mines

in the world, which is located in

Chile (5 x 5,000 kW). For the over-

Las Bambas mine, located at 4,000 m

in the Peruvian Andes

The next generation

Declining ore grades, leading to increased material transport and plant

throughput requirements, are one of the major challenges in the current

mining environment. With direct conveyor drive systems, mining operators

can surpass the mechanical limits of conventional drive systems and

benefit from economies of scale – as demonstrated in several projects in

South America.

Mining

01.2016 | siemens.com/magazine/industry

land conveyor provided by thyssen-

krupp with a length of more than

10 km, Siemens supplied five direct

drive systems (for a total of four

conveyors) with the largest con-

veyor motors in operation at pres-

ent.

The overland conveyors at Las

Bambas copper mine in Peru were

designed and supplied by thyssen-

krupp and have been in operation

since the fall of 2015. Each of the

two overland conveyors is approxi

mately 2.5 km long with a lift of

almost 300 m and transports ore

from the mine to the processing

plant. The belts are 1,830 mm wide,

travel at 6.5 m per second, and

are designed to transport approxi-

mately 9,400 tons of material per

hour. The stockpile at the end of

the conveyor system is more than

50 m high and can supply the pro-

cessing plant with up to three days’

worth of copper ore for processing.

The drive system for each of the

two overland conveyors comprises

two low-speed synchronous

motors – each with a total power

of 4,400 kW – and the associated

Sinamics SL150 cycloconverters.

Smooth execution and start-up

The overland conveyors at Las

Bambas were commissioned very

quickly and the conveyor system is

now in operation. “The project has

been very successful and we are

running the conveyors at nominal

capacity with few issues. The gear-

less drives are beneficial from a

service point of view, given that

there are no motor bearings or

gearboxes, which simplifies ongo-

ing maintenance requirements,”

says Timothy Mess, project direc

tor at thyssenkrupp. Peter Mizera,

MMG’s general manager for Las

Bambas project delivery, shares

this positive view of the project

outcome: “Las Bambas has been

a great success, and Siemens was

a large contributor to this outcome.

Siemens provided solid support

during construction, precommis

sioning, and commissioning, and

as a result we were able to complete

the overland conveyor commis

sioning very quickly – in just under

two months. This was a fantastic

achievement.”

Next project on track

Following Las Bambas, Siemens

recently supplied the world’s high-

est-powered direct conveyor drive

system to the Cuajone mine in

Peru. The modernization project

will entail the installation of a new

gyratory crushing and conveyor

system from thyssenkrupp by 2016.

Siemens proposed an Integrated

Drive System with direct conveyor

drives to power this conveyor sys-

tem, which has an output totaling

12,000 kW.

The conveyor belt system com-

prises three individual sections

that are equipped with a total of

five Integrated Drive Systems. For

the largest of the belt sections,

Siemens is supplying two drive sys-

tems with an output of 6,000 kW

each, comprising a low-speed syn-

chronous motor and a Sinamics

SL150 cycloconverter. The two

smaller feed and discharge belts

will be driven by two 500-kW low-

voltage motors using Sinamics

S150 converters with regenera

tive feedback capability and one

1,200-kW medium-voltage motor.

The converters and motors as well

as the gearboxes and couplings

for these drives are all supplied by

Siemens. The automation compo-

nents and the drive and power

distribution technology are pro-

vided in modular electrical rooms

(E-Houses). Over the years Siemens

has improved and optimized the

cooling system, the modular de-

sign of the E-Houses, the power

distribution, and the automation

and drive control so that they are

perfectly aligned with the mining

industry’s specific requirements.

At Cuajone, Siemens will con-

tinue the company’s impressive

track record of successful projects

in South America – and reinforce

its position as one of the leading

suppliers of electrical and automa-

tion systems for the global mining

industry.

siemens.com/mining

christian.dirscherl@siemens.com

»Siemens provided solid support during

construction, precommissioning, and

commissioning. As a result we were

able to complete the overland conveyor

commissioning very quickly – in just

under two months. This was a fantastic

achievement.«

Peter Mizera

General Manager for Project Delivery, MMG

Siemens AG

siemens.com/magazine/industry | 01.2016

Mining

Fitting off-road

mining trucks with

onboard energy

storage systems

can significantly

improve efficiency

and profitability

A major overhaul

In the mining industry, energy efficiency and productivity

are paramount. Incorporating onboard energy storage

systems could generate gains in both of these areas, thereby

significantly improving hauling operations.

The battery systems consist of

standardized modules encased

in robust, specially designed

housings.

01.2016 | siemens.com/magazine/industry

Mining

typical mining facility uses off-road mining

trucks to haul materials such as coal, ore, and

overburden from the pit to a stockpile where

the material can be stored or processed. A conventional

haul truck operates with a diesel engine, which adds

considerable fuel expense to the entire mining opera

tion.

The main objective of haul trucks is to achieve the

lowest cost per ton of hauled material, which means

that improving overall system efficiency and reducing

maintenance for any given payload is critical. One

way to improve efficiency is to fit the truck with an

onboard energy storage system. These systems store

regenerative energy and reuse it at low-efficiency

operating points, thereby reducing fuel consumption,

decreasing emissions, and increasing profitability.

Opportunity for improvement

Use of diesel-electric trucks for payloads of more

than 200 tons has been on the rise in recent years.

And among diesel-electric trucks, the trend has been

moving toward AC drive technology. Although signi

ficant improvements have been made to electric drive

and control technology, the use of energy storage sys-

tems is practically nonexistent in trucks, resulting in

a lost opportunity to improve fuel economy through

regenerative braking and engine-idle operation.

Mining trucks have onboard diesel engines that

serve as their fixed source of power. Because these

engines have parasitic losses and other auxiliary

loads, not all of the engine capacity is available for

propulsion. This is where energy storage comes into

play. A suitably configured energy storage system

can store a portion of the regenerative energy and

feed the auxiliary systems, making 100% of the engine

capacity available for propulsion without consuming

additional fuel. The speed of a truck is directly pro

portional to the available power; hence, if the energy

storage could provide 10% additional power, the

speed of the truck would increase by 10% – resulting

in reduced cycle time and increased productivity.

Overcoming the challenges

Mines present a unique set of challenges when it

comes to the selection of suitable energy storage de

vices, as they are often located in remote locations

with extreme climatic conditions. In addition, mining

trucks are subjected to extreme shocks and vibrations

during operation, which means that any energy sto-

rage device would need to operate reliably under these

conditions. Batteries offer excellent energy storage

potential. Their high energy density makes them well

suited to delivering power for longer durations. Ad-

vances in lithium-ion-based high-performance battery

systems have made it possible for these systems to be

used in a wide range of applications for public trans-

port, commercial vehicles, and stationary storage sys-

tems, among others.

The space on the truck deck is limited, and hence

system integration is very important. The modular

configuration of the lithium-ion batteries allows them

to be adapted to any load profile and type of installa-

tion. The battery systems consist of standardized

modules encased in robust, specially designed hous

ings. The battery-management system incorporated

into these modules constantly monitors cell voltages

and temperatures while balancing differences in

potential. Communication takes place via a smart

controller area network (CAN) interface. The battery

systems offer high cycle stability and outstanding

protection against thermal runaway, and their high

efficiency and low maintenance translate into a

very favorable cost/benefit ratio for mining opera-

tions. In addition, the systems are designed to be

both intrinsically safe and environmentally friendly.

Increased efficiency, productivity,

and sustainability

Reducing fuel consumption in hauling trucks

through the implementation of onboard energy

storage systems from Siemens can have a significant

impact on the efficiency, productivity, and sustain

ability of mining operations. This ultimately results

not only in higher profits for the mining industry,

but also in a cleaner and safer environment for local

communities.

siemens.com/mining

joy.mazumdar@siemens.com

thyssenkrupp

siemens.com/magazine/industry | 01.2016

Mining

mproving productivity

of open-cast operation has

been and will always be

a challenge. The quality of the ore

body continues to deteriorate and

therefore more ore needs to be

transported in the most economi-

cal way to optimize productivity.

The aim is to lower the cost per ton

of transported ore and improve

the environmental footprint.

Typically, uncrushed ore is trans-

ported by trucks, which often

leads to congestion on busy road

stretches. The trucks usually

travel fully loaded with ore one

way to the dump or to the crusher

station outside the mine and

travel back to the pit empty. And

the process repeats itself. The

cycle can easily take up more

than 30–40 minutes, depending

on the depth of the pit.

In order to optimize the truck

utilization, to reduce the fuel

consumption, and to increase

the productivity of the mine,

a new transportation system,

the Chevron MegaPipe conveyor

has been developed.

Conveyor systems

Pit perfect!

ContiTech, Siemens, and thyssen

krupp, in a joint research and

development consortium, have

developed a solution that can

reduce this heavy-duty traffic

and the associated emissions and

risks: the Chevron MegaPipe con-

veyor. This new continuous con-

veyor for bulk materials requires

just one primary crushing stage

in the feeding station area and

sets new standards in terms of

ascent capability and transport

capacity.

The new conveyor is a further de-

velopment of traditional conveyor

systems, which are already being

used instead of trucks in extensive

open-pit mines with general slope

angles of under 30°. The conveyor

system consists of a tubular belt

with profiled cover plates on the

carrying side. When the MegaPipe

is rolled up from a troughed form

into a tubular form in the material

feeding area, the material in the

pipe is “compressed,” which wedges

the product particles together and

thus increases the internal friction

coefficient of the bulk materials.

This compression, together with

An open-pit mining operation involves dozens of trucks

that are loaded by excavators, transport mined material

over steep and sometimes unsurfaced roads out of the

mine, and then return empty. This truck operation over

long distances is not always efficient or economical,

resulting in enormous fuel costs and CO

emissions.

ContiTech, Siemens, and thyssenkrupp show that there

is another way.

the special profiling on the belt,

enables the economical transport

of large material flows over slopes

with moderate incline angles and

open-pit mine depths of several

hundred meters, right after the

primary crushing stage.

Direct drive for high performance

The drive technology is another

key component of the new con

veyor system. About five years ago,

Siemens and thyssenkrupp devel-

oped a direct drive for powerful

conventional belt conveyors based

on the also jointly developed Band-

berg Prosper, a 3.8 km-long under-

01.2016 | siemens.com/magazine/industry

Mining

siemens.com/mining

norbert.becker@siemens.com

ground conveyor system rising

approximately 800 meters, in-

stalled at RAG Prosper-Haniel in

1985. Thanks to the simple and

robust mechanical design, inte

grated drive drums, and a direct

drive motor in combination with

cutting-edge converter technology,

as well as the proven control sys-

tem, the drive solution allows large

belt conveyor systems to be oper-

ated economically. The complete

drivetrain, consisting of a flange

for the disc brake, drum/motor

bearings, and a rotor flange with

rotor and stand, was designed to

use just a few robust components

that can be integrated into the belt

conveyor station in a space-saving,

maintenance-friendly way.

Nonstop benefits

The consortium has now also

investigated the feasibility of the

MegaPipe concept and has con-

firmed that the conveyor system

can economically transport ores

and waste material with grain sizes

of up to 350 mm over slopes with

inclines of 30° to approximately 50°.

Alternative conveyor systems like

the Chevron MegaPipe conveyor are

becoming increasingly attractive in

view of the fact that in many mines

around the world the ore content

is diminishing, and thus an in-

creasing amount of material needs

to be transported. These systems

also help mine operators overcome

the logistic challenges of extract-

ing raw materials in an environ-

mentally friendly, efficient, and

safe manner.

A viable alternative to shovel/truck

operation in open-pit mining: The

MegaPipe system can transport material

with grain sizes of up to 350 mm

over steep slopes from 30° to 50° and

over several hundred meters.

Siemens AG

siemens.com/magazine/industry | 01.2016

Mining

Mining for productivity

and profit

Kalumbila Minerals Ltd., a subsidiary of First Quantum

Minerals Ltd., had ambitious output goals for Sentinel, its copper

mine development project in northwest Zambia, and needed to

recruit an entire workforce to build the infrastructure from scratch,

all while minimizing costs. Siemens was happy to assist.

01.2016 | siemens.com/magazine/industry

Mining

arsh environments, rising energy costs, and

water scarcity are just a few of the challenges

facing the world’s mines. Kalumbila Minerals

was not only confronted by these challenges but also

had more to grapple with when building two mines

in an isolated area 150 kilometers west of Solwezi,

Zambia.

The two milling trains of Kalumbila

Minerals process 55 megatons of ore

per year and achieve a top ranking in

terms of performance and efficiency

The region had practically no infrastructure for

transportation or energy supply, and no workforce

with the skills to build one. The local population

worked in farming and ranching and had no experi-

ence with large construction projects. But having

committed to source at least half of its workers locally,

Kalumbila Minerals needed to find and train at least

4,000 people to lay roads, weld pipes, erect pylons,

and even construct a new airstrip. A further challenge

was Kalumbila Minerals’ ambitious production tar-

gets: 300,000 tons of copper and 38,000 tons of nickel

concentrate per year within the first six years of

operation. Meeting this output target would demand

advanced drive technology that could power all the

mining machinery around the clock with minimal

downtime.

To overcome the challenges and make the project

a success, Kalumbila Minerals recognized the need for

a partner that could offer a comprehensive solution

for both training new workers and providing high-

performance integrated drives. End-to-end process

optimization was the only way the company could

hope to overcome its production challenges while

minimizing operational and extraction costs.

“For projects involving limited local skills and

complex equipment, what we look for in a technol-

ogy provider is a robust product and a skilled team

with the ability to transfer knowledge to our local

expert teams,” says Nevin Scagliotta, commission-

ing manager for First Quantum Minerals Projects

Division. “With mills of this size, reliable and

high-efficiency drives are top priority and crucial

to project economics.”

Driving recruitment and power

As a technological leader in the global mining

industry, Siemens was the obvious choice to provide

the advanced drive technology that would give

Kalumbila Minerals the power and the cost optimiza-

tion it needed. With its experience in implementing

and managing large-scale mining projects all over

the world, Siemens also knew what steps to take to

successfully source and train the new workforce.

To fulfill its commitment of hiring 50% local staff,

Kalumbila Minerals recruited 4,000 workers from

the surrounding towns and hired 4,000 indirectly

through on-site contractors. Siemens’ project team,

comprising professional engineers, seasoned assem-

bly supervisors, and on-site start-up engineers, then

transferred its expert knowledge to the local teams

Benefits of Siemens’ gearless

drive technology

◾

Reliability – rugged design that

assures 99.5% availability

◾

Low cost – optimized electrical

efficiency and no wear and tear

◾

Integrated solution – end-to-end

technology and services that keep the

mills running

◾

Minimized downtime – dedicated

maintenance

modes that keep perfor-

mance high

◾

High productivity – efficiency of 95%

thanks to the gearless design

siemens.com/magazine/industry | 01.2016

Mining

siemens.com/mining

helmut.liepold@siemens.com

so the mine could be running productively in the

shortest possible time.

Rugged power and close control

With projects of this size, it is advantageous to re-

duce the number of supplier interfaces, and thus to

have the entire drivetrain supplied by a single source.

Integrated Drive Systems from Siemens offer the only

true one-stop solution for drive systems worldwide.

To power the extraction of 300,000 tons of copper

and 38,000 tons of nickel concentrate per year, Siemens

provided the motor and drive systems for two 40-foot

semi-autogenous grinding (SAG) mills powered by

28-MW gearless mill drives (GMDs) and two 28-foot

ball mills powered by 22-MW GMDs.

Among the world’s big-

gest and most powerful

drives, the integrated GMDs

from Siemens provide

Kalumbila Minerals with

the end-to-end process opti-

mization essential to maxi-

mize efficiency and mini-

mize cost. The drives also

provide outstanding reli-

ability due to the advan

tages of the gearless design.

With no moving gears,

there is no variance in the

motor and no vibration.

This vastly reduces energy

loss, as all the force is

transferred touch free via

the magnetic field. The lack

of moving parts also vir

tually eliminates wear and

tear and the risk of down-

time. In the event that

maintenance is required,

the drives maintain high

availability thanks to their

dedicated maintenance

modes, such as creeping or

inching with rollback of the

mill.

“Torque and speed control, and especially the

frozen charge protection keep the mill operating in

the safe range, minimize downtime, and keep pro

duction high,” says Axel Fuchs, project manager at

Siemens Process Industries and Drives. “The Siemens

GMD offers 28 MW and a 150% overload – no other

drive is able to do that at 9.1 rpm.”

The integrated drive train came along with Simatic

PCS 7 and Sinamics SL150 cycloconverter technology.

The Simatic PCS 7 controller for the mill drive and

Kalumbila Minerals’ existing distributed control sys-

tem could be seamlessly integrated thanks to their

common platform, while the rugged Sinamics SL150

offers exceptional overload capacity and high effi-

ciency through direct energy transformation, which

results in availability of

more than 99.5%.

A proven mining partner

Siemens proved itself to

be a trusted partner with

the provision of a quality

service. This included the

professionalism with which

its team managed the proj-

ect and the engineering

expertise demonstrated by

its gearless drive technol-

ogy. Ultimately, Siemens’

know-how and experience

were successful in helping

Kalumbila Minerals in-

crease the productivity of

its mines while reducing

costs, demonstrating why

Siemens continues to be regarded as the partner of

choice for the world’s global mines.

“For a critical and complex piece of equipment

like the mill drives, it is vital to have a self-managing

and professional vendor. This is what Siemens has

provided with its gearless mill drives and the commis

sioning team,” says Nevin Scagliotta of First Quantum

Minerals.

»Torque and

speed control,

and especially

the frozen charge

protection keep

the mill operating

in the safe range,

minimize down

time, and keep

production high.«

Axel Fuchs,

Project Manager at Siemens Process Industries

and Drives

Siemens AG

01.2016 | siemens.com/magazine/

xxxxxx xxxxxxxx

Mining

Increasing throughput

the smart way

fter years of operation

in mining processes, mills

often require higher

throughput from the gearless mill

drive (GMD) or even the entire

concentrator. This in turn demands

more power. Siemens has devel-

oped a structured study to analyze

whether a power increase is feasible

on preinstalled GMDs.

A power upgrade could be re-

quired, for example, if the rock

hardness increases as a result of

excavating at deeper levels, caus-

ing the throughput of the grinding

mill to decrease. To keep the

throughput constant, the power

of the GMD needs to be increased.

Power can be increased by modi-

fying the motor voltage or the cur-

rent, or a combination of the two.

Every solution has specific con-

siderations in terms of costs

for replacement parts and

implementation time. To

accurately evaluate all

the options, detailed

knowledge is required

regarding the GMD sys-

tem (especially its most

important parts – the

motor itself, the trans-

formers, and the cyclo-

converter) and the rela-

tionship between the

different variables.

The mechanical calcu-

lation for the motor lies

at the core of the analysis:

if the design of the motor

does not support the power increase,

the required power level cannot

be achieved – not least because

strengthening the motor structure

on-site is complex and uneconomi-

cal. The mechanical study is based

on the finite element (FE) model

of the motor (see illustration) and

different load cases. Once the

mechanical study is complete and

indicates sufficient reserves, all

the other components of the GMD

system must then be verified.

The Siemens study structures

the engineering process in consec-

utive steps to determine the new

power level, with each step build-

ing on the results of the previous

one. If a step is not completed

successfully, the next one cannot

begin, and the study must be re-

started using a different technical

solution or a lower power level.

A rewarding investment

Together with the analysis report,

Siemens provides a price indica-

tion for the necessary new equip-

ment, as well as a draft shutdown

and sequence plan for the imple-

mentation – all the information

needed by the customer to evalu-

ate whether the project offers a

satisfactory return on investment

(ROI).

Based on the experience of

recently implemented power in-

crease projects, the power level

typically increases by approxi-

mately 10% to 15%, and the ROI

can be achieved within one year

or less. The combination of the

comparatively low investment and

short implementation time for the

GMD systems offers clear advan-

tages for the mining industry.

Siemens utilizes

advanced modeling

to assess the

feasibility of a power

upgrade, performing

studies based on a

finite element model

of the GMD motor

siemens.com/mining

stefano.scagliola@siemens.com

Siemens AG

Mining

siemens.com/magazine/

xxxxxx xxxxxxxx

| 01.2016

Steep challenge

Continuous 24/7 operation, 100% availability, and maximum energy

efficiency: the requirements for the mill drive solution in a new

copper concentrator project were quite a challenge for Siemens.

The solution – a dual-pinion drive with an induction motor – not only

hit the mark in terms of reliability and efficiency but was also

implemented in a very short time.

Arizona, the leading copper-

producing state, produces

60% of the total copper for

the United States

Siemens AG

Mining

01.2016 | siemens.com/magazine/industry

he two dual-pinion mill drives for two new

24' × 40' ball mills, each with 2 × 6.5 MW

(2 × 8,700 hp) power, are the first two mill drive

systems using slow-speed squirrel-cage induction

motors with cycloconverter technology in grinding

mills, and they combine the benefits of both systems.

Cycloconverters are well proven in mining, especially

for ring motor (wraparound motor) applications. They

are perfectly suited for mill drive applications due to

the low-frequency drive, the robustness and efficiency

of the thyristor technology, and the low number of se-

miconductors. Consequently, the solution designed by

Siemens features the highly reliable components and

high system robustness required by the application.

Integrated solution for maximum efficiency

The Siemens scope of delivery included the induction

motors and the cycloconverters for variable-speed

drive operation with the corresponding insulating

transformers, as well as premanufactured E-Houses

and 13.8-kV switchgear, perfectly coordinated with the

drive, and the complete harmonic study. The water-

cooled, compact, and totally enclosed IP55 motors

were shipped fully factory-tested in one piece. The

motors have a nominal speed of 180 rpm and a torque

of 345 kNm and are equipped with sleeve bearings,

including a jacking unit. The motor shaft is directly

coupled to the pinion via a torque-limited coupling.

The cycloconverter is an air-cooled Sinamics SL150

with a power rating of 8 MVA. For smooth operation

of the two motors on a dual-pinion drive system, they

are equipped with a controller that provides accurate

load sharing under all working conditions. The mill

technology control package also includes smooth

start-stop operation modes, creeping mode for main

tenance, and inching mode for positioning the mill in

case of liner exchange, as well as the required frozen

charge protection. The drive system is designed for an

overload capability of 150% during the mill start-up

and 115% continuously (1.15 service factor). The oil-

cooled insulation transformers are sized according

to the mill drives’ requirements. To minimize instal

lation and commissioning time, the air-cooled drives

were installed and precommissioned by Siemens,

including the 13.8-kV circuit breakers, in a new con

tainerized E-House.

Rising to the challenge

The customer received a perfectly tuned drive system

from a single source. The solution is the most robust,

reliable, and energy-efficient option currently avail

able on the market. Over the first year of commercial

operation, it has demonstrated excellent reliability

and performance, even running occasionally at over-

rated capacity, and incurring minimal maintenance

costs.

Maximum drive reliability and efficiency

for horizontal mills

Horizontal mill pinion drives are widely used in the

mining industry to grind materials to a requested

size. To maximize productivity and cost-effectiveness

of operation, the equipment needs to operate at

optimum efficiency. Carefully selected drive solu

tions, which are needed for speed and torque control,

can improve speed control, lengthen maintenance

intervals, and lower energy costs.

The benefits at a glance:

◾

Up to 24 MW of mill power (higher power upon

request)

◾

Smooth mill start to minimize wear on the entire

drivetrain

◾

High flexibility and availability at low cost

◾

Availability of frozen charge detection

◾

Excellent load sharing for twin drive systems

to reduce wear and tear

◾

Water-free solution to preserve valuable water

resources

◾

Suitability for installation at up to 5,000 m

elevation

Learn more: sie.ag/1JozF8T

The solution for the Arizona copper concentrator features the world’s

largest dual-pinion drive systems with low-speed induction motors

siemens.com/mining

luis.galarzas@siemens.com

alf.banse@siemens.com

Siemens AG

siemens.com/magazine/industry | 01.2016

Mining

Coming full

circle

ickel mining companies

have been achieving signi

ficant gains in both pro

ductivity and efficiency in recent

years by improving the operation

of conveying and crushing systems

through automation. In a typical

configuration, nickel ore is loaded

onto a conveyor belt, where it is uni-

formly distributed by a profiling

gate located at the infeed. After trav-

eling on the belt, the nickel is dis-

charged into a surge hopper above

the jaws of a crusher. The efficiency

of the crusher depends on a consis-

tent flow of material being fed into

it – which in turn requires a moni-

toring system capable of quickly

and accurately identifying process

upsets.

Monitoring critical to process

performance

When it comes to nickel production,

the automation of conveying and

crushing systems presents a num-

ber of challenges. First, monitoring

instrumentation must be able to

reliably determine the amount of

material on the conveyor belt so as

to establish a flow rate that is opti-

mal for operation of the crusher.

A powerful combination of Siemens

technologies is allowing nickel producers

to come full circle in terms of plant

automation. And it’s producing significant

benefits in the process.

Second, the level of the material

in the crusher must be continu-

ously monitored so that the speed

of the conveyor belt can be changed

accordingly. If the level of the

crusher gets too low, the belt must

be sped up to increase the rate of

delivery of raw material. Conversely,

if the level gets too high, the belt

must be slowed down. The second

condition is especially critical be-

cause if there is too much ore in the

bin, the additional load on the jaws

can strain the crusher and reduce

its effectiveness.

Most importantly, the measuring

devices need to be able to work to-

gether effectively to communicate

these situations to the control room

so that appropriate action can be

taken and process upsets can be

prevented.

Integrated solution for conveyor

and crushing systems

Such an integrated solution can be

easily set up using aligned systems

for material weighing and level

monitoring from Siemens. To meet

the needs of flow rate monitoring,

producers can install a Milltronics

MSI belt scale, a Sitrans WS300

Siemens AG

A Milltronics belt scale and speed sensor on a conveyor belt moving mining material

01.2016 | siemens.com/magazine/industry

Mining

speed sensor, and a Milltronics

BW500 integrator. This solution

delivers instantaneous measure-

ment to ensure that raw material

is conveyed from the infeed into

the crusher at a variable rate that

is based on the level of material in

the crusher. The second system

needed is for level measurement in

the crusher. The best option in this

case is a noncontacting device such

as the Echomax XPS15 transducer

mounted in the open air above

the bin and connected to an ultra-

sonic level controller, for example,

a Sitrans LUT420 device.

Detailed process data help optimize

control

With this configuration of Siemens

equipment, nickel plant installa-

tions have two systems that work

together with high and low alarms

on both the crusher bin and the

conveyor belt. The milliampere

output of the Sitrans LUT420 acts

as an analog input into the variable-

frequency drive of the conveyor

to control its belt speed so that

when the level of raw material

drops in the crusher hopper, the

belt speeds up. When the level gets

too high, the belt slows down.

Additionally, the onboard relays

of the Sitrans LUT420 make it pos-

sible for high and low set points to

activate an alarm to ensure that

maintenance crews perform visual

inspection and diagnose any prob-

lems. Similarly, the milliampere

output of the Milltronics BW500

can monitor flow rate, as the unit

has onboard relays for load-based

high and low set points – allowing

proper action to be taken in the

event of feed starvation on the

conveyor.

Integration leads to higher

efficiency and additional savings

With an integrated solution for the

crusher application, a nickel pro-

ducer can come full circle in terms

of plant automation. This circle

begins with the removal of manual

operator intervention, resulting

in safer practices, improved plant

efficiency, and reduced mainte-

nance costs. The money saved can

then be invested into further plant

automation.

siemens.com/sensors/mining

mark.yseboodt@siemens.com

Siemens AG

siemens.com/magazine/industry | 01.2016

Mining

Powering the gold rush

One of the world’s largest mechanically driven horizontal

mills has been built for a gold mine in Russia. The mill is driven

by gear units designed especially for this application. Their

load-sharing system transmits high power loads to the mill via

a girth gear for an extremely efficient ore grinding process.

»From a technical,

commercial, and time

point of view, the drive

solution selected here,

incorporating Siemens

DMG2 gear units, was

the best solution.«

Stefano Pellissetti,

Authorized Manager

and Purchasing Director at Cemtec GmbH

Cemtec

siemens.com/ballmill

dirk.mensing@siemens.com

Rubrik

01.2016 | siemens.com/magazine/industry

Two gigantic mills driven by up-to-the-minute Siemens-built motors and gear-unit systems

for a gold mine in Russia

emtec – Cement and Mining

Technology GmbH, an Aus-

trian family-run company

with some 240 employees and now

managed by the second generation

of the family – plans, develops, and

executes projects for the cement

and processing industry worldwide.

One of its latest projects is the de-

livery of a mill system to Russia,

where, following initial start-up in

2014, two gigantic mills process

up to 30,000 tons of ore every day

to extract gold. In only 10 months’

construction time, Cemtec, together

with the drive specialist Siemens,

developed and built a complete

solution – one that is unique in

terms of its size, performance, and

speed of implementation.

High-performance technology

Two mills are used to grind up

the ore: a semi-autogenous mill

measuring 10.4 m x 6.1 m with a

drive output of 15 MW, and a ball

mill with a drive output of 18 MW.

The first mill grinds down lumps

of rock with a maximum size of

250 mm (F80 = 152 mm) to 2 mm,

and the second then grinds these

2 mm grains (F80 = 1,000 µm) down

to particles as small as 74 µm. Only

then can flotation take place to ex-

tract the gold. The ball mill mea-

sures 8.2 m x 14 m, and in terms of

its power, which is transmitted me-

chanically by means of gear units,

it is one of the world’s largest hori-

zontal mills, if not the largest. It

is driven by two 1RR5108-6FA90-Z

three-phase asynchronous motors

from Siemens that feature slip

ring rotors delivering an output of

9 MW each. The two motors in oper-

ating mode S1 have an efficiency of

97.2%. They are started in parallel

by a liquid starter, which was also

delivered by Siemens. However, the

highlight of the drive technology,

apart from the gigantic size of the

two mills, is in fact the gear-unit

technology. The semi-autogenous

mill and the ball mill are each

driven by two of these gear units.

On a conventional drive variant,

only one engagement per pinion

with the girth gear is possible per

side, which creates a power limit of

about 8 MW per drive. With its spe-

cial DMG2 gear units, Siemens was

able to increase this to as much as

12 MW per drive. “So the DMG2 was

the right choice here,” says Stefano

Pellissetti, authorized manager

and purchasing director at Cemtec.

Compact solution

One reason for the high power

transmission is the self-aligning

drive pinions, which guarantee an

optimum contact pattern. The gear

unit has an internal load-sharing

system that ensures the power

being transmitted is always opti-

mally and evenly distributed be-

tween the two drive pinions, which

mesh with the girth gear, thanks

to the free axial movement of the

intermediate shaft. The gears are

case hardened and have ground

flanks – the toothing quality ac-

cording to DIN 3990 is at least 6 or

higher. The output pinions can tilt

to ensure that they are always opti-

mally adjusted to the profile of the

girth gear. Two fundamental ad-

vantages result from this dual-

pinion construction: at 570 mm,

the mesh width of the tooth flanks

is considerably smaller than on a

conventional single-pinion solu

tion, and it does not require ex

pensive helical gear teeth and a

large-dimensioned thrust bearing.

Consequently, the DMG2 is about

30% smaller than conventional

gear-unit solutions.

Room to move

FEM (finite element method) analy-

ses were used to optimize the gear-

unit housing – making bearing

replacement on the input shaft, for

example, significantly easier. In

addition, wear-free labyrinth seals

are used on the drive shaft. On the

output side, a flexible bridge cre-

ates an oiltight connection between

the housings and the girth-gear

hood. An innovative oil lubrication

system ensures optimum lubrica-

tion of the pinion/girth-gear con-

nection, resulting in higher effi-

ciency and ultimately a longer over

all system service life. While a size

25.4 gear unit for the semi-auto

genous mill weighs about 36 tons,

a size 30 ball-mill gear unit weighs

as much as 70 tons. “Here too, this

very compact design has important

advantages, because transporting

such gigantic mill systems, along

with their drive systems, is in itself

an incredible challenge,” explains

Pellissetti. “As far as I know, there

is no other solution of this magni-

tude operating in the mining envi-

ronment.”

But Cemtec is already thinking

much further ahead. With the

Siemens drive solutions, it could be

possible to generate outputs of up

to 24 MW or more in this type of

application, so the productivity of

future systems could be 30% higher

than the current maximum output.

Such a massive increase in output

would be worth a mint to mining

operators.

Cemtec

Drive retrofit not only helps reduce capital expenditure but also improves operations, for example by reducing energy consumption

siemens.com/magazine/industry | 01.2016

Service

o extend the life of machines

and plants and avoid the risk

of unscheduled downtime,

old drive systems must be replaced.

But rather than representing a cap-

ital loss on the balance sheet, retro-

fitting an Integrated Drive System

can actually pay for itself within

months and boost profits for years

to come. The replacement of exist-

ing drives creates the perfect oppor

tunity to implement new energy-

saving technologies that can im-

prove efficiency and reduce costs.

Siemens has been helping compa-

nies gain these benefits with its

retrofit service for decades. From

its enormous inventory of compo-

nents and design plans, Siemens

can upgrade machinery to the latest

standards and thus boost perfor

mance. “Retrofits for Integrated

Drive Systems are Siemens’

strength,” says Annett Stollberg,

Siemens’ retrofit product lifecycle

manager. “Our approach takes

the entire drivetrain into account,

not just individual components, in

the realization of energy savings

potential.”

Retrofits raise

profits

Integrated Drive Systems are the heart

of machinery and industrial plants.

They have to run reliably and safely

for years in harsh environments. But

inevitably, wear and tear takes its toll

and they need to be replaced. Retrofit

for Integrated Drive Systems can avert

these risks and provide significant

support for maintaining reliable plant

operation over the long term.

Siemens AG

01.2016 | siemens.com/magazine/industry

Service

Upgrading the entire drivetrain

with a fully integrated solution is

a long-term investment in energy

efficiency and longevity. This can

include changing from fixed-speed

to variable-speed operation with

frequency converters, replacing DC

motors with AC motors, or migrat-

ing to a gearless design. When

these upgrades are combined with

diagnostic capabilities, processes

can be optimized to reduce energy

consumption without lowering per-

formance. “What’s most important

is to understand the application

and the customer’s requirements

for the production process. In many

cases we can offer a variety of solu-

tions so customers can weigh up

the differences and advantages,”

says Stollberg. “Once a customer

has chosen a solution, Siemens

then handles the entire engineer-

ing process, from planning to

commissioning.”

A fan of retrofits

Hanson Purfleet now saves £175,000

a year after reducing its energy

consumption by 36% following the

successful retrofit of an Integrated

Drive System in one of its fans.

Previously the fan was powered

by a fixed-speed drive, running

continuously at 350,000 m

/hr but

Individual retrofit solutions

Siemens offers a comprehensive

retrofit program for both its prod-

ucts and those of other brands;

the choices are tailored to the

needs of the individual customer.

The first option is 1:1 duplication

of the motor: if the long-standing

configuration is already deliver

ing proven performance and low

energy consumption, an identi

cal motor can be selected from

Siemens’ extensive inventory. This

eliminates the need for expensive

requalification of new machines.

The second is replacement: an eco-

nomical and efficient option, with

the lowest up-front investment

cost, is to replace the drive with

a standard product. Additional

customization can then be per-

formed in the factory or on-site.

The third option is an upgrade:

for the highest efficiency gains,

upgrading old motors and drives

to the latest cutting-edge technol-

ogy from Siemens’ product range

can pay for itself within months

through lower energy consumption

and optimized processes.

Siemens offers an extensive retrofit program tailored to the needs of the individual customer

damped to 241,000 m

/hr. This

meant more than 100,000 m

/hr

was being wasted, thus adding

considerable unnecessary costs

to the company’s energy bill.

After Siemens retrofitted the

fixed-speed motor, the drop in

power usage was dramatic. The

motor is now constantly monitored

with sensors, and the airflow is

regulated by a frequency converter.

This system optimizes performance

while ensuring that energy con-

sumption never exceeds the opera

tional requirements. “The Siemens

solution means we are now run-

ning with the damper open 100%

of the time, yet actual energy con-

sumption has dropped by around

360–400 kW,” says Hanson Purfleet

electrical engineer Dave Jackson.

Along with energy savings of

36%, the company has achieved a

1,487-ton reduction in CO

emis-

sions. The large ongoing savings

on energy bills mean that the en-

tire Integrated Drive System will

pay for itself within two years,

highlighting how a Siemens retrofit

turns capital expenses into long-

term profits.

siemens.com/retrofit-ids

uwe_schulz@siemens.com

Benefits

◾

Greater productivity through

optimized speed and process

performance

◾

Improved flexibility, with

faster run-up/run-down times

◾

Standardization

◾

Higher productivity and less

maintenance

◾

Long-term availability of spare

parts and simplified manage-

ment

◾

Totally Integrated Automation,

communication, and diagnostics

◾

Recovery of up-front cost

through lower energy costs

Siemens AG

siemens.com/magazine/industry | 01.2016

Cement

ietnam is undergoing rapid industrialization

and modernization. One of the results of this

transformation has been a substantial increase

in the country’s demand for cement. With a capacity

of 12,500 tons of clinker per day, the new production

line at the Cong Thanh cement plant was built to help

meet that demand. The increased capacity has made

the plant one of the largest cement-production facili-

ties in Asia.

Siemens was contracted by the Cong Thanh Cement

Joint Stock Company, a subsidiary of the Cong Thanh

Group, to provide all the electrical and automation

infrastructure for the plant’s new production line,

including cabling for the medium- and low-voltage

distribution systems, switchgear units, uninterrupt-

ible power supply and battery systems, power factor

compensation system, transformers, low-voltage dis-

tribution panels with intelligent motor control centers,

and variable-speed drives. The scope of supply also

included the majority of the process instrumentation

for the plant, along with the complete distributed

control system (DCS), which controls the various

stages of the cement production process.

Single-source advantages

As is the case with any production facility, high up-

time and reliability are critical to the operation of the

Cong Thanh cement plant. The implementation of an

In an environment characterized by tightening

emissions standards and rising production costs,

Cong Thanh cement plant in Vietnam benefits

from a one-stop solution comprising an integrated

automation and drive system from Siemens.

A holistic

approach

At the heart of the process: Operators in

the control room use a Cemat system based

on Simatic PCS 7 to monitor and control the

entire plant

Siemens AG

siemens.com/cement

amos.todt@siemens.com

01.2016 | siemens.com/magazine/industry

Cement

Integrated Drive System (IDS) from Siemens has been

fundamental in achieving these goals, as it provides

a single point of contact for the entire drivetrain –

which consists of motors for the mill, limestone crusher,

and kiln, along with gear units, frequency converters,

and control systems. In addition to allowing for rapid

resolution of problems in the field, which effectively

minimizes downtime, having a single provider elimi-

nates the finger-pointing that is often prevalent in

multivendor engagements.

“By having a single provider, we’ve been able to re-

duce interface losses, resonances, and wear by means

of design, engineering, and optimally matched com

ponents,” says Le Than, project manager at Cong Thanh

Group. “This translates into reduced operational and

maintenance costs, outstanding availability, and

higher energy efficiency. It also helps facilitate pur-

chasing and lowers warranty costs, which is some-

thing many cement manufacturers don’t always take

into consideration.”

Optimization through integration

At the heart of the plant’s automation system is Cemat,

an integrated process control system from Siemens.

Cemat has been installed at more than 800 facilities

worldwide and is based on Simatic PCS 7. “Cemat

offers many unique features that make operation of

the cement plant simpler and more efficient, such as

numerous blocks and modes for advanced control

functionality,” explains Amos Todt, senior project

Located in the scenic hills of the province of Thahn Hao, the Cong Thanh cement plant

is one of the largest single cement production lines in Asia

manager at Siemens. “It also provides the capability

to monitor all process components of the plant in real

time, which allows operators to quickly diagnose prob-

lems and evaluate the status of various areas of their

facility.”

In addition to providing the framework for inter-

connecting drives, belt conveyors, dampers, and

measuring equipment, the scalability advantages

offered by Cemat and Simatic PCS 7 were a major rea-

son for the solution’s implementation at the plant.

“We needed a highly innovative DCS that could help

us stay competitive over the long term,” adds Than.

“Cemat not only offers great compatibility with legacy

systems, but it also gives us the ability to expand the

plant if needed and integrate current infrastructure

with future innovations.”

Maximum productivity

Sourcing from a single vendor allowed the Cong Thanh

cement plant to leverage automation systems beyond

the cost of their implementation, according to Le Tien

Dung, deputy general director of the Cong Thanh

Group. “Partnering with Siemens to implement the

IDS met the needs of our facility,” he says. “We’ve

benefited greatly from high energy efficiency, reliabil-

ity, and reduced operational and maintenance costs –

in simple terms, maximum productivity.”

Siemens AG

siemens.com/magazine/industry | 01.2016

Cement

Smart move

Excellent teamwork ensures short

downtime: Siemens engineers

from Indonesia during the hardware

installation

In Indonesia, a collaboration between

long-standing partners Indocement

Tunggal Prakarsa and Siemens

demonstrated how cement production

facilities can benefit from increased

integration and process optimization

thanks to a smart control system

migration.

Siemens AG

01.2016 | siemens.com/magazine/industry

Cement

he cement industry is booming in Southeast

Asia. Indonesia, for example, has made signif

icant investments in new infrastructure in

recent years in an effort to modernize and promote

economic growth. One of the results of this effort has

been an increase in the country’s demand for cement.

Indonesian cement producers are thus coming under

increased pressure to boost output and improve oper-

ational efficiency in order to meet this demand and

avoid supply shortfalls.

An important industry player

Indocement Tunggal Prakarsa is Indonesia’s second-

largest cement producer, yielding over 20 million tons

of cement per year. The company was founded in 1975

and in 2001 was acquired by the German multinatio

nal giant Heidelberger Cement. Indocement operates

a total of 12 plants in Indonesia, located at three inte

grated cement factory sites. The company’s largest

installation is its integrated megaplant at Citeureup,

which features nine dry kilns and has a total produc-

tion capacity of 13.6 million tons of cement per year.

Migration for success

From its inception, Indocement has been committed to

continuous improvement through integration and pro-

cess optimization – hence the company’s decision in

2013 to commission its long-standing partner Siemens

to migrate the outdated control systems at three pro-

duction facilities (Citeureup, Cirebon, and Tarjun) to

the Cemat integrated process control system, which is

based on Simatic PCS 7.

With a presence in Indonesia that can be traced back

more than 160 years, to 1855, Siemens offers a unique

combination of expertise and local resources that made

the company a logical choice of partner for Indocement.

Furthermore, Cemat has been installed at more than

800 facilities worldwide and represents a proven

solution for helping cement producers reduce costs

through advanced resource management and pro

ductivity monitoring.

A significant improvement

The primary goal of the upgrade project was to im-

prove reliability and efficiency at the production facil-

ities so that Indocement could reach its production

goal of 30 million tons of clinker per year by 2018. In

addition to maximizing uptime and decreasing the

overall cost of production, the company wished to

replace the existing distributed control systems with

a more advanced and integrated platform that could

provide added visibility into the overall operation of

the plants.

The project scope involved the migration of seven

production lines – four at Citeureup, two at Cirebon, and

one at Tarjun. A new coal mill (a future project) will also

be integrated into the new control system. The migra-

tion of the production lines required the replacement

of programmable logic controllers (PLCs) as well as the

addition of remote I/O substations and HMI upgrades.

Prewired I/O rails with connectors were selected due to

a need for short exchange time. Work at the facilities

was performed by a combination of Indocement person-

nel and Siemens engineers based throughout Indonesia.

Having the advantage of worldwide presence, Siemens

also involved experts from India to speed up the com-

missioning. Safe migration with minimum downtime

was Indocement's main priority, and together with

Siemens, this target was achieved.

Cemat provided an advanced framework for intercon-

necting drives, belt conveyors, dampers, and measuring

equipment and allowed Indocement to access relevant

cement production data in a virtual real-time environ-

ment. Simatic PCS 7 also offered superior compatibility

with legacy systems and provided the flexibility to ex-

pand plant capacity in the future if needed. Standard-

ized libraries for automation functions also helped en-

sure better maintenance and service – leading to lower

costs and increased efficiency at each of the facilities.

Leveraging expertise

The expertise and global presence offered by Siemens,

coupled with the operational experience of Indocement,

allowed for a smooth upgrade at all the facilities. The

success of the migration project has led to further

collaboration between the two companies: the new P14

kiln line will also be controlled by the Cemat system.

This partnership is just one example of how a perfect

fit between portfolio and expertise can create cost-

efficient solutions that help improve reliability, reduce

complexity, and achieve long-term operational success

for cement plants.

siemens.com/cemat

wilhelm.braunecker@siemens.com

Simatic PCS 7 also

offered superior

compatibility with

legacy systems

and provided the

flexibility to expand

plant capacity in the

future if needed.

More than 50 years of cement production: The Rezzato

facility not only has a long tradition within Italcementi

but, since the modernization, is also a leader in terms of

technology

siemens.com/magazine/industry | 01.2016

Cement

A greener

brownfield

All photos courtesy of Italcementi

01.2016 | siemens.com/magazine/industry

Cement

ith a production capacity

of 61 million tons per year

and subsidiaries on four

continents, Italcementi Group is one

of the world’s largest cement pro-

ducers. The company has repeatedly

won awards for its commitment to

innovation and sustainability, and

continually sets new standards – for

example, with the modernization of

its plant in Rezzato, Italy, originally

put into operation in 1964.

A step into the future

The Rezzato project, given the

green light in 2010, is proof of Ital-

cementi’s future orientation. One

of the company’s main objectives

was to transition from a semidry

clinker manufacturing process to

a modern, more energy-efficient,

and sustainable dry process. For

the automation and process control

of the new line, Italcementi chose

Simatic PCS 7 – as it had for vari-

ous successful installations in the

past. The complete engineering,

supply, and commissioning of this

main control system (MCS) was

awarded to Fast S.p.A., an experi-

enced automation services pro-

vider and systems integrator for

Siemens.

New possibilities with Profinet

Because the assets of a cement plant

are often dispersed over a wide

area, the design of the communi

cation network architecture is a

critical issue in MCS engineering.

Normally, a centralized layout is

the solution of choice – with all

smart devices located near the cen-

tral control room, all peripherals

in the distributed electrical rooms,

and all the devices connected via

a Profibus DP–based star or ring

network.

Rezzato chose a different ap-

proach and became the first project

worldwide to use a unique Profinet

ring with Simatic PCS 7, which con-

nects all the controllers to all the

Profinet users. This solution, de-

vised by C.T.G. (Italcementi Group

Technical Center), was designed

by Siemens and Fast S.p.A. and sig

nificantly simplifies the network

architecture. Any peripheral device

in any electrical room can be con-

nected to any MCS controller, any-

where in the plant – simply by

means of optical fibers. In addition,

it is possible to easily link third-

party local programmable logic

controllers (PLCs) into the network

and to access them for mainte-

Through an extensive modernization project that combined new

technologies with sustainability and involved upgrading the process

control systems with a state-of-the-art industrial network, Italcementi

Group has not only improved the productivity and efficiency of its

Rezzato plant, but has also built the foundations for future innovations.

nance or service from wherever an

engineering station is plugged in.

More than one reason to celebrate

During the installation and

commissioning of the system,

experts from CSMT (Centro Servizi

Multisettoriale e Tecnologico – the

Profibus and Profinet Competence

Center headquartered at the Uni-

versity of Brescia) conducted exten-

sive surveys and performance au-

dits and also assisted in the detail

engineering phase. With their di-

agnostic tools, they could examine

all network nodes, resolve connec-

tion and configuration issues, and

release network performance cer

tification reports.

Thanks to the close collabora-

tion of all the participants, the

modernization project was a big

success. The Rezzato facility, which

began operating in 1964 during the

100th anniversary of the founding

of Italcementi, started up its new

line in November 2014 in time for

the 150th anniversary.

The project at a glance

siemens.com/cement

Claudio Locatelli

Italcementi Group, Italy

Italcementi improved the sustainability and eco-foot-

print of its operations at the Rezzato plant by replacing

and upgrading several process units:

◾

Replacement of the two existing long kilns with a

new kiln that includes a five-stage suspension preheater

◾

Installation of a new raw meal grinding unit

◾

Installation of a high-temperature bag filter

downstream from the clinker cooler

◾

Installation of a selective non-catalytic reduction

(SNCR) system and a selective catalytic reduction (SCR)

system for nitrogen oxide abatement

◾

Installation of a sulfur dioxide abatement system

based on dry injection of sodium bicarbonate

◾

Process automation upgrade with Simatic PCS 7 and

Profinet

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