Takraf GmbH

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Takraf GmbH
TypeGmbH - Private Company
IndustryMining and associated industries
Founded1948
HeadquartersLeipzig, Germany
Area served
Worldwide from 24 locations in 14 countries
Products• Mining Systems & Equipment • Bulk Material Handling • Minerals Processing • Services & Components • Dry Stack Tailings (DST) Management • In Pit Crushing & Conveying (IPCC)
Websitetakraf.com
Map showing TAKRAF offices

TAKRAF Group (“TAKRAF”) is a global German industrial company. Through its brands, TAKRAF and DELKOR, the Group provides equipment, systems and services to the mining and associated industries, with a focus on energy saving, lowering environmental impact and meeting operational requirements.

According to its website, the TAKRAF portfolio covers high-capacity run-of-mine and bulk material handling from overburden removal, to raw material extraction, comminution, conveying, loading/unloading, processing, homogenizing, blending and storage to final loading for onward shipment. TAKRAF has supplied the most powerful conveying system in the world.[1]

Liquid/solid separation and wet processing solutions are provided through the DELKOR brand and cover flotation, sedimentation, filtration, screening and gravity separation systems. Amongst the new technologies DELKOR has recently developed and introduced is high performance flotation equipment.[2]

TAKRAF Group services cover project studies, planning, engineering and design, to fabrication, supply, site erection and commissioning. Equipment and systems supplied by TAKRAF Group are supported with aftermarket services, including technical assistance, supply of spares, upgrades and refurbishment.

TAKRAF gearless underground conveyor
TAKRAF gearless overland conveyor
TAKRAF crushing plant

Foundation and History

While the official foundation date of TAKRAF Group is given as 1948, its origins stretch back to 1725 when the Lauchhammer works for fabricating construction equipment were established, in then Prussia, together with the first blast furnace for producing iron. [3]

The 19th century saw, in 1809, the start of activities as a mechanical engineering company, as well as major milestones being contributed to Germany’s industrial history. These included, in 1874, the Lauchhammer works commencing high-rise - and iron bridge construction in Oberhammer, and the start of fabrication of overburden and lignite mining equipment. [4]

The Lauchhammer works continued to contribute important firsts into the 20th century. The first overburden conveyor bridge was supplied in 1924, followed, two years later, in 1926, by fabrication of the first three bucket-wheel excavators. [5]

The years following the foundation of TAKRAF (TAKRAF is short for Tagebergbau-Ausrüstungen, Krane und Förderanlagen (surface mining equipment, cranes and conveying equipment)), then known as ABUS, in 1948, saw supply of the first 60 m moveable overburden conveyor bridge for the Welzon Sued lignite mine in 1973. This was followed by the construction of four other similar conveyor bridges prior to 1991, when the world’s largest bridge complex, the 60 m overburden conveyor bridge in the Klettwitz-Nord opencast mine was commissioned. [3] The bridge (Visitor Mine “F 60 Lichterfeld”) is open for visitors at the Internationale Bauausstellung Fürst-Pückler-Land (International Mining Exhibition Fürst-Pückler-Land).

In 1990, the 500th bucket-wheel excavator was supplied. [6] Large scale equipment was developed for on-off heap leach technology for copper ore in 1994. In 1998, large, customized gearboxes for bucket-wheel drive gearboxes were developed while, in 2000, the longest conveyor for its time was supplied. In 2006, the first TAKRAF mobile conveyor bridges for stacking and reclaiming were developed and supplied. [7]

Renamed as TAKRAF GmbH in 2006, it was, 1 year later, acquired by the international Techint Group,[8] operating within Tenova SpA under the brand name Tenova TAKRAF.

2010 and the years following saw the development of the first TAKRAF mobile crushing plant [9]], the double-roll crusher for oil sands [10]] and sizer technology, including the X-TREME class sizer range for hard rock processing [11]]. The integration, in 2014, of DELKOR, specialising in minerals processing, added liquid/solid separation and wet processing capabilities to the product line [12]].

A contract for the world’s most powerful conveyor system was awarded in 2015, a project which features the application of gearless drive conveyor technology as well as a number of other innovations [13]] [14]].

In 2017, High Pressure Grinding Roll (HPGR) technology was developed for specific comminution requirements [15]] and, in 2020, the MAXGen mechanism was incorporated within the DELKOR BQR flotation cell to optimize metallurgical performance.[3]

Following a rebranding in 2020, simply calling itself TAKRAF Group,[16] the entity is headquartered in Leipzig, Germany and has several representations worldwide.

Products and Technologies

TAKRAF Group focuses on specific areas within the technological mining and minerals processing chain that it has identified as critical for reliable and sustainable operations.

  • Mining Systems & Equipment: Excavating; Primary Crushing Plants, including In-Pit Crushing & Conveying (IPCC) Systems; Conveying; Dumping/Spreading; and Auxiliary Equipment
  • Bulk Material Handling: Stockyard & Disposal Facilities; Loading/Unloading Equipment; Conveying; Port Facilities; Continuous Heap Leach Systems; and Various “In-Plant” Handling Equipment
  • Minerals Processing: Comminution; Liquid/Solid Separation; Wet Processing; and Dry Stack Tailings (DST) solutions
  • Services & Components: Project Development Services; Fabrication & Components; Construction & Commissioning; Technical Services; and Spare Parts

Fabrication Capabilities

TAKRAF Group has in-house fabrication facilities located in Lauchhammer, Germany and Bengaluru, India, both of which are located close to major international transport routes to facilitate dispatch of fabricated components and equipment worldwide.

With a covered production area of 17,900 m2 and crane capacities of up to 130 t, the Lauchhammer facilities are able to accommodate fabrication and testing of massive, over-sized, high-value mechanical components. The in-house minerals laboratory is equipped to conduct material tests across various conditions to determine factors such as crushability and wear, while technology improvements are developed and applied to increase the wear life of critical parts. The facilities are certified for compliance with relevant ISO quality (9001:2015; 14001:2015) and SCC:2011 and OSHAS 18001:2007 occupational safety, health and environmental protection standards.

The Bengaluru facility focuses on fabrication of DELKOR liquid/solid separation products, as well as a variety of metal and mineral processing equipment. The facility comprises 10,131 m2 of covered space and is fully equipped with cranes ranging from 2 t to 25 t. QA/QC and SHE initiatives are fully aligned to the TAKRAF Group policy, with certified ISO 9001:2015 compliance.

Advances in Belt Conveyor Technology

[13] [14]TAKRAF Group was awarded the contract to supply the principal ore transportation system at Codelco’s Chuquicamata mine, moving crushed copper ore from 60 m high underground storage bins to the surface processing site at 11,000 t/h. Transportation to the surface with a minimum number of material transfer points was required, as each point requires an underground chamber with a crane for maintenance work, power supply, transformers and electrical and mechanical drive technologies, with adapted ventilation and suitable access paths.

With ever-increasing energy costs making drive efficiency and conveyor running resistance more important, direct or gearless drives were employed. Gearless drives eliminate the need for a gearbox, thereby significantly reducing the number of main wear parts, which results in increased efficiency and reliability, as well as less maintenance being required. Further advantages include a considerable reduction in the drive system’s footprint and emissions. CO2 emissions are reduced by 66% as compared to diesel truck engines for the same copper production volume.

Even though these drives were a well-proven technology, they were relatively new in conveyor design. TAKRAF, in partnership with ABB, integrated features within gearless drives that had long been standard features for conveyor drive systems, for example, ease of alignment and drive change.

Installed in a tunnel that extends some 6,400 m to the surface, the inclined conveyors were designed to overcome a not insignificant difference in elevation of 950 m. In order to minimize the number of transfer points, the inclined conveyor section employs just two conveyors, requiring the use of newly developed components that redefine the performance limits of belt conveyor technology. This includes St 10,000 quality conveyor belting and 20,000 kW drive power per conveyor, with gearless drive technology.

See also

References

  1. ^ "Awarding of the World's Most Powerful Belt Conveyor System". Engineering News. April 15, 2016. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  2. ^ "New Delkor BQR flotation cell with MAXGen efficiency". Canadian Mining Journal. June 29, 2021. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  3. ^ a b c "Tenova TAKRAF: Global legacy in mining and bulk handling systems". Business Chief. May 19, 2020. Retrieved June 22, 2022.{{cite web}}: CS1 maint: url-status (link)
  4. ^ "TAKRAF - A long and dependable history in industry". In Motion (1 2015): 4–5.
  5. ^ "Mega structures. The world's largest excavator Bagger 293". Sudonull. Retrieved June 22, 2022.{{cite web}}: CS1 maint: url-status (link)
  6. ^ Noland, Randy (July 1, 2009). "Bucket Wheel Excavators: 3D Machine Control on a Large Scale" (PDF). MachineControlOnline (July, 2009).
  7. ^ "TAKRAF Surface Mining and Bulk Handling Equipment". Mining Technology. June 22, 2022. Retrieved June 22, 2022.{{cite web}}: CS1 maint: url-status (link)
  8. ^ "Techint acquires Takraf". bulk-online. August 19, 2007. Retrieved June 22, 2022.{{cite web}}: CS1 maint: url-status (link)
  9. ^ "Mobile crushing: A new generation". ResearchGate. April 1, 2010. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  10. ^ "Tenova TAKRAF defines the new generation of extreme class". mining.com. January 12, 2018. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  11. ^ "TAKRAF X-TREME sizers go the distance at Guinea bauxite mine". International Mining. January 14, 2021. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  12. ^ "Tenova acquires Bateman Engineering". Mining Technology. May 30, 2019. Retrieved January 13, 2012.{{cite web}}: CS1 maint: url-status (link)
  13. ^ a b Dilefeld, M (April 21, 2020). "Gearless Belt Conveyor Drives – New Technology for high Capacity Systems". bulk-online. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  14. ^ a b "Record breaking TAKRAF underground mining conveyors with ABB gearless drives progressing at Chuqui". International Mining. May 30, 2019. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  15. ^ "Tenova TAKRAF's High-Pressure Grinding Roll (HPGR) Competence". Mining World. April 17, 2019. Retrieved July 20, 2022.{{cite web}}: CS1 maint: url-status (link)
  16. ^ Owen, Will (December 14, 2020). "TAKRAF revises its branding to present itself as a group". Dry Bulk. Retrieved June 22, 2022.

External links

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