Mining
WEG supplies motor for ball mill in mining plant in Argentina
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The use of a ball mill in the grinding process is a traditional technique widely used for particle size reduction or for mixing materials, used in various industrial works, such as mining companies. In this sense, because it is a more severe environment, it is necessary to use a motor with greater resistance and protection.
With efficient solutions in the mining sector, WEG supplied a slip ring motor from the M Mining line, frame 560, 1,300 kW, 3,300 V, 4 poles, 50 Hz to drive the ball mill of a mining company in Argentina. The applied motor makes the process more efficient, ensuring greater operational security, in addition to having simple and reduced maintenance.
WEG motors of the M Mining line were specially developed with electromechanical characteristics that provide durability, resistance and robustness, ideal for operating in harsh environments in the mining and cement segment. The big difference in this project is that to reduce the need for field adjustments, WEG adapted the manufacturing process to scale the solution according to the customer’s needs.
This supply consolidates WEG as one of the main suppliers of motors for the mining segment in Latin America, in addition to reinforcing the company’s flexibility in meeting the specific needs of its customers. For the customer, it increases reliability in operation and reduces downtime for maintenance.
Advantages of the motorized brush lifting system
The new brush lifting system is the evolution of the already established WEG brush lifting system, with the incorporation of the operating logic, fault investigation capabilities, operation monitoring via HMI simplifying and reducing the costs of motor installation, operation, and maintenance. In order to carry out the operation logic in a simpler way, its operation is via PLC. The monitoring of the operation and eventual faults is available via the integrated PLC’s display so that the user has full control over the performance of this system.
The need for maintenance compared to a fixed brush system reduces considerably, due to the brushes being lifted after the motor starts, in addition to allowing the elimination or reduction of several variables, such as:
- Suitability of the brush to the environment (humidity, patina formation)
- Brushes wear (very low or high temperature, ring roughness and spring pressure)
- Brushes compartment cleaning
- Cooling
The lifting set has a gearbox driving the operation, adding robustness, reliability, and simplicity to the system. The brush holder works with constant pressure springs and has three inspection points, allowing agility and visibility in preventive, predictive or corrective maintenance. The internal position of the lifting mechanism is read by means of inductive sensors and they have a system that indicates their operating status.
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WEG supplies refrigeration project solution for underground mine
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Howden South America, in partnership with WEG, are supplying the refrigeration project (phase 1) for Caraíba Mine in Jaguarari, state of Bahia, Brazil. Supported by Cooling System Howden technology, the project ensures safe and economical underground refrigeration. Howden counted on WEG’s key participation with emphasis on an E-house for a refrigeration and an electrical package to drive the plant from the initial engineering stage, to manufacturing, commissioning and start-up, including transport to the mine site.
In addition to the W22Mining super premium electric motors, the WEG solution included a 2500 kVA dry transformer, a complete ELW Mining E-house with auxiliary Wall Mounted air conditioning systems, fire protection and other internal circuit as well as an intelligent CCM06 that includes CFW11 frequency drive, Enterprise nobreak and automation system with PLC panel. The solution provided by WEG in partnership with Howden brought together the technical teams of both companies and reduced the time required for electrical interconnections and equipment start-up since the E-house is supplied with all internal interconnections and fully tested at the factory.
Howden Sales Director, Edson Luis Geraldini, stated that the Howden and WEG partnership represents a significant drop in the internal temperature, in a 1400-meter deep mine with 105 kilometers of galleries and 8400 meters of ramps thus providing a more pleasant environment for the workers. At the same time, the equipment for the second phase of the project for the new mines that are part of the Caraíba Mine industrial complex are already in production at WEG with operation expected for the first quarter of 2022.
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WEG supplies refrigeration project solution for underground mine
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Howden South America, South Africa and Howden VentSim, in partnership with WEG, are supplying the refrigeration project (phase 1) for Caraíba Mine in Jaguarari, state of Bahia, Brazil. Supported by Cooling System Howden technology, the project ensures safe and economical underground refrigeration. Howden counted on WEG’s key participation with emphasis on an E-house for a refrigeration and an electrical package to drive the plant from the initial engineering stage, to manufacturing, commissioning and start-up, including transport to the mine site.
In addition to the W22Mining super premium electric motors, the WEG solution included a 2500 kVA dry transformer, a complete ELW Mining E-house with auxiliary Wall Mounted air conditioning systems, fire protection and other internal circuit as well as an intelligent CCM06 that includes CFW11 frequency drive, Enterprise nobreak and automation system with PLC panel. The solution provided by WEG in partnership with Howden brought together the technical teams of both companies and reduced the time required for electrical interconnections and equipment start-up since the E-house is supplied with all internal interconnections and fully tested at the factory.
Howden Sales Director, Edson Luis Geraldini, stated that the Howden and WEG partnership represents a significant drop in the internal temperature, in a 1400-meter deep mine with 105 kilometers of galleries and 8400 meters of ramps thus providing a more pleasant environment for the workers. At the same time, the equipment for the second phase of the project for the new mines that are part of the Caraíba Mine industrial complex are already in production at WEG with operation expected for the first quarter of 2022.
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WEG-CESTARI launches new industrial gearbox platform
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The new WCG50 gearboxes are versatile, reliable, and have a modular design, which allows them to be used in a wide range of applications in the most diverse segments, such as mining, steelmaking, sugar and ethanol, fertilizers, and cellulose and paper.
Efficiency and modularity in a versatile solution
The modular and split housings were designed to facilitate maintenance and assembly in the most diverse working positions. The 2-stage models have finned casings, offering better thermal dissipation and oil circulation, providing longer life to its components.
The gearing, with optimized tooth profile, has been specially developed to reduce noise levels and increase durability and efficiency. Available with parallel and orthogonal shafts in R and T shapes, it has a greater variety of sizes with better torque distribution and fewer components, offered in two, three, and four-stage gear ratios from 6.3 to 450 and a torque of 22 kNm to 92 kNm.
Modular in design, singular in performance
Designed with a modular motor flange, it allows for a greater number of motors with fewer components, is able to receive a fan, and has optional coupling for classified areas. Available with single and double ended solid output shaft, hollow shaft with keyway or shrink disk.
Designed with standard coil thread and cartridge-type heater, dipstick-type oil level and VITON retainers, and with standard forced lubrication and cooling SKID.
A reference in manufacturing high-efficiency gearboxes in Brazil, this launch is one more of the versatile and efficient solutions with the WEG-CESTARI guarantee and reliability.
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Cement plant in Russia have WEG solution applied to raw mill
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Reliability and low maintenance! This is what customers are looking for when choosing a WEG product. Novoroscement, a cement company located in Russia, needed higher plant reliability and less maintenance costs.
Thanks to WEG specialists the whole case scenario was taken into consideration and many options were offered, such as overload capacity, insulation class, etc. Also, there were many special requirements involved like trouble-free operation, full interchangeability of the new motor complying with all dimensions of the existing motor, including connections with the power grid and control lines.
Novoroscement now owns a motor with the best technology available on the market for slip ring motors with motorized brush lifting systems. The replacement motor is a M line, 6400 kW, 6 poles, 6 kV and was applied to a raw material mill.
WEG has developed a fully custom interchangeable motor for Novoroscement, adding the new brush lifting system of the M Mining line, delivering to the customer an up-to-date product with all the differentials mentioned above. The mill is one of the main pieces of equipment in a cement plant and if the equipment is out of operation, it can result in substantial production loss. Due to the customer’s production requirements, plant downtime needed to be minimized.
All the planning done by WEG and the leadership in the execution of the services during downtime brought to the cement plant the confidence and guarantee that it would be executed within the expected time and with quality.
About JSC Novoroscement:
JSC “Novoroscement” is one of the largest domestic cement producers in Russia. The company was founded in 1882 and has more than 136 years of history.
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WEG provides maintenance and repair service on a 54-ton gearbox
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Besides being regarded as a global reference in electrical machines with a wide portfolio of efficient and complete products and solutions, WEG also has extensive expertise in maintenance and repair service for gearboxes.
For this reason, the company Cimento Itambé chose WEG to provide a maintenance program with the replacement of bearings, seals, recovery of all planetary gears and frame, as well as checking and repair on the other items of a large gearbox installed in the cement mill, allowing the equipment to operate as originally designed. Supplied by a third-party manufacturer out of Brazil this gearbox impresses for the size and weight which is approximately 54 tons.
The development of this partnership focused on providing services and maintenance is quite positive for Itambé since the company has now the production capacity of its plant back to normal with the gearbox in proper operating conditions. In addition, non-stop operating conditions and technical support provided by TGM – WEG allows Itambé to have the expected financial return.
With the equipment back to normal operating conditions, the company can provide now full production grinding capacity which is 290 tons of cement per hour.
The entire maintenance and repair service were performed by the WEG Group company TGM.
Counting on infrastructure and advanced technology equivalent to the world´s top players, TGM is considered the largest company in Latin America for steam turbines, gearboxes and speed multipliers.
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WEG supplies solution to one of the world’s leading suppliers of mining technologies
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Energy moves the planet, connects the world and drives business. From small systems to large projects around the world, WEG offers the best solutions when it comes to energy. For this reason, the Finnish company Metso Outotec, one of the world’s largest suppliers of mining technologies, chose WEG equipment for some of the projects they are carrying out in mineral processing plants in Brazil.
The equipment package provided by WEG includes two Vertical Three-Phase Induction Motors of the Master line, model MGI630, 2,300 kW and MGI560, 1,600 kW of power, a Medium Voltage Frequency Inverter model MVW3000, in addition to seven 150 hp motors, focusing on the operation of the main vertical mills of the plants in Brazil.
This supply reinforces the expertise and quality of WEG products for the mining segment and strengthens the partnership with Metso Outotec, an important player in the market. In addition, the choice of WEG equipment guarantees all the technical and after-sales assistance necessary for the greatest efficiency of the solutions.
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WEG Branch in Russia steps towards Mining Industry with reliable solutions
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This is another important supply made by the WEG´s Russian Commercial Operation (WRU) for the customer PJSC Polyus Gold, in the Magadan Region, the largest gold producer in Russia.
The scope of supply included a pair of Slip Ring Motors of 9000 KW at 1000rpm, and another two motors of 7500 KW also at 1000rpm and fully designed to be interchangeable with the old existing motors providing a smooth drop-in replacement.
The motors will be applied, in pairs, at huge SAG and Ball mills that operate through dual pinion drive summing their power to each mill.
Historically, the customer was facing a troublesome operation due to a number of different reasons such as mechanical fits, overheating of antifriction bearings and electrical overload events.
With prompt attention to the customer, the WEG team evaluated different options in order to offer the most reliable product. A robust design of slip ring rotor motors was recommended including reliable features such as fixed or liftable brushes, internal or external slip ring chamber and different series of sleeve bearings or antifriction bearing in oil bath.
The final design was approved after customer inspection at WEG headquarters facilities in Brazil and a technical visit to a cooper mine in Chile where similar WEG motors are successfully operating.
A key factor for this project was the local WEG specialists in the market providing fast response to the customer and listening carefully to the customer needs.
The WEG Slip Ring Mining motors were designed in such a way to allow another technical key factor for this project where they can operate both as a slip ring motor or as an induction motor fed by inverter when the temperature is very cold (-50°C) and the ore inside the mills gets frozen and then the mills speed can be automatically controlled.
The electric motors were delivered in July 2020. Due to sanitary restrictions, the commissioning was postponed to December and work was carried out from November 15 to December 23, 2020.
About Polyus Gold Mine – Natalka
PJSC Polyus is the largest gold producer in Russia and is among the top 10 gold producers globally with one of the lowest cost profiles.
The Company also holds the world’s third largest gold reserves with 61 million ounces of proven and probable gold reserves underpinning its strong growth profile.
Polyus´ main operations are located in Krasnoyarsk Territory, Irkutsk Region, Magadan Region (Natalka) and the Republic of Sakha (Yakutia) and include 5 operating mines, alluvial operations and several advanced development projects.
The target for Natalka is 1200 tons of ore per hour, and the average in 2019 was 1400 tons per hour. In the fourth quarter, hourly productivity usually exceeded 1500 tons!
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WEG supplies M Mining slip rings motors to Vale Verde mining company
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The mining segment has sought solutions in the market that meet their needs and complexities. Aware of this demand, WEG, which offers modern and efficient solutions for the most diverse segments and applications, supplied to the mining company Vale Verde, located in the state of Alagoas – Brazil, two M Mining slip rings motors with output power of 5,400 kW and rated voltage of 13,800 V.
The motors will be responsible for driving the main mill of the plant supplied by the company FLSmidth. The WEG M Mining slip rings motor has a new automatic brush lifting system, which discerns the WEG product in this segment and places it in a prominent position in mining slip rings motor projects. The motors were specially developed with electromechanical characteristics that provide durability, resistance and robustness, being able to operate in severe environments of the mining and cement segments.
In addition to the above advantages, M Mining line motors, with automatic brush lifting system, incorporate operating logic, resources for fault investigation, monitoring of operation via HMI and prevention of improper maneuvers, simplifying and reducing maintenance costs, motor installation, operation and maintenance.
The mining company, which intends to process 4.1 million tons of ore with an average content of 0.70% Cu and recover 84.9% of this total, will thus guarantee more modern equipment and all technical assistance and WEG after-sales support, the most complete in Brazil in the electric motors segment, which allows greater safety and reliability in the operation.
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