Siemens provides gearless drive systems for Peruvian copper mines
Siemens offers gearless drive systems for belt conveyors and mills for Peruvian copper mines
The Siemens Industry Business Drive Technology Group successfully completed the commissioning of a gearless belt conveyor system at the Antapakai copper mine in Peru. This is the first large-scale case where the technology is applied outside Germany. The Antapakai copper mine is located at an elevation of 4,200 meters and is part of the Xstrata Copper Company. It plans to mine for more than 20 years and plans to produce an average of 160,000 tons of copper concentrate per year in the first few years. The application of gearless technology will significantly increase the efficiency and reliability of the mine conveyor system while reducing the need for equipment maintenance compared to conventional conveyor systems. The products supplied by Siemens to the mine also include all switchgear, gearless drive systems for a 40-foot semi-autogenous mill and two 26-foot ball mills, and their corresponding power distribution systems.
The supplier of belt conveyor systems at the Antapakai Copper Mine is ThyssenKrupp. The system is used to transport ore to a concentrator that is 6.5 km away from the mine. The conveyor belt has a width of 1,370 mm and a conveying speed of 6.2 m per second. It can transport about 5,260 tons of ore per hour. The belt conveyor system is the world's second belt conveyor system with gearless transmission technology. The first set was provided by Siemens and ThyssenKrupp (formerly O&K) in 1986 and successfully used in Germany. Prosper Hanner Mine of Stankel Co., Ltd.
Semi-autogenous mills and ball mills in the Antapakai mining area use Siemens' gearless drive systems
Siemens gearless transmission system on land conveyors in the Anapakai mining area
The conveyor system of the belt conveyor consists of two low-speed synchronous motors from Siemens (each with a rated power of 3,800 kW) and a matching Sinamics SL150 AC and converter transformer. Compared to the high-speed motor and gearbox combinations commonly used in other belt conveyor systems, this gearless transmission solution has many advantages: the motor model is not limited by the current gearbox specifications, and there is no need to install a multi-motor drive system. A belt drive wheel requires only one drive system. Therefore, the number of switching devices required for the motor can be correspondingly reduced, saving space and reducing weight. In addition, its reduced mechanical and electrical components can increase overall system reliability and productivity by 3% to 4%. Another advantage of this system is that it greatly reduces the maintenance requirements of the drive train. This is very important because the annual cost of gear maintenance alone can be as much as 5% of the original gear investment.
In addition, Siemens also provides high-voltage switchgear and gas-insulated medium-voltage switchgear used in the main distribution system, as well as low-voltage switchgear used throughout the plant. Even in the harsh environment of typical high-altitude mountainous areas, these equipment can provide safe and reliable power distribution for the mine. This is a decisive prerequisite for mining companies. In addition, these power distribution products are characterized by long-term maintenance-free operation.
Located in Brisbane, Australia, Xstrata Copper is part of Xstrata and operates mining and production plants in Argentina, Australia, Chile, Canada and Peru. The company is the fourth largest copper producer in the world. The Antapakai copper mine in southern Peru was put into production in the fourth quarter of 2012. Prior to the belt conveyor project in 2010, Siemens began supplying electrical equipment to the three mills in the mine in 2008, installing a gearless drive system. In this project, Siemens is responsible for the configuration, production and supply of electrical equipment for the mill. The gearless drive system installed in the semi-autogenous mill is rated at 24 MW and the gearless drive system of the ball mill has a power of 16.4 MW each. Siemens' scope of supply also includes transformers, electronic control stations, drive control systems, cooling systems, protection equipment and operator control systems.
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