You are on page 1of 29

BU Minerals PG Material Handling and Grinding

Gearless Conveyor Drive (GCD) Conveyor Portfolio Meeting

Overland Conveyor
Change in Market demand

New market demands on Overland Conveyors

Environmental friendly transport of material Increased length e.g. concentrator plant on lower altitudes Increased length reduce number of flights and transfer stations Higher conveying capacity

Higher drive power required, it means:

Gear power for angular gears limited to approx. 3000 kW @ ~ 70 min-1 New drive concept with new equipment needed

ABB Group September 28, 2012 | Slide 2

Overland Conveyor
Conventional Drive Configuration
Pulley 1 (twin drive) 2 x 1045 kW, 1793 min-1, 4kV Coupling Brake Angular Gearbox Pulley with antifriction bearings Frequency Converter ACS1000

Pulley 2 (single drive) 1 x 1045 kW, 1793 min-1, 4kV Coupling Brake Angular Gearbox Pulley with antifriction bearings Frequency Converter ACS1000

Angular gear box and brake in single or twin drive configuration

ABB Group September 28, 2012 | Slide 3

Overland Conveyor
Change to gear- & bearing-less drive solution

Helical gear box and brake in single or twin drive configuration

ABB Group September 28, 2012 | Slide 4

Overland Conveyor
Longer belts with higher capacity

ABB Group September 28, 2012 | Slide 5

Conveyor Drive Technology


Mechanical Configuration
General arrangement of head drive station (Takraf GmbH) with Gearless Drives (ABB) on one side and disc brakes on the opposite side

Gearless Drives

ABB Group September 28, 2012 | Slide 6

Conveyor Drive Technology


Less Equipment with Gearless Conveyor Drives

Conventional Drive Configuration Tail: 2 x 2500 kW Head: 2 x 2 x 2500 kW

New Drive Configuration Tail: 1 x 5000 kW Head: 2 x 5000 kW

New Drive Configuration allows a equipment reduction by 50%, means only one:

Driven Motor shaft per pulley Motor, Frequency Converter, Transformer, MV-breaker in case of single drives per pulley or smaller Multidrive system.

ABB Group September 28, 2012 | Slide 7

Conveyor Drive Technology


Less Equipment with Gearless Conveyor Drives

Conventional Drive Configuration Tail: 0 kW Head: 2 x 2500 kW

New Drive Configuration Tail: 0 kW Head: 1 x 5000 kW

New Drive Configuration allows a component reduction of 50%, means only one:

Driven Motor shaft per pulley Motor, Frequency Converter, Transformer, MV-breaker in case of single drives per pulley or smaller Multidrive system. Max. belt tension might be higher (to be checked for each project)

ABB Group September 28, 2012 | Slide 8

Conveyor Drive Technology


Less Equipment with Gearless Conveyor Drives
Overland Conveyor 1 Transfer Station Overland Conveyor 2

Tail: 1 x 2500 kW

Head: 2 x 2500 kW Tail: 1 x 2500 kW Head: 2 x 2500 kW

New Gearless Drive Configuration

Tail: 1 x 5000 kW

Head: 2 x 5000 kW

Avoiding limiting Gears (max.3 MW), the new Gearless Drive Configuration allows:

Longer Overland Conveyors due to new Belt and Reduction of number of Flights and Transfer-Stations

ABB Group September 28, 2012 | Slide 9

Maintenance
Gear Reducer

Gear reducers: - limited to ~ 3 MW - intensive maintenance required - life time ~ 10 years The bearings of the gear reducer (failures on input bearings are most common) have a life time of down to 3 - 4 years. The change of the bearings is linked to a major overhaul. High focus on lubrication is required. Common issues: - Water contamination - Inadequate oil supply to individual bearings - Defective or unsuitable shaft seals The life time of gear reducers of approx. 10 years are not matching the life time expectations of the conveyor and need to be replaced.

ABB Group September 28, 2012 | Slide 10

Conveyor drive technology


Wear & tear parts / MTBF of drive train
MTBF of drive train (excl. pulley & pulley bearing)
Disk Brake 1 Motor 1 Coupling 1.1 Gearbox1 Coupling 1.3 Load Coupling 2.3 Gearbox 2 Disk Brake 2 Coupling 2.1 Motor 2

> 22 wear & tear parts MTBF < 3 4 Years


(MTBF = Mean Time Between Failures)

Motor 1

Motor 2

Benefits:
2 main wear & tear parts MTBF > 30 Years
(MTBF = Mean Time Between Failures)

Load

2.5 MW

2.5 MW

High efficiency
Motor 1

5 MW

Load

Preferred solution

ABB Group September 28, 2012 | Slide 11

Low Speed & Bearing-less Solution


Cooling forms & accessories

Cooling : typical IC37, IC666, IC86W, others on request Protection class up to IP55 PT100s for winding Space heater Speed and position encoder Sole plates, anchor bolts and shim

Make up filters are not accepted due to high dust content in ambient air. Protection class at least IP55 (preferred IP65)

ABB Group September 28, 2012 | Slide 12

Conveyor Drive Technology


Mechanics and Installation
Motor with or without bearings ?

Motor with bearings limited life time of bearings reduced reliability additional supervision for bearing higher Capex & Maintenance Costs larger size and higher weight (transport, crane capacity) longer drive train (higher tendency to oscillations)

Motor without bearings much higher reliability almost maintenance free motor design, means: - excitation-, earthing-brushes & cooling device only Air gap sensors to keep air gap in tolerance no maintenance required on the heavy components

ABB Group September 28, 2012 | Slide 13

Gearless Conveyor Drive Description / Flange Connection up to ~ 4 MW


Connection between motor / rotor and drive pulley with rigid flange

ABB Group September 28, 2012 | Slide 14

Gearless conveyor drive Description / flange connection > ~ 4 MW


Connection between motor / rotor and drive pulley with rigid flange
Motor Pulley - Flange Supports for bearingless rotor
ABB Group September 28, 2012 | Slide 15

Gearless Conveyor Drives


Transport & Installation of Motor

ABB Group September 28, 2012 | Slide 16

Transportation

After test run motor is dismantled and stator and rotor are mounted on steel supports and enclosed with wooden boxes

ABB Group September 28, 2012 | Slide 17

Transportation

Rotor inside transportation cage is uncrated and turned to vertical position. Lifting ring is mounted around the rotor at factory.

2300

4600

ABB Group September 28, 2012 | Slide 18

Rotor / Stator installation (bolted flanged rotor)

Flange connection. Sleeve bearing on load side.

ABB Group September 28, 2012 | Slide 19

Gearless Conveyor Drives


System Comparison

Efficiency comparison Price comparison drives (without mechanical part)

ABB Group September 28, 2012 | Slide 20

Efficiency (typical)
System HSS/LSS 2 x 2500 kW / LSS 1 x 5000 kW
Efficiency vs Motor Load (IEC)
2 x 2500kW to 1 x 5000 kW Motor @ 100% speed
98 96

SM 1 x 5000 kW
94

SM 2 x 2500 kW
92 Efficiency [%] 90 88 86 0.3 0.4 0.5 0.6 0.7 Motor Load [T/Tn] 0.8 0.9 1.0 1.1 1.2

VSD with Squirrel Cage (SCIM) + Gear Slip Ring Motor (WRIM) + Gear VSD with Synchronous Motor (SM) VSD with Synchronous Motor (SM)

No load operation example @ 35% of nominal motor load SM Efficiency (5 MW): + 6.2% higher than SCIM + 5.8% higher than WRIM

Operation at nom. conveying capacity Eff. design point for equipment: Over sizing factor: 125 135% approx. 75% of nominal motor load of nominal motor load SM Efficiency (5 MW): + 4.3% higher than SCIM + 4.3% higher than WRIM

ABB Group September 28, 2012 | Slide 21

Lifecycle Costs
CAPEX (2 x 2.5 MW, 1 x 5.0 MW, 20 years)
High Speed Geared Drive
VSD HSS 2x12-p. VSD HSS 24-p.

Gearless Variable Low Speed Drive 24-p.


VSD LSS Bearing VSD LSS Bearingless

2 x 2.5 MW
100 % (142 %)

2 x 2.5 MW
114 % (158 %)

2 x 2.5 MW
146 %

2 x 2.5 MW
133 %

1 x 5.0 MW
96 %
Motor ACS Trafo

200 % 180 % 160 % 140 % 120 % 100 %



Gear repl. after 10 y. Gear Gear repl. after 10 y. Gear Motor Motor

Investment Costs

80 % 60 % 40% 20 %
Trafo Trafo Motor ACS Motor ACS ACS ACS

0%

Trafo

Trafo

Investment costs (3-stage gear box, 1 add. Coupling) Investment costs (drive system), Price adder for high efficiency EUR 50000 / 2500 kW Motor Excluding mechanics, foundations & control (not available yet) Gear overhaul or replacement after approx. 10 years operation required
ABB Group September 28, 2012 | Slide 22

Lifecycle Costs Europe


CAPEX & OPEX (2 x 2.5 MW, 1 x 5.0 MW, 20 years)
High Speed Geared Drive
VSD HSS 2x12-p. VSD HSS 24-p.

Gearless Variable Low Speed Drive 24-p.


VSD LSS Bearing VSD LSS Bearingless

2 x 2.5 MW
100 % 100 %

2 x 2.5 MW
101 %

2 x 2.5 MW
97.7 %

2 x 2.5 MW
95.9 %

1 x 5.0 MW
93.1 %

100 % 90 % 80 % 70 %

> 7.0%

Lifecycle Costs

88.2 %

85.9 %

85.9 %

60 % 50 % 40 %

9.8 %

6.6 %

8.0 %

5.8 %

20% 10 %

Trafo, ACS, Motor, Gear

Trafo, ACS, Motor, Gear

5.6 %

Trafo, ACS, Motor

Trafo, ACS, Motor

Trafo, ACS, Motor, Gear

0%

Investment costs (3-stage gear box, 1 add. Coupling) Investment costs (drive system) Maintenance & Service Costs Operation, Energy Costs (EUR 0.065 / kWh)
ABB Group September 28, 2012 | Slide 23

+ LESS DOWN TIME with Gearless and Bearingless Drives

(Gearless 2500 kW drive: Energy savings 2.3% at 85% drive load)

1.8 %

6%

2%

6%

2%

30 %

100 %

88.2 %

85.7 %

Gearless Conveyor Drives


References

ABB Group September 28, 2012 | Slide 24

ABB Drive Solutions


References

Same drive technology used for mine hoist drive Power demand up to 8000 kW @ 50 min-1 Drive System consisting of: - Synchronous Motor - Frequency Converter ACS6000 - Converter Transformer - Control System - etc.

No. of worldwide installations in operation:


ACS6000 Single- & Multi-Drive (several applications)

~ 1000 systems

Low Speed Synchronous Motors (several applications) ~ 1000 pcs

ABB Group September 28, 2012 | Slide 25

ABB Drive Solutions


References

Mine Hoist drive installations:

~ 100 systems

Operation conditions harder compared to conveyor applications: - High number of start / stop cycles - Change from motoric to regenerative operation

Number of overland conveyor with ACS6000 drive installations high speed solution with gear box: 9 drives - 3 ACS6000 Multi-Drive uphill - 1 ACS6000 Multi-Drive downhill Active Front End - 1 ACS6000 Single-Drive uphill 3 x 2 x 2000 kW 3 x 2000 kW 1 x 2000 kW

Other conveyor installations: - 32 projects since the year 2000 with approx. 120 LV- & MV-Drives

ABB Group September 28, 2012 | Slide 26

Actual Projects
Gear- & Bearing-less Conveyor Drive

1 Project: Order expected in October 2012

Gearless Conveyors with several 12 x 2500 kW Drives Gearless Conveyor with 3 x 7000 kW, Design study with several solutions Power range 2000 kW . 7000 kW

Engineering Order for Development Project in Progress

Several Projects in Discussion (Feasibility Study)

ABB Group September 28, 2012 | Slide 27

Summary
Gear- & Bearing-less Conveyor Drive

Benefits of Gear- & Bearing-less Synchronous Motors

Compact and simple design less space High efficiency, better than induction motor (no slip losses) No gearbox losses Less components less interfaces, engineering, project management and spare parts Drive train free of oscillation Almost maintenance free drive system No gearbox cooling, monitoring, supervision, oil coolers / heaters No back lash during oscillations and at load reversals Less installation and commissioning Higher availability & reliability

ABB Group September 28, 2012 | Slide 28

ABB Group September 28, 2012 | Slide 30

You might also like