Coal Age

MAY 2019

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May 2019 17 crushing systems continued Load sensing eliminates all that, he said. "It is just overall cost-effi- cient," Cerise said. "It prolongs the life of your mechanical parts, too." The drives can be calibrated based on site specifications. "We can adjust the speed of the conveyor to match your belt speed so you are not over- loading the belt," Cerise said. "And we can calibrate the CT brains to where you can let your cutter get to, say, 40 amps, then it slows down or you can go all the way to 100," he said. "For your belt speeds, for your load you want on your breaker, everything is adjustable." Cerise described adoption and installation of the drives as simple. "What we can do is, if they have a ma- chine and they want to retrofit it and upgrade it, then we can actually take this and integrate it into their feeder breaker, and change it out to this sys- tem," he said. "Or if you are an OEM manufacturer, we can integrate it into a brand-new feeder breaker." Saminco will oversee installation and train users. "We've got a program- mer that adjusts it, or we have a display so that you can do a potentiometer to change the speed you want it to go to match your belt speeds," Cerise said. The solution can be rigged for remote monitoring from the control room, he said. Thus far, most customers have declined that option. "Right now, they just set it up where they want it, how they want it, and then let it go." Among those customers is Alliance Coal and a couple trona mining oper- ations. So far, Cerise said, the feedback has been positive. "Everybody loves a variable frequency conveyor and the load sensing because it is all-ad- justable and the maintenance goes away," he said. "You get more produc- tion because of less downtime." Couplings Cut Costs Voith reported SafeSet torque-limit- ing couplings (TLC) now come stan- dard on many OEM crushers, to in- clude those made by major suppliers in the coal space. Manufacturers and miners who adopt the solution for new equip- ment realize a couple key benefits, Stephen Klein, application engineer, Voith, said. "Integrating the SafeSet in from the start will save the end-users significant costs in the future, but also it can be a little difficult to retrofit one in after the fact because things have to be moved back and a lot of times the equipment doesn't allow that," he said. "If we can get the SafeSets in at the start, it also helps the OEM of the crusher sell it because the mainte- nance will be significantly less." This also means maintenance- related downtime will be reduced. Adoption comes at a cost that Klein said is muted when in the right context. "There is a high initial cost at the beginning," he said. "But when you think about how much money you are going to be saving not repairing equip- ment or trying to get whatever back up and running, it is worth that money." Installed on a driveline, SafeSet, the simplest and flagship offering from Voith's line of TLCs, cuts main- tenance and downtime by preventing torque spikes from damaging a system when, for example, a crusher jams. SafeSet contains two specially coat- ed friction sleeves that are engaged with applied hydraulic pressure. Like a fuse, in an overload situation, the coupling releases the hydraulic pressure instant- ly and freely rotates on internal bear- ings, transmitting no torque through the driveline and saving it from failure. "There is no metal on metal," Klein said. "What it does is it will re- lease the oil pressure, allowing it to free spin and preventing that torque from transmitting back to your very expensive gearbox or motor and sav- ing you the expense of costly damage Queensland Miner Purchases More Sizers McLanahan Corp. reported it received the second order in one year from a Queensland coal miner for DDC-Sizers. The sizers are scheduled for delivery and commissioning before Q2 2020. The mine currently operates three McLanahan feeder-break- ers and four sizers. The equipment will operate in a parallel configuration with two three-stage crushing modules, Brad Anstess, coal specialist, McLanahan, said. The circuit will process 715 tons per hour of raw coal. The sec- ondary sizer will process minus 250 mm coal from the ROM feeder breaker. The tertiary sizer will render product in the 50-mm range. McLanahan sizers complete 3.5 hours of factory testing pri- or to delivery, the company reported. Bearings, motor couplings, and gearboxes are monitored for vibration and temperature. The miner is "happy" with the equipment, Chris Raines, mechanical engineer and project manager, McLanahan, said. "Particularly with the design improvements we've made over previous machines." Above, the DDC-Sizers were tested at the factory where the McLanahan team focused on ensuring roll center adjustment was accurate, a key concern of the miner, the company reports. (Photo: McLanahan Corp.)

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