Gearless conveyor drive strategic partnership to reach even greater heights

TAKRAF and ABB, a global technology leader in electrification and automation, recently renewed their ongoing strategic partnership regarding the deployment of Gearless Conveyor Drive (GCD) technology on TAKRAF bulk material handling solutions enabling a more sustainable and resource-efficient future.

ABB Head of Sales Mining Germany, Frank Kschamer and Thomas Jabs, TAKRAF Group CEO, together with Ulf Richter (ABB Product Manager Mining Conveyor Systems), Frank Enderstein (TAKRAF Group Head of Sales & Marketing) and Daniel Greune (TAKRAF Group Vice President Systems) entrenching both partners’ commitment to the strategic partnership at the recent celebratory event held in Leipzig, Germany.

In an important development for the global mining industry and as a commitment to both groups’ efforts in achieving a more sustainable and resource efficient future, TAKRAF Group and ABB, renewed their ongoing strategic partnership, dating back to 2011, regarding the deployment of GCD technology.

Gearless drives eliminate the need for a gearbox, hereby significantly reducing the number of main wear parts, which results in increased efficiency and reliability, as well as less maintenance being required.

Further advantages include a considerable reduction in the drive system’s footprint and emissions. In fact, for a large copper mine in Chile, studies showed that CO2 emissions were reduced by 66% as compared to diesel truck engines for the same copper production volume.

In 2019, TAKRAF delivered equipment for the principal ore transport system for Chuquicamata, one of the world’s largest copper ore mines, moving ore extracted underground to an above-ground processing plant using GCD technology (11 x 5MW gearless synchronous motors). This incredible system, boasting a total installed drive power of 58MW, transports crushed copper ore from underground storage bins to the surface along a 7km underground tunnel that overcomes 1km of vertical elevation. Once on the surface, the ore then travels along an overland conveyor that transports it the final 6km to the distribution silo.

Thomas Jabs, TAKRAF Group CEO, had this to say recently at the strategic partnership event, “We are proud of our ongoing partnership and association with our drive technology partner, ABB. This is a relationship that dates back more than 12 years and has resulted in some incredible technology achievements, not to mention delivery of the world’s most powerful belt conveying system at Chuquicamata using GCD technology. GCD’s bring numerous benefits, which are important to us as a company and the complete solution offering we present to our clients. With decreasing ore grades, ever-deeper mines and a general tendency to move from an open pit operation to underground, powerful, efficient and small footprint conveyor drives will only become evermore important in an industry in which safety and sustainability are also increasingly important. We look forward to this new chapter and, together with ABB, look forward to future GCD installations.”

Takraf And The Chuquicamata Copper Ore Mine

The incredible ore transport system, from TAKRAF, for Codelco’s Chuquicamata Underground Mine Project in Chile, transports crushed copper from underground storage bins to the surface along a 13km conveyor system, 7km of which is underground.

The underground system (comprising two conveyors of about equal length) as well as the overland conveyor boast advanced gearless drive technology provided by TAKRAF’s drive technology partners, ABB. Total installed drive power for the entire system, including various feeder conveyors, totals 58MW, of which there are 11 x 5MW gearless synchronous motors.

Another significant achievement is the installation of the newly developed steel cord belt, ST10000, on the uphill tunnel conveyors. This marks the world’s very first conveyor system to employ this premier steel cord belt technology.

TAKRAF Group, through its established and well-known brands, TAKRAF and DELKOR, provides innovative technological solutions to the mining and associated industries. It leverages its experience, acquired over more than a century, to provide equipment, systems and services that best satisfy its clients’ mining, comminution, material handling, liquid/solid separation and beneficiation requirements.

Owners and operators around the world trust TAKRAF’s engineered solutions to lower the total cost of ownership and reduce environmental impact by improving efficiency with safe and reliable equipment. TAKRAF Group offers sustainable solutions backed by expert service.

Since 1959 with Ferdinand Kisslinger as owner, the Condor corporation (which includes Condor and Isomonte) is a recognized supplier of solutions for material handling bulk such as soy, wheat, sugar, fertilizer, coal, salt, and iron ore for maritime and river pier, train cargo, factory, silo, and warehouse store.

In a strategic partnership with Germany, its factory installs mechanical and pneumatic equipment for a wide variety of companies, always leading technological developments for bulk solids handling.

The group’s activities involve the integration of systems for storing, processing, and handling of bulk handling, equipment, and electromechanical control systems. Nowadays, the group works mostly on infrastructure projects in Brazil, supplying technologically advanced equipment to meet the needs of its clients.

Condor’s pursuit of technological development highlights the group’s commitment to increasing its already prominent position in the Brazilian and international markets. Led by its history of innovation since 1959, Máquinas Condor reinforces the material handling bulk market, delivering effective and competitive solutions. With a forward-looking approach, the group is actively driving technology innovation and making significant contributions to its industries.

Product Line

Máquinas Condor stands out as an expert in manufacturing a wide range of essential industrial equipment for the logistics and port sectors. The portfolio includes ship and barge loaders and unloaders, pneumatic conveyors, belt conveyors, enclosed belt conveyors, bucket elevators, and chain conveyors. The company also provides expertise for special projects and turnkey solutions for intermodal terminals and integrators, ensuring operational efficiency and excellence in every application.

Condor’s reputation is built on decades of innovation, quality, and dedication to the specific needs of its clients. Beyond producing high-quality equipment, the company has strong expertise in customizing, and adapting to the unique challenges of each project.

Whether enhancing logistical efficiency, optimizing port operations, or developing solutions that fit each customer, Máquinas Condor is an ideal partner for driving operational success across a range of industrial sectors.

Company Clients

Máquinas Condor S/A boasts an extensive and prestigious client portfolio, spanning various sectors of the national and international industry. The confidence shown in its services and equipment contributes to its ongoing success in serving important and benchmark players in the field. These partnerships reflect not only the quality of the products but also Condor’s dedication to meeting the specific needs of each client, establishing Máquinas Condor as a reference in industrial equipment manufacturing.

Recent Technological Developments

Máquinas Condor is advancing its product line with enclosed belt conveyor technology. This development reinforces its commitment to excellence and sustainability, providing an innovative solution for the large-scale grain handling. Benefits of the enclosed system include excellent environmental control, absence of leaks and dust emissions, ensuring operational safety — with bearings protected against explosive atmospheres. With reduced maintenance needs and a modular, standardized construction, this technology elevates operational efficiency, providing better visibility in port operations.

About Condor Group

The Condor Group an ‘equipment modelling’ approach in its projects, which helps it to stand out among competitors. This approach, using specific software, significantly pushes machine development, improving reliability, and ensuring the excellence of the final product. In addition to remarkable agility in development, the methodology incorporates essential considerations about equipment design and operation through structural analyses and detailed monitoring of production processes. This results in reduced overall execution and manufacturing time, enabling quick market entry, thereby strengthening competitiveness and business reliability.

Condor is a highly advanced company, which uses advanced software to achieve exceptional results. This use of advanced software, combined with extensive knowledge of equipment and Finite Element Analysis (FEA) practices, demonstrates a commitment to technical excellence, focusing on precise analyses and detailed simulations. This emphasizes the dedication to meeting the demands of an increasingly demanding market.

Why cover your conveyor belt? STANDARD INDUSTRIE explains

Belt conveyors often generate dust and material losses, resulting in frequent cleanings, loss of productivity and a negative impact on the environment and operators’ health. The presence of dust containing CMR chemical agents increases the risk to the health and safety of workers, as well as creating a nuisance for neighbours. In addition, maintenance work on conveyors can be frequent and risky.

To address these issues, STANDARD INDUSTRIE International has designed and further improved a containment solution called LIFTUBE®. This patented item of equipment is placed on belt conveyors to optimize their tightness. This system ensures a reduction in dust emissions, material losses, maintenance time and guarantees operator safety.

LIFTUBE® replaces three roller stations on conventional conveyors. In practical terms, standard one-metre modules that can be upgraded are easily installed on all or part of a new or existing conveyor, while retaining the original belt, frame and motorization. The system is installed between the loading and unloading points, and is available in widths from 500 to 1,600mm.

Thanks to the LIFTUBE® design, the belt is contained within a sealed envelope, reducing the risk of material escaping to the outside. Because the cover can be clipped on, it fits perfectly into the upper grooves of the edge supports. It is also watertight thanks to the foam-laminated hoops installed at each end, which enclose the strip.

When a plant shows interest in covering its conveyor with LIFTUBE®, STANDARD INDUSTRIE International systematically carries out a full on-site audit to study the installation of the conveyor and the behaviour of the belt during material transport.

If a new conveyor is to be installed, the LIFTUBE® study is carried out on the basis of plans and according to the plant’s objectives. For example, in a limestone quarry: to avoid as much loss as possible when material falls onto the belt.

During the site survey, the following control points are addressed:

Study of feeding points. This is where v there is a major safety issue for operators. This area of the conveyor is particularly in need of protection.

Check the width of the conveyor, v troughing and inclination.

Observe the belt running when empty v and loaded. See if it runs to the left or to the right. Check in which direction it moves the most, and whether it vibrates.

Check whether the belt is turning v over.

Check where the material falls. This is v where there is a major risk of material loss and the spread of dust. The material must be prevented from spreading across the entire width of the belt.

Validation of the need for an v installation resistant to high temperatures.

Check the motor power required for v the planned equipment (more or less than 20 metres of LIFTUBE®).

The VEOLIA power generation plant in Germany chose the LIFTUBE® to reduce emissions by sealing its ageing conveyor belt.

THE BENEFITS OF LIFTUBE® INCLUDE :

All areas of the conveyor equipped v with LIFTUBE® are protected, guaranteeing operator safety. Sealing is optimized to prevent dust v emissions.

The belt edge is held in place along its v entire length, avoiding the chain effect. The drop zone is equipped so as to v keep the vein of material well in the middle and to achieve throughputs of around 10 to 15% higher with the same width of strip. This equipment ensures that all the material flows in the right direction and not into the environment.

The unique roller tilting system v provides easy access for changing this wear part.

The LIFTUBE® can be fitted to belts v with an incline of up to 22°.

Some LIFTUBE® installations can v handle more than 1,000 tonnes of material per hour.

ON WHICH TYPES OF CONVEYORS AND FOR WHICH APPLICATIONS IS THE INSTALLATION OF LIFTUBE RECOMMENDED?

In mines and quarries: conveyors for v transport to crushers, conveyors at mine exits (ores: gypsum, anhydrite, etc.)

In cement plants: kiln feed conveyors v (transport of coal, alternative fuels), mill feed conveyors, fly ash conveyors, clinker cooling conveyors, clinker feed conveyors, shipping dome conveyors, truck loading conveyors, etc.

Glassworks: cullet and broken glass v conveyors (production scrap), protection against crystalline silica dust emissions.

Waste treatment and biomass v power plants: conveyors for fuel, sawdust or hazardous waste.

Steel industry: conveyors v transporting ore, limestone, coke, coal and sinter.

CASE STUDIES IN THE USE OF LIFTUBE®

VEOLIA GERMANY - POWER GENERATION

PROBLEM: this recycled wood plant producing energy based in Bavaria was looking for a solution that would fit in with its plan to reduce emissions and seal its old conveyor belt. The passage of shredded wood of different particle sizes required optimum sealing to avoid overflowing and the risk of the belt shifting. The 650mm belt is fed with raw material by a loader, which delivers all types and shapes of wood regardless the size of material. This creates jolts in the belt and risks the covers being torn off. In addition, the specific nature of the region, with its high snowfall in winter, meant that the hoods had to be more resistant.

SOLUTION: STANDARD INDUSTRIE, in collaboration with REMA TIP TOP, developed a specific solution to meet the requirements of the plant’s main conveyor sealing project. As a result, 55 metres of LIFTUBE® 650 were installed on a conveyor belt carrying shredded wood to the boiler for energy production.

RESULT: raised hoods with an extra-large opening allow wood to pass through without a badly trimmed board tearing the hoods off. What’s more, if a piece gets stuck, the oversized hatch allows the user to grab and pull out oversized pieces. What’s more, the LIFTUBE® design offers a special joint to ensure watertightness. The hoods have been developed with a thickness greater than the standard dimensions to withstand the weight of the snow, so they won’t sag.

WIENERBERGER FRANCE - BRICKWORKS

PROBLEM: Wienerberger is a brick and tile factory that dates back to 2011 and produces 150,000 tonnes of bricks a year. To achieve this level of productivity, the heart of the plant, where production takes place, is automated: “Everything works by itself. That’s our advantage here. We are one of the most automated and robotized plants in the group.”

In 2021, regulations will require factories using silica to control the emission of so-called CMR (Carcinogenic, Mutagenic, Reprotoxic) dusts. This is what is motivating the Group to invest in improving the safety of its staff.

SOLUTION: the project involves equipping three existing belt conveyors:

TB3: complete LIFTUBE® equipment v on a 1,200mm-wide belt transporting clay.

TB2 & TB1: partial LIFTUBE® v equipment on a 1,000mm-wide belt, mainly at the drop points and the protection of re-entrant points. The hood prevents dust emissions. It prevents the conveyed product from being polluted by contact with the outside environment. The thickness of the cover is greater, adapted and recommended for product chutes. The centreing plates channel the material in the middle of the belt so that it is not in direct contact with the lateral curtains, thus limiting wear on the lateral curtains.

RESULT:

Environment: reduced dust emissions v between loading and unloading.

Quality: full protection of the v material. No product pollution.

Total safety: protection of entry v points.

Economy: minimum and very simple v maintenance.

Cost-effectiveness: optimized flow v rates.

Standard, adaptable, upgradeable v components.

Installation of the LIFTUBE® system v without modifying the installed power.

Conclusion

To meet the challenge of efficient powder waste management in processing industries, containment devices on conveyors are becoming essential. While current solutions such as the LIFTUBE® are effective,

STANDARD INDUSTRIE

International understands that changing environmental standards and increasing corporate environmental awareness are driving a continuous search for innovation. The future of powder waste management will involve the integration of intelligent technologies, increased automation and even more sustainable practices. However, it is vital to remain vigilant when it comes to implementation costs.