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SIMINE for conveyors

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Siemens AG
Industry Sector
Drive Technologies
Mining Technologies
Schuhstrae 60
91052 ERLANGEN
GERMANY

Subject to change without prior notice 09/12

Order No.: E20001-A230-T195-X-7600
DISPO 21662
SCH26136 GD.LD.VM.MIMI.52.2.02
GB 120265 WS 06122.0
Printed in Germany
Siemens AG 2012

The information provided in this brochure contains merely

general descriptions or characteristics of performance which
in case of actual use do not always apply as described or which
may change as a result of further development of the products. An obligation to provide the respective characteristics
shall only exist if expressly agreed in the terms of contract.

siemens.com/mining

All product designations may be trademarks or product names

of Siemens AG or supplier companies whose use by third
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owners.

Answers for industry.

Your challenge:
Moving mountains reliably and efficiently

Comprehensive requirements
Belt conveyors operate under the harshest conditions, often far removed from
centers that provide replacement and
spare parts. To operate efficiently, it is
essential that these conveyors remain
failure-free, a factor that in turn depends
on high availability and reliability. High
availability coupled with ease of maintenance must ensure a long service life,
which is possible only if all the electro
technical components and mechanical
elements are perfectly coordinated.

More than just technology

Besides production-oriented concerns,
mine operators must increasingly
consider ecological aspects as well,
including compliance with emissions
guidelines and maximum energy efficiency wherever possible. The appropriate fuel-efficient drives not only reduce
energy costs but also reduce the carbon
footprint.

Mines subsist on moving raw and

bulk material. This makes conveyor
solutions business critical in terms
of performance and availability.

SIMINE for conveyors generates:

High system availability
Low operating
and energy costs
Low maintenance costs

To meet worldwide demands for raw materials, underground mines and open pit mines are being established
in increasingly remote areas. Every year, billions of tons
of bulk materials such as ore, coal, copper ore, and mining waste have to be moved powerfully, reliably, and
efficiently.

Our solution:
Comprehensive belt conveyor expertise
from a single source

Where it all fits together

Modern belt conveyor systems place
high demands on the equipment used.
Seamless interaction between the individual components above all between
electrical and mechanical components
is a basic requirement for the safe, optimal operation of a belt conveyor. Based
on our many years of experience in these
areas Siemens developed SIMINE as a
comprehensive concept for belt conveyors. Combined with SIMINE, we cover
the entire life cycle of the belt conveyor
and its components, offering a complete,
broadly based range of belt conveyor
products.

Customized solutions
Siemens specialists are available to assist
you from the planning phase, construction, and commissioning to service and
maintenance.

With its comprehensive portfolio,

Siemens covers the entire life cycle
of conveyors, thus ensuring productivity at all times.

On the following pages the most important products, systems, and solutions
for belt conveyors will be presented. Of
course, this can be no more than a brief
introduction, but well naturally be glad
to meet with you individually at any time
to discuss your own particular on-site
requirements.

Service

Communication

Sensors,
measurement

Automation/control

Power distribution

SIMINE
Siemens provides belt conveyor solutions for the mining
industry from electrical drives to instrumentation. And
we are one of the few international companies with
sufficient know-how to combine all the relevant components into a truly integrated over-all concept.

Converter
technology

Mechanical drive
components and
systems
Motors

Drive systems

Each mine is different. The demands

on belt conveyors also differ depending on the material being conveyed
and the particular landscape. Drives
must be sufficiently versatile. Siemens
offers both conventional constantspeed drives and variable-speed
drives.

The right power for every application

Conventional drive systems,

fixed speed
Asynchronous motor
Resistance starter

Modern drive systems,

speed-controlled
Asynchronous motor
Hydraulic coupling

Asynchronous motor
Frequency converter

Resistor

Transformer

Transformer

Starter

VFC

VFC

Asynch.
motor
SRM

Asynch.
motor

Asynch.
motor

Synch.
motor

Hydraulic
Coupling

Coupling
Brake

Brake

Gear box
Coupling

Gear box
Coupling

Belt
drive
pulley

Synchronous motor
Gearless drive

Starter

Coupling
Brake

SRM
VFC

Conventional drives quickly up to

speed
In the case of conventional drive systems, the belt conveyer is operated at
a constant speed. Asychronous motors
executed as slip ring motors or squirrelcage motor.

Slip Ring Motor

Variable Frequency Converter

Gear box
Brake

Coupling
Belt
drive
pulley

Belt
drive
pulley

Belt
drive
pulley

In connection with a gear unit, they

deliver the necessary speed and the
necessary torque to the belt conveyor.

Both drive systems employ frequency

converters that can adapt drive behaviour to various operating conditions.
Proven control options make it possible
to adjust the interaction between a drive
system and belt conveyor precisely as
needed. Such control algorithms permit:

Whether you are looking for constant or variable speed drives, Siemens offers the right solutions.

Simultaneous starts and stops of the

entire conveying routes
Load sharing for multi motor and multi
pulley belt conveyors
Reduced slip between drive pulleys and
belt during starting and stopping
Smooth starts and stops to reduce wear
and tear on mechanical components

The slip ring motors start up behaviour

is determined by the starting resistors,
which are switched on in stages until
the motor and belt conveyor reach their
rated speeds, or with liquid starters.
Drive systems with a squirrel-cage motor
use modern hydraulic couplings. At start
up, the motor is practically load-free and
achieves its rated speed very rapidly.
As the coupling halves slowly fill, the
belt conveyor accelerates until it reaches
its rated speed.
Modern drives flexible and efficient
Modern drive systems use variable-speed
(speed-controlled) drives. Asynchronous
motors executed as squirrel-cage motor
are combined with a gear unit.
For belt conveyors that require several
megawatts of power, drive systems
without gear units that are, direct
drives with synchronous motors are
also used.

Motor

Mechanical
components

The heart of your belt conveyor solutions

Everything for the efficient transmission of power

Series

Power

Voltage

Type

Operating type

kW
N-Compact
IEC
Standard

2001,000

400 V690 V

asynchronous for controlled

drivesquirrel- drive systems
cage rotor

H-Compact
IEC

2003,000

690V11kV

asynchronous for constant

drivesquirrel- speed as well as
cage rotor
for controlled
drive systems

Vario

3151,900

400V11kV

asynchronous
driveslip ring
rotor

Low speed
synchron
motor

The heart of every conveyor is its

motor. Siemens makes it beat
reliably.

2,00010,000

690V13.2kV

Thanks to our various type series, you

can select the right motor for each
operating mode required, whether
constant speed, variable, or direct
drive. Our robust, reliable motors are
the perfect basis for your customized
belt conveyor as well as for modernizing existing systems.
For maximum availability
In addition to tried-and-tested geared
drives, Siemens also produces gearless
synchronous motors, which, when interacting with a corresponding converter,
generate the requisite speed and torque
and transfer it to the belt conveyors
drive drum. Our direct drive systems are
individually configured for each application in terms of speed, torque, and other
requirements.

synchronous
motor

for constant
speed

We offer our customers all the components needed for an efficient transmission of power from the motor to
the drive shaft of the belt conveyor,
either as individual elements or as a
complete drive system.
Gear units
Proven FLENDER gear units are ideally
suited to the requirements of belt conveyors and guarantee the reliable operation of the drive system.

for speed
controlled drive
systems

Economically attractive
In addition to providing a solution that is
optimally matched to individual requirements, our direct drives also offer concrete economic advantages. Elimination
of the gear unit means elimination of the
majority of moving parts, thereby significantly reducing wear, extending the
service life, lowering maintenance costs,
and increasing overall availability and
productivity.

Drive unit for belt conveyor with gearbox

B3SH26, with external oil cooler OLGE 09/V2,
operation torque 439.220 Nm, power rating
2052 kW, input speed 980 rpm, transmission
ratio 22,4

The right gear unit is available for every

drive task. Thanks to extensive standardization, all the components are perfectly
coordinated, which not only increases
reliability but also improves efficiency
with distinct cost advantages compared
to solutions that are not coordinated.
Couplings
Couplings form the link between motors
and gear units, and often between gear
units and drive drums as well. The connection permits a reliable transmission
of speed and torque, and can also for
example, by means of hydraulic couplings influence the start up behavior
of the entire drive system.

We supply high-quality FLENDER couplings and offer a wide range of flexible, highly flexible, torsionally rigid and
hydrodynamic couplings in a number
of different sizes and versions. Some
FLENDER coupling series are maintenance-free, while others have long
maintenance intervals. Wearing parts
can be easily replaced and are available
worldwide, thus reducing downtimes to
a minimum.

With its comprehensive portfolio

Siemens ensures the efficient power
transmission.

Geared motors
Geared motors combine motors and gear
units in an extremely compact structure.
For power ranges up to 200kW and
torques up to 20,000 Nm, versions are
available with helical, flat, or bevel helical gear units.
Complete drive system
The individual components are combined
into complete drive systems for belt conveyors. Our complete solutions are configured to meet your exact requirements
for the specific application. Thanks to
the high quality of our components, we
build reliable, efficient, economical drive
systems.

Conveyor Drive FLENDER Self Aligning SystemTM

as integrated drive train with SIEMENS Motor,
input coupling, gearbox and ouput flange

Converter technology
Converters for variable drive systems

Medium-voltage converters from the

world market leader
As the undisputed number-one supplier
of MV drives, Siemens sets worldwide
standards in terms of installed capacity,
market share, and breadth and depth of
offerings. For belt conveyor solutions,
we offer various voltage source converters, load-commutated inverters, and
cycloconverters. In addition to simple
air-cooled converters, also water-cooled
models for the higher power ranges are
available.

Low-voltage converters for maximum

flexibility
Our low-voltage converters are suitable
for all performance levels and feature
maximum flexibility, functionality, and
engineering comfort. Converters in this
range can operate in two- and fourquadrant mode.

Converter LV
Type

Whether medium or low voltage

Siemens delivers the converter that
meets your needs.

Converter MV

Power

Voltage

Type

Apparent power

Voltage

kW

MVA

kV

G130

75800

380690

GM150

0.821

2.34.16

G150

751,500

380690

SM150

3.431.5

3.34.16

S120

1.64,500

380690

ROBICON Perfect
Harmony

0.15120

2.313.8

Dynavert T

2.26,600

230690

SL150

325

14

Convert types and functional range (power, voltage) specialized for mining
Efficiency is always a question of
control. SINAMICS is our answer.

10

For variable-speed drives to operate at maximum efficiency, they

must have the right frequency converter. Siemens SINAMICS family
offers proven converter technology

for a variety of tasks. Depending on

requirements, services range from
the simple movement of a machine to
open- and closed-loop control of complex motion sequences.

11

Power distribution
Over 160 years of power know-how

Reliable switchgear for every situation

This includes reliable connection on
every distribution level, for every performance range, for every type of appli
cation, and for every system type.

On the medium-voltage level, the SIVACON models are supplemented by our

NXPLUS C and 8DA10 switchgear.

Our unique transformer portfolio

For over 100 years and in more than
100 countries, Siemens transformers
have been synonymous with top quality.
Our expertise as a technology leader
enables us to provide the right transformer for every task, from large power
transformers to compact distribution
transformers. Above all, our GEAFOL
cast-resin transformers have seen
decades of successful use wherever compact designs are required that also meet
the highest safety standards. GEAFOL
has none of the limitations of liquidimmersed transformers while retaining
their operational reliability and long service life.

GEAFOL transformers

Siemens medium voltage switchgear NXPLUS C

Siemens has developed product series

that are exactly in line with the specific
requirements. Our SIVACON models, for
example, have stood the test at the lowvoltage level. With a switching capacity
of up to 7,000 A, they offer sufficient
reserves to guarantee a safe, flexible,
and cost-effective power supply.

When it comes to power distribution there is hardly any competitor

with a comparable track record like
Siemens.

12

Every belt conveyor needs power,

which includes the corresponding
infrastructure of medium- to low-voltage power distribution. As the worlds
leading provider in the area of power
distribution and with over 160 years
of experience, we contribute to the

The switchgear and transformer

solutions from Siemens meet the
needs of mine operators at any
point.

sustainable and responsible use of

electrical energy. Our comprehensive
portfolio for medium- and low-voltage
power distribution makes it possible to
implement intelligent power networks
and thus lay the foundation for industrial applications.

13

Automation
Brings intelligence and connectivity
to your conveyor

SIMINE Automation is the result of

Siemens unique experience in both
automation technology and conveyor
expertise. Its reliability and efficiency
has been proven in numerous installations around the world.
Minerals Automation Standard
The Minerals Automation Standard provides a comprehensive library focused
on mining-specific requirements and is
highly scalable from single equipment
like conveyors up to automation of complete mine operations. With its modern
architecture based on SIMATIC PCS 7
the Minerals Automation Standard is the
ideal basis for future-proof and economical solutions for the mining industry.
Open communication standards such as
ethernet and industrial WLAN are the
basis for easy communication to the central control level.

Maintenance and diagnostic

Our standardized solutions offer
enhanced diagnostic features to reduce
unplanned shut down times to a minimum. Siemens devices are available
with intelligent diagnostics and condition monitoring. The valuable information is available for local diagnostics
and Plant Asset Management via remote
connection.

Industrial automation
Siemens offers a complete range of automation products for the mining industry
starting with the world market leading
PLC SIMATIC S7, a comprehensive solution for a plant wide DCS with SIMATIC
PCS7 and the library Minerals Automation Standard, Industrial PC, and SIMATIC
IT the MES solution from Siemens.

SIMINE Automation products and

solutions for conveyors help you to
engineer, operate, and maintain
your conveyor efficiently and
reduce the project risk due to standardized and out of the box
solutions.

Siemens Automation for conveyors:

A complete field instrumentation and
automation portfolio for mining
Automation for vendor packages including seamless integration into
the automation of a complete mine
Advanced control packages for speed
and volume control from single conveyors to complex conveyor systems
Advanced stockyard management systems from precise material tracking to
3D stockpile management including autonomous operation solutions

14

Siemens Automation products and

solutions for conveyors are designed
to increase through-put and product
quality,

Sensors and communications

A wide range of instrumentation, sensors
and communication solutions include
high precision belt scales, flow meters,
level instruments, industrial switches,
and WLAN products that meet the industrial requirements to operate in harsh
mining conditions.

Belt weighing
With Milltronics, Siemens offers systems
for belt weighing, which feature simple
mounting and low maintenance requirements isolated from lateral forces, with
minimal hysteresis and maximum linearity. Together with our high-resolution
speed sensors you can achieve a high
measuring accuracy and repeatability.

to minimize maintenance and wear

and tear,
to protect man and conveyor during
continuous operation,
for operation under harsh environmental conditions,
to comply with environmental regulations, and
to control and minimize energy
consumption.

15

Intelligent mine operation needs

information. Siemens provides the
necessary measuring equipment.

Instrumentation

Technology-based services

Know whats happening

For a greater competitive edge

Optimal conveyance of bulk materials depends on having the very latest

information. A comprehensive network of measuring points and sensors
is required to ensure the necessary
information density and quantity.
Siemens offers a comprehensive portfolio of Process Instrumentation. Our
solutions cover the most diverse applications and requirements.

With a track record for consistent performance in

harsh environments, Milltronics conveyor belt
scales combine simple, drop-in installation, low
maintenance and repeatable accuracy for productive operations.

Belt weighing
Siemens offers systems for belt weighing, which feature simple mounting and
low maintenance requirements isolated from lateral forces, with minimal
hysteresis and maximum linearity.
Together with a high-resolution speed
sensor high accuracy and repeatability
are achieved. The belt scale data can be
collected in a stand-alone integrator or
seamlessly integrated in SIMATIC S7 with
a SIWAREX weighing module.

16

Point level measurement for all

applications
Siemens level switches are built to resist
the most demanding conditions in the
mining industry. Various technologies,
such as non-contacting ultrasonics,
vibrating forks, paddle switches, tilt
switches and capacitance technology allow the best solution for every
application.
Continuous level measurement
Continuous level measurement monitors
dynamic processes. These measurements
are transmitted as an analogue signal or
digital value. For this purpose, Siemens
is a world leader in solids level measurement and offers numerous solutions
based on ultrasonic, radar, capacitance,
gravimetric, and hydrostatic technologies.

Minimum downtime and the optimum

use of staff and resources are key to
sustainable success in industry. Siemens
provides the basis for greater productivity, flexibility, and efficiency with technology-based services throughout the
life cycle of an industrial plant reliably,
globally, and around the clock. In-depth
technology and product knowledge as
well as industry expertise within Siemens global network of experts ensure a
considerable competitive edge.
Siemens offers far more than just products and systems: A comprehensive
range of services is available for the mining industry worldwide.
From the start-up, to the mine operation
across the entire lifecycle for products
and systems, Siemens p
rovides industry
services tailored to the mining needs.

Engineering support and technical consulting from Siemens assist customers

with specialist expertise right from the
beginning. In the start up phase of a
mine operation, Siemens provides services and solutions, suchas online and
technical support.
For mining operations, the available
operational support and maintenance
services can be enhanced, e.g. by repair
and spare parts services as well as field
services. Furthermore, Siemens supports
mine operators to face new challenges
and changing conditions with the
necessary know-how and experience
providing mine-specific technologies for
modernization and optimization requirements as well as energy and environmental features.

SITRANS LR560 2-wire, 78 GHz FMCW radar level

transmitter for continuous monitoring of solids in
silos to a range of 100 m (328 ft.)

Robust motion sensors

Monitoring moving equipment in a
mine is essential for safe operation of
the process. Siemens motion sensors
are developed for the most demanding
conditions and can monitor over-speed,
under-speed or zero-speed of all kinds
of conveyors. With a sensing distance
of 100 mm, they can be installed in the
most challenging installations.
17

Our references
Measure us by what we do

Asynchronous motor
Frequency converter

1998 Coarse ore conveyor system

Minera Los Pelambres, Chile
Conveyor characteristics
Length:

12.7 km

Capacity:

8,700 t/h

Solution
Transformer
VFC

Asynchronous motor
Resistance starter

2007 14 km conveyor line

for Neyveli Lignite Corporation, India

Resistor

Conveyor characteristics

Starter

Total length:

8 conveyors, 14 km

Belt width:

2,000 mm

Belt speed:

5.4 m/s

Asynch.
motor
SRM

Asynch.
motor
Coupling
Brake
Gear box
Coupling
Belt
drive
pulley

Solution

Coupling
Brake
Gear box
Coupling
Belt
drive
pulley

The conveyor system consists of 4 x 630 kW

drive units

3 single belt conveyors consisting of 10 x

2,500 kW drive units, each comprising of 1
squirrel-cage motor fed by 1 SIMOVERT ML
voltage source converter 3,3 kV
Downhill conveyor, permanent generating

2010 Coal conveyor

Lignite Open Cast Mine Reichwalde, Germany
Conveyor characteristics
Length:

13.5 km

Capacity:

6,000 t/h

Solution

Conveyors with slip ring motors with

resistance starters

6 single belt conveyors consisting of totally 9

x 1,250 kW drive units and 9 x 900 kW drive
units
Conveyor speed adjustable according to load
requirements

Asynchronous motor
Hydraulic coupling

2010/2011 26 belt conveyors

for llolar Lignite Open Pit Mine, Turkey
Conveyor characteristics

Starter
Asynch.
motor
Hydraulic
coupling

26 conveyors, 17.4 km

Capacity:

6,900 t/h and 9,350 t/h

Belt width:

1,800 mm

Solution
Total installed power: 46,300 kW

Brake
Gear box

Coupling
Belt
drive
pulley

18

Total length:

Synchronous motor
Gearless drive
Transformer
VFC
Synch.
motor

Installation of drive systems consisting of

Siemens motors, Fludex turbo couplings
and Siemens-Flender gear boxes

1985 Belt conveyor with gearless drive

Solution Prosper Haniel Coal Mine, Germany
Conveyor characteristics
Length:

3.8 km

Capacity:

2,800 t/h

Belt speed:

5.5 m/s

Lifting height:

800 m

Solution
Brake
Belt
drive
pulley

 x 3,100 kW gearless drive systems, each

2
consisting of a low-speed synchronous
motor with cycloconverter
Gearless tandem drive located at the head

19