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Bringing out the bestSIMINECIS – Completely Integrated Solutions for the mining industry

Mining Technologies

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Overview

How can your mine meet the continuing demand for raw materials such as coal, copper, and other precious metals? How can it operate more eco-nomically, and at the same time offset rising energy prices? The challenges are clear. You need to boost production, cut costs, and save energy – while ensuring maximum safety for personnel, machinery, materials and the mine and, of course, conserving natural resources such as water and air. A full set of tasks that calls for integrated solutions.

A booming business …

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Overview

The key benefits when working with us:K You get complete system solutions for

your process. By integrating VAI, we have consolidated expertise in technology, mechanics, drives, automation controls and IT at Siemens. We work closely with dependable partners to convert this extensive knowledge and experi-ence into complete machines, vehicles and plants – up to and including end-to-end, turnkey solution packages from a single source.

K You get solutions designed to optimize your entire process chain from excava-tion to beneficiation. With end-to-end consistency that’s much more effective than the sum of its parts.

K You get solutions that pay off through-out the entire life cycle of your opera-tion. Because we continually focus on maximizing availability. And because our innovations help make your systems even more energy-efficient, productive and environmentally compatible.

A dependable partner in a tough business

With 7,500 employees, Metals Technologies – a Division of Siemens Industry Solutions – is one of the major solution providers, pro-cess turnkey suppliers, and life-cycle part-ners in the mining and metals industry. The Siemens name is synonymous with financial soundness, and we have a global presence in 190 countries and tremendous innovative strength. What’s more, our customers know that we will stand by them well beyond the current project. We are flexible, fair and supportive – and everywhere you need us to be.

Your success is our goal.

… needs world-class

solutions.Make Siemens your partner and we will help you increase the efficiency, performance, and environ-mental compatibility of your mine.

Contents

SIMINECIS – our solutions for your processes:

Excavation and transportation 6–1� Mine winders 8–9

SIMINECIS Winder

Discontinuous mining 10–11

SIMINECIS DRAG: Draglines

SIMINECIS SH: Shovels

SIMINECIS TR: Trucks

Continuous mining 12–13

SIMINECIS EXC: Excavators

SIMINECIS CON: Conveyors

Beneficiation 14–19

Noniron 16–17

Preparation:

SIMINECIS MILL: Mill drives

SIMINECIS PUMP: Pump drives

SIMINECIS FLOT: Flotation

Iron 18–19

SIMINECIS Pellet: Pelletizing

Production management �0–��

SIMINECIS MES 22

Manufacturing Execution System

SIMINECIS CC 23

Comprehensive IT solution

Secondary processes �4–�7

SIMINECIS Water 24–25

Power solutions 26

Security systems 27

Turnkey packages �8–�9

Maintenance �0–�1

Worldwide installed base ��–�5

Milestones

SIMINECIS �6–�7

Completely Integrated Solutions

Ausklappseite innen

The SIMINECIS solutions family.

SIMINECIS includes:

K Solution packages for the individual process segments

K Solutions you can use individually – or in combination as a solution package

K Optimization of auxiliary processes including balancing of all subsystems in the plant

K Life-cycle services

Increase your productivity.

Ausklappseite aussen

Crushing

Continuous Mining

Mine Winder

Discontinuous Mining

Crushing

Crushing

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Overview

But SIMINECIS offers much more

It also ensures improved control and coordination of your processes with production management solutions that are part of our core expertise. And it covers the entire life cycle from systems engineering to modernization, including service from experienced people who are right at home in the mining industry.

Our solutions also take all auxiliary processes at your mine into account, because they’re no less important to your success. From water technology to safety and security, we cover the entire range with in-house solutions.

This is what we call Completely Integrated Solutions from Siemens.

Crushing Grinding Water Treatment Pellet Plant

Grinding Flotation Water Treatment Filtering and Drying Ore Concentration

Mineral ProcessingElectro WinningLeachingStockpile

Stockpile Conveyor Power Plant

Coal

Non-Ferrous

Iron

Crushing

StockpileCrushing

Stockpile

Material Preparation

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Overview

Completely Integrated Solutions leverage hidden potential to create greater profitability and productivity. From a single source. At all levels. Across the entire operation – and throughout the entire life cycle. This is how SIMINECIS becomes your tool for making your business even more competitive. In every way.

Why Completely Integrated Solutions deliver more.

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Excavation and transportation

A better cut. More throughput.Anything less doesn’t cut it.

Right now it’s up to you to keep pace with the rising market demand. That means everything has to work together just right during excavation and transportation – especially when it comes to equipment availability. Gear-less drives, perfect interaction between sensors, IT, and mechanics, and intelligent service strategies are key terms here – and with Siemens you’re always at the cutting edge of technology.

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Excavation and transportation

Let’s keep things moving – with preconfigured solution packages.

The solution packages SIMINECIS DICONT for discontinuous mining, SIMINECIS CONT for continuous mining and SIMINECIS Winder for mine winders cover both primary and secondary processes. Their modular com­ponents are designed especially for mining applications, providing all technological, electrical, automation, and IT solutions.

A topic that’s important to you: How can the entire excavating and transporta-tion process be optimized so all the productivity improvements add up? As a provider of integrated solutions, we’re perfectly positioned to create this added value for you. Through precisely synchronized excavation and transportation. And with solutions that deliver a bigger payload for a lower investment.

So put us to the test. Not just to deliver complete solutions, but to optimize your processes – from planning to maintenance. So you’ll be sure to make the best cut.

Anything less doesn’t cut it.

Excavation and transportation

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The hoisting equipment at the Philippsthal salt works of K + S Kali GmbH, Germany,

was modernized without loss of production.

The performance of underground mines depends critically on the capability of the hoisting equipment. SIMINECIS Winder ensures the highest safety and improved throughput – thanks to innovative solutions for drive engineering, performance-optimizing drive-level closed-loop controls and safety-oriented automation engineering.

We focus on the recommendation and implementation of the appropriate drive system – adapted to the conditions of the power supply system and tailored to your power rectifier “philosophy.” Our technological closed-loop controls ensure the harmonious customization of travel behavior to the specific requirements of your shaft system.

SIMINECIS WinderThe solution package for mine winders

Modernization without interruption

K + S Kali GmbH in Philippsthal (Germany) had very little time available for the com­plete modernization of their shaft hoist­ing system. Our solution: a completely preassembled winding machine with

integrated motor placed directly on the foundation. In this way, the conversion work could be completed during the va­cation period in summer 2006 without interrupting production.

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Excavation and transportation

Speeds of up to 70 km/h (44 mph), high acceleration rates, and gentle braking – SIMINECIS Winder guarantees safe, reliable operation for extreme requirements.

Control and safety – integrated in the speed regulator

SIMINECIS Winder contains our speed regu­lator that integrates all regulatory, control and safety functions. The platform used is SIMATIC, the world’s leading automation system, unrivaled in terms of capacity, interface optimization, flexibility, and in­vestment protection.

On this platform, special technology mod­ules (FM 458), communication modules, and decentralized I/O peripherals demon­strate their strengths. All safety­related functions are supported by redundant hardware models.

Competitive throughout the entire life cycle

SIMINECIS Winder looks at the life­cycle aspect of your plant within the context of a holistic solution. This includes profes­sional services in the operating phase: from user training through maintenance and spare parts to around­the­clock emergency service. But it also includes a systematically planned and implemented modernization process. With the man­power of a major company on call at all times, we are your reliable partner, how­ever tight the deadline.

Single-source solution

In implementing your solution you natu­rally want to avoid loss of time and costly coordination efforts. SIMINECIS Winder stands for our complete package cover­ing consulting and project management, design and calculation, project planning and equipment testing, commissioning and customer service. It also covers the centralized purchase of components by a single source up to the delivery of a turnkey shaft hoisting system, including all necessary construction work and me­chanical components. In this way you can take full advantage of our many years’ experience in plant construction.

Main benefits

K Increased performance through shorter cycle times and lower maintenance costs

K Increased availability as a result of the careful treatment of mechanical com­ponents

K Reduced travel time thanks to intelli­gent travel control

K Maximum safety through the use of a redundant, tested safety system

K Investment protection through the use of standardized industry components

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Excavation and transportation

Increased excavation quality with maximum availability: power shovel in use

at Athabasca Tar Sands, Canada

98% availability with SIMINECIS DICONT

In 2002, Siemens equipped the shovel excavators at the Athabasca Tar Sands mine with three-phase IGBT drives and data acquisition systems as a part of a SIMINECIS DICONT package. Since then, average availability of the machinery has been 98%. The integrated data acquisi-tion system includes diagnostic tools, real-time monitoring of the machines and a payload system for blending. A crucial advantage is the ability to detect and control the quality of the excavated material.

SIMINECIS DICONTThe solution package for discontinuous mining

SIMINECIS DICONT is our solution package for discontinuous mining, optimizing the individual process steps as well as the entire process chain. The overall solution combines proven mechanics, electrical engineering and technological solutions: SIMINECIS DRAG for draglines, SIMINECIS SH for shovels, SIMINECIS TR for trucks, and SIMINECIS CON for conveyor belts – each of them equipped with inno-vative features. Individualized matching of these solutions produces synergies for greater performance, security and availability of all equipment.

Powerful performance in Colombia

The haul trucks at the Cerrejon coal mine in Colombia have to transport loads of 320 metric tons and even more. Two Siemens 2-MW three-phase motors pro-vide the necessary power. Thanks to their high start-up torque and correspondingly high operating speed, these motors allow higher transport capacities, and can offer clear competitive advantages.

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Excavation and transportation

Draglines > SIMINECIS DRAG

Eliminates all DC generators, mechanical hoist and drag gears, and associated equipment. The future-oriented gearless technology delivers productivity gains of up to 20% and approximately 20% higher efficiency, and mini-mizes maintenance requirements.

Main benefits

K Higher drive system efficiency

K Lower life-cycle operating costs

K Less maintenance – for cost savings of more than $1 million per year

Shovels > SIMINECIS SH

Combines over 25 years of Siemens AC shovel drive ex-perience with innovative IGBT technology. The system allows for higher stall torque, faster acceleration, and higher speeds in field weakening. It operates routinely at over 98% availability and requires no routine main-tenance. Future-oriented gearless technology delivers productivity gains of up to 20% and approximately 20% higher efficiency, and minimizes maintenance requirements.

Main benefits

K Benchmark reliability

K Lower life-cycle operating costs

K Excellent distribution system compatibility, less than 5% harmonic distortion

Trucks > SIMINECIS TR

The most powerful electric truck drive available (up to 6,000 hp). It combines high torque, high power and ease of operation in an AC drive system – for increased payloads, shorter cycle times, and higher system reli-ability. Proven converter technology and innovative remote monitoring and management tools minimize life-cycle ownership costs.

Main benefits

K Maximum rim-pull capability, drive power, and system reliability

K 6 to 7% greater efficiency than comparable DC drives

K Reduction in operating costs far beyond diesel/mechanical limits

K Increased productivity and energy savings through trolley truck system

SIMINECIS DICONT – solution overview

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Excavation and transportation

Excavators > SIMINECIS EXC

Allows excavators to be loaded to their performance limits, while avoiding load peaks and the intensive wear and tear and maintenance they cause. This is achieved by intelligent features such as the new auto­matic conveyor system, a package of control measures, and the proven drive and automation technology which has been optimized for open­cast mining.

Main benefits

K Dependable high performance without excessive wear and tear

K Fast, efficient fault clearance by means of diagnostic systems

K Fewer interfaces for project planning and data exchange

Conveyors > SIMINECIS CON

Guarantees reliable operation thanks to rugged three­phase motors backed by high­performance automation systems. Our drive controllers minimize wear and tear, increasing the life of mechanical components. A belt speed controller system ensures that the belts are always optimally loaded, providing energy savings of up to 20% depending on the load.

Main benefits

K Efficient use of electric energy in every phase of op-eration thanks to load-dependent control of the belt speed

K Increased productivity through simultaneous starts and stops of all conveyor systems

K Higher system availability, longer service life of me-chanical components and reduced operating and maintenance costs due to wear-minimizing operation

SIMINECIS CONT – solution overview

Stacker / reclaimer, Vattenfall Bucket chain excavator, Vattenfall

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Excavation and transportation

Reliable transport over mile-long routes: the Los Pelambres copper mine in Chile

SIMINECIS CONTThe solution package for continuous mining

SIMINECIS CONT integrates our solutions for all process steps in continuous mining. These include mechanics as well as our power supply, automation and drive systems for bucket chain and bucket wheel excavators, merged together in the SIMINECIS EXC solution. SIMINECIS CON guarantees safe and economical operation and optimized output for conveyors. And by integrating diagnostic tools, we ensure efficient maintenance and reduced life-cycle costs throughout the entire process.

Peak performance in Chile

The ore from the Los Pelambres mine in Chile is mined at a height of up to 3,200 m (10,500 ft) and must then be conveyed over a distance of 12.7 km (nearly 8 miles). This is made possible by a SIMINECIS CON solution with ten 2,500­kW squirrel­cage motors. Transport of the copper ore from the mine to the concentrator generates approximately 17 MW of electrical power, which is fed back into the plant network. This reduces the production costs for copper concentrate considerably. Addi­tionally the lower conveyor belt tension reduces wear and increases maintenance intervals. At the same time, load­depen­dent controlling of the conveyor speed cuts power consumption.

Two decades of increasing productivity

From 1982 to 2001, SIMINECIS EXC en­sured that more than 30 bucket wheel excavators, stackers and reclaimers at the Neyveli open­cast mine in India oper­ated smoothly. Thanks to the elaborate comprehensive concept which included everything from the drive systems and automation with SIMATIC PCS 7 to the visual displays, material was subjected to considerably less stressing. This resulted in less wear and tear, higher availability, reduced downtimes and increased throughput.

Bucket wheel excavator, RWE

Beneficiation

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“ Beneficiation” and “benefit”

On the one hand, the quality requirements of the metals industry are always increasing – on the other, economical and environmental constraints are only too real. We help you make ends meet – with solution packages that are the cutting edge of grinding and beneficiation.

have a lot in common.

One example is the preparation of cop-per ores in concentration plants. Being competitive in this case means increasing output while at the same time reducing wear and tear and costs for service and repairs. Solutions from Siemens allow you to meet all these requirements, while additionally keeping water and power consumption within bounds.

Siemens supports the operators of the Los Pelambres copper mine in Chile with a comprehensive bundle of measures, from drive and automation technology and power supply to monitoring and maintenance services. 15

Beneficiation

Conventional pelletizing processes suffer from their high specific energy consump-tion and enormous volumes of waste gas. This is where Siemens comes into play. Together with a renowned partner we have created a completely new process design. This helps you meet increasingly strict environmental regulations – while at the same time lowering production costs.

have a lot in common.

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Beneficiation

Solid grinding at El Teniente

When it came to installing three ball mills and two SAG mills in El Teniente, Codelco opted for a complete solution with SIMINECIS MILL, covering everything from manufacture to commissioning. The amortization period was extremely short thanks to very high system availability and substantially lower maintenance costs.

SIMINECIS PREPThe solution package for preparation

SIMINECIS PREP is focused on process optimization, increased output and lower operating costs in preparation plants in the copper industry. Therefore it integrates mechanics, electrical engineering, automation and drive technology from a single source and creates end-to-end improvements that are greater than the sum of the individual parts.

Siemens equipped mine in Mongolia with largest slurry pump system.

Siemens has installed a pump system for a copper mine in Mongolia (Erdenet Mining Corporation). The purpose of the pump system is to improve the tailings extraction process in the copper mine and to cope with the increase in the mine’s production. The system was sup­plied and installed by Siemens and start­ed operating at the beginning of 2007. It is the largest slurry pump ever supplied to a mine.

Beneficiation

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Mill drives > SIMINECIS MILL

A drive system that has been synonymous for years with virtually wear-free operation. The concept eliminates all mechanical parts between motor and mill. Fed with vari-able frequency from a fuseless short-circuit-proof cyclo-converter, SIMINECIS MILL features the highest operating efficiency of any variable-speed drive available – leading to reduced mill downtimes and substantial energy savings.

Main benefits

K Controlled acceleration, deceleration and stopping of mill

K Precise and fast positioning in inching and creeping mode

K No downtimes due to lack of girth gear/pinion maintenance

Pump drives > SIMINECIS PUMP

Enhances concentrator productivity significantly, while eliminating the reducer gear between motor and pump and all corresponding maintenance. Because the drive operates at variable speed, it supports adjustment of pulp flow to the process changes – yielding energy savings of up to 30%.

Main benefits

K Energy savings of up to 30%

K Higher availability of the cyclone pump

K Lower operational cost over the entire life cycle

Flotation > SIMINECIS FLOT

Combines the advantages of mechanical and pneumatic flotation in a compact solution. Using no agitator or drives, the system not only saves space but also uses less energy. High separation quality is achieved by the patented aeration technology which effectively pre­vents agglomeration of granules.

Main benefits

K High separation quality

K Two flotation processes in one cell

K Low energy consumption

SIMINECIS PREP – solution overview

Energy costs at the Chuquicamata mine in Chile have been substantially reduced as a result of the installation of eight new SIMINECIS PUMP systems.

Siemens flotation cell increased productivity in the Molybdenum plant of Mineria Los Pelambres.

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Beneficiation

As part of the Lebedinski GOK project, Siemens developed the SATOP process model for standardized pellet quality together with

NPWP TOREX, Yekaterinburg.

Increasingly strict environmental stipulations, rising energy prices, and customers’ high quality expectations are typical of the demands facing pelletizing plant operators. Patented technology from SIMINECIS Pellet places the entire pelletizing process on a new basis. Signif-icant overall improvements, for example an increase in output, can be expected thanks to a recirculation of the gas and heat supply, optimization of the process and a new in-process measuring method.

SIMINECIS Pellet is also ideally suited for plant modernizations and generally pays for itself within one to three years.

SIMINECIS PelletThe solution package for pelletizing

Standard platform for process monitoring

As part of a plant modernization project, Lebedinski GOK, Russia’s biggest ore pro­cessing combine, opted for SIMINECIS Pel­let as the central control and monitoring platform. The integrated process control system SIMATIC PCS 7 and patented

algorithm provide a guaranteed means of accurately predicting pellet quality. Use of energy and raw materials was reduced in all process steps, with a corresponding decrease in environmental pollution.

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Patented process for the drying zone

With the optimized “traveling grate” method, pellets are placed in two layers, with the predried pellets in the lower layer, and the damp pellets in the top layer. The supply of air from the top and the residual heat from below ensure even drying, which prevents stressing and deformation of the pellets, minimizes rejects and con­siderably reduces the creation of dust.

Efficient gas and heat recycling

An intelligent design for ducting exhaust gas from upward and downward gas streams enables gases and process heat to be reused to optimum effect. The air blown upwards in the grate zone is fed back to the preceding drying zone with gas streams directed downwards and used there again. In this way, the gases can recirculate several times over the entire process.

SIMINECIS Pellet, on the other hand, mea­sures the size of the pellets continuously with a granulometer. The patented algo­rithm determines the exact size of the individual pellets every few seconds from a video image. Even partially concealed pellets are measured to an accuracy of 0.25 mm. This contactless method al­lows the process to be optimized directly while it remains running, and it is no longer necessary to stop the plant to take samples. The result is consistent product quality and reduced power consumption.

Beneficiation

With SIMINECIS Pellet, the quality of the pellets produced can be monitored and controlled more or less in real time.

Optimized process management with mathematical model

The SIMINECIS Pellet process is based on a deterministic mathematical model which determines the individual parameters with high resolution, and enables the process to be optimized continuously.

To do this, the values measured above and below the pellet layer are fed into the model. The stored algorithms calculate the nature and the behavior of more than 3,000 different parameters. If values devi­ate from the set values, the system either automatically adjusts itself online or in­forms the operator how to set the directly controllable parameters.

Consistent pellet sizes

In the past it was necessary to determine the diameter of pellets by taking samples manually, a time­consuming task which involved interrupting the process. A fre­quent consequence was uneven layering which resulted in increased use of energy.

K More accurate prediction – improved operation

K Standard pellet sizes – optimized energy utilization

K Sustained efficiency throughout the entire life cycle

Main benefits

K Increased production – 5 to 7% higher specific output

K Improved product quality – 5 to 7% greater strength of pellets in compari­son to the conventional grate process

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Production management

As a decision-maker you need to keep an eye on key indicators of your production. That enables you to react faster, to exploit opportunities and to control processes reliably. And for this you need the right information, analyses and controlling instruments. The key is the mining-specific information technology (IT).

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Everythingunder control.Anytime. Anywhere.

Production management

Siemens can put this key in your hands with consistent, end­to­end IT architec­ture. This makes the entire mining pro­cess transparent from excavation to ore processing. At the same time, it facilitates vertical information flow from production control level to the ERP system. Network solutions from Siemens provide both the infrastructure for exchanging data in the field and high­performance data high­ways for linking the areas together.

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The information is compressed and pro­cessed at MES level, providing a platform for mine planning and mine operation. It covers everything from geoengineering to production or material logistics, and the ERP system as well. All this is based on SIMATIC IT, the open and flexible framework proven in industry­wide appli­cations, to help you keeping everything under control at all times.

3D stockpile image: different colors signify different materials and provide an in-depth overview of the available stockpile.

Optimized performance as a result of seamless machine and material dispatch

Production management

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The tracking and tracing module records the products’ genealogical data from raw material source up to intermediate / final stockpile. Customer­specific mate­rial mixes can be composed exactly to requirements with the aid of 3D views of stockpiles. Efficient tracking and routing functions open up possibilities for inno­vative fleet management.

SIMINECIS MESThe solution package for production and material logistics

SIMINECIS MES provides a sound basis for decision-making based on real-time data and an efficient method of managing production resources and stock-piles. As a solution package, it combines everything that belongs together at MES level:

The production logistics module generates production instructions for a defined time frame based on geological data and availability of production units. The process information module provides the visual display, analysis and documentation of all process data. An integrated material monitoring system delivers an overview of required material qualities and material storage locations.

Main benefits

K Better performance through availability of real­time information

K High investment security through openness and easy integration of automation systems

K Faster decision making (KPI monitoring)

K Reliable quality planning based on highly precise 3D stockpile models

Everything at a glance

The German power supply company RWE Power chose SIMINECIS MES for stockpile management at its Fortuna open­cast mine. A Web­based production informa­tion system provides continuously updat­ed stockpile information while material movements can be controlled fully auto­matically from the control center.

All relevant operating parameters can be monitored online by means of detailed records and analyses.

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Production management

In the Spence copper mine in Chile, SIMINECIS CC offers mine operator BHP Billiton

a perfect overview.

Automation and data handling of the entire process chain are based on a stan­dardized system. This not only provides a secure and reliable means of tracking the production process but also allows user­friendly and flexible process control. Expansions and modernizations are easy, even in heterogeneous environments. Bottlenecks and wait times caused by nontransparent processes are eliminated – contributing to increased productivity.

SIMINECIS CCThe solution package for open-cast mining

SIMINECIS CC is our comprehensive automation solution for control, SCADA and engineering, data management, and service throughout the entire open-cast mining process. Based on proven compo-nents of the SIMATIC family, it provides you with a modular, interface-optimized solution tailored to the requirements of the mining industry.

Main benefits

K Fully transparent overview of the entire plant

K Optimal tracking of the production process

K Low operating costs due to central maintenance and servicing

A new approach to “data mining” – with SIMINECIS CC

With the opening of the new Spence open­cast copper mine in Chile, BHP Billiton is relying on Siemens’ automa­tion and control expertise in a big way. A SIMATIC PCS 7 system with hardware and software for 5,000 control points and 150 displays forms the mine’s informa­tion backbone. Siemens was involved in the project throughout – from the plan­ning phase to the rollout workshop and after­sales services.

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Secondary processes

SIMINECIS Water – Water management solutions

Key areas of water processing in mining operations are: process water prepara­tion, flotation process water recovery and leaching processes.

Siemens is one of the world’s leading suppliers of water treatment technology. Well-known brand names such as Envirex and Memcor make up our impressive product portfolio.

SIMINECIS WaterTreatment solutions for a valuable resource

The importance of water cannot be overstated. Only 1% of the world’s water is suitable for drinking; therefore it is our responsibility to utilize this resource as efficiently as possible. The mining industry is also facing new legislation imposing stricter environmental regulations and making water and energy more significant cost factors.

SIMINECIS integrated solutions can be applied to the entire water cycle within your facilities.

Solutions include:

K Tailings dam water reuse

K RO seawater desalination

K ARD / AMD (acid rock / mine drainage)

K Turnkey water projects for the mining industry

Main benefits

K Reducing capital and operating costs associated with the water treatment process

K Meeting the process requirements while achieving 100% compliance with environmental regulations

K Recycling the maximum amount of water possible, thus assisting in the preservation of a valuable raw material

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Single-source provider

From the treatment technology to pro­cess automation and controls, Siemens provides turnkey water solutions for your mine. Engineering, commissioning and performance­based contracts are a few of the value­added services we provide. A single­source provider assists in the coordination effort and accelerates the time line from project creation through to start­up.

With SIMINECIS, you get customized, in­novative solutions meeting the specific needs of your mine and helping to pro­vide a clean future.

Biological treatment of mining wastewater

Secondary processes

K Pretreatment: Siemens can customize a solution that will produce water suitable for use in your production processes from a wide range of sources, including seawater, surface water, well water and wastewater.

K Process water treatment: Siemens water solutions are supported by the experience drawn from over 4,000 commercial applications in the last 15 years.

K Wastewater treatment systems: Complete solutions from microfiltration to biological treatment.

K Recycle and reuse applications: Completely inte­grated recycling solutions combining the complete spectrum of treatment technologies from physical to chemical to membrane separation systems.

Leading-edge solutions for water treatment

Mining wastewater treatment

Siemens offers biological treatment technology designed to treat streams containing cyanide, thiocyanate and am-monia. Operations treating tailing pond discharges have demonstrated the appli-cability of rotating biological contactors (RBC) in the treatment of these waste streams. RBCs have successfully been ap-plied in the treatment of a wide range of industrial effluents including those from refineries, chemical plants and mining operations, in addition to hundreds of municipal wastewater installations.

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Secondary processes

Around the world our specialists keep an eye on a reliable power

supply in the mining industry.

Power supply – it’s all about distribution

Voltage dips and reductions can incur high costs when they lead to production downtimes. Therefore, secure power sup­ply is one of the prerequisites for success­ful plant operation.

Our solutions are designed to meet the requirements of the industry and the high demands with respect to operator safety and operational reliability. You can expect products that are easy to use and highly cost­effective. So that your production runs smoothly and reliably – without downtimes caused by power failures or fluctuations.

Power solutionsOptimized supply and quality for the mining industry

Nothing works without power in mining. This is why the gen-eration and distribution of electrical power is one of the basic prerequisites for success – after all, the safety, reliability, and cost-effectiveness of the plant largely depend on its power supply.

With a worldwide network of experienced experts, we offer the development, manufacture and installation of systems for substations and distribution – tailored to your requirements, and based on state-of-the-art technology.

Power quality – more safety, more stability

Large electrical loads in mines have a significant effect on the public electrical supply network. Network disturbances such as reactive power generation, volt­age distortion or voltage variation occur frequently. To minimize such disturbanc­es and to prevent penalties for exceed­ing the given limits, we have developed compensation systems. They do not only reduce the negative impact of typical plant loads to specified limits, but can also result in energy costs savings – and can thus pay off quickly.

Main benefits

Delivering a complete system from the aspects of:

K Network and load data

K Space availability

K Low maintenance and investment costs

K Low electrical losses

K High availability and reliability

K Optimized power supply quality (meeting utility requirements)

K Personnel safety

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Secondary processes

Plant security

We create an integrated solution based on a full range of well­coordinated com­ponents – for example, alarm systems, closed­circuit television (CCTV) and access­control zones. Management systems can help you make the right decision in case of security­relevant events. Our service portfolio guarantees high availability, reliability and long service life for your security systems.

Security systemsSafety first – for people, equipment and data

Your plant can only be profitable when your assets are protected. When your production equipment is as secure as your buildings and your data. When manipulation, theft or eavesdropping by unauthorized persons is prevented – or at least made as difficult as possible. We develop and implement tailored solutions for your specific application.

Data security

Unfortunately, open communication systems such as the Internet offer not only fascinating possibilities, but also involve risks. We can help you minimize these risks – with a comprehensive solution that is tailored to your needs.

With our assistance, you can protect peo­ple, technology and data – reliably and in the long term.

Applications for maximum mining security

K Access control – time recording

K ID cards – biometric systems

K Video surveillance – scanning & detec­tion – burglar alarm management

K Danger management system – notifica­tion of security staff

K IT security – communications security – security on the move (tracking & tracing)

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Turnkey packages

SIMINECIS gives you an overview of maintenance requirements at all times, to help you keep

costs under control.

What can you expect from us?

Our graduated concept offers three basic options. We can take responsibility for:

K the complete electrical and automation package.

K the design, implementation and life­cycle management of the entire system – including machines, vehicle and system building.

K additional plant components and secondary processes.

This concentration of responsibility in the hands of a single company minimizes technical and organizational interfaces,

Turnkey packagesThe fast path to higher performance

Turnkey packages from Siemens are a proven way of implementing projects reliably, speeding up return on investment and reducing life-cycle costs. We take responsibility for the complete functional packages along your entire process chain based on the prin-ciple of “one face to the customer.” Also included are all secondary processes such as water, electric power supply and security.

and provides a solid basis for handling even complex projects within short time frames. And that allows you to focus more on your core business.

Turnkey partnership – closer to your requirements

As an experienced provider of turnkey packages, Siemens has systematically fo­cused on the requirements of the mining industry. Our presence in all important regions keeps our lines of communication short. Experienced project leaders coor­dinate the integration of innovative solu­tions, for example, for reducing energy consumption, in the overall solution. You can rely on the financial solidity, manpower and powerful implementation capabilities of a partner that is as global as the mining industry itself.

This coal conveying system in Nochten, Germany, was modernized completely by Siemens.

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Turnkey packages

New conveying and loading system in Nochten

In November 1997, 25 years after pro­duction commenced at Nochten open­cast mine, a new conveying system, a new train loading facility, and the first stage of a coal handling area began op­eration. The new conveyor system is only slightly longer than the old one, but cuts rail transportation distances by 16.5 km. This means that the newly erected part of Boxberg power station can be supplied with coal directly by belt conveyor. The investment funds were released in May 1996, and a contract for the work was awarded to Siemens (as prime contrac­tor) in November 1996. With regard to the construction of the facility a main­tenance contract was entered into with Siemens. The work had to be completed in an extremely short period of time.

Complete electrical and automation solution

Siemens supplied a complete turnkey electrical solution for the Moma Titanium Minerals Mine Project in Mozambique. We have been awarded an order from the Multiplex/Bateman Joint Venture (MBJV) to supply a complete electrical solution for Kenmare Resources’ Moma Titanium Minerals Mine Project in Mozambique. The order includes the design, enginee­ring, installation and commissioning of the entire electrical solution for the mine, as well as a 170­km 110­kV overland transmission line. Siemens delivered a complete engineered electrical solution for the entire mine including on­site power generation, power distribution, automation and communication, drive systems and associated electrical equip­ment.

Development in Lumwana

Siemens has received orders from Equinox Copper Ventures Ltd., Canada, for the supply of electrical equipment and systems for open­cast mining trucks, mills and “in­pit” reticulation required for the development of the new Lumwana copper mine in Zambia.

Large drives

Drives

Substation

Vendor 2

Vendor 3

Siemens

ServicesEngineering &delivery

All electricalequipmentSiemens

Cold commis-sioning

Start-up

Productionoptimization

Commercialproduction

Plant performance

Subvendormodel

E EPCmodel

Processturnkeymodel

AutomationVendor 4

Best

per

form

ance

Process turnkey model with KPI-based service

Process turnkey model without KPI-based service

Subvendor model

Process turnkeysolutions –examples for:- Conveyors- Pumps

Siemens

Vendor 5 Mechanicalequipment

Installation,start-up services,

maintenance,revamp/modernization

Installation,start-up services,

maintenance,revamp/modernization

Installation,start-up services,

maintenance,revamp/modernization

...

Vendor 2 Mechanicalequipment

...

Vendor Otherequipment

...

Vendor Otherequipment

...

Vendor Otherequipment

The performance curve shows the economic advantages offered by process turnkey packages in terms of optimized interfaces, reduced com-plexity and clear-cut spheres of responsibilities compared with individual work contracting. Maintenance contracts based on key performance indi-cators can boost performance figures on a lasting basis.

Siemens offers you a range of different turnkey levels to suit your needs, from turnkey implementation of the electrical section to complete delivery of machines, vehicles and systems – including life-cycle management and equipment for the secondary processes.

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Maintenance

The need for maintenance can be detected early through remote monitoring of components.

The maintenance of your plant is a substantial cost factor. But even though it accounts for up to 40% of ongoing operating costs, it is the only alternative to unplanned downtime. That makes it even more crucial to optimize maintenance processes – for the performance of your equipment and your mine.

With the SIMINECIS product family, we offer a comprehensive plan covering consulting and implementation, technical support, the assumption of maintenance processes, and plant modernization and optimization packages – all tailored to the needs of your plant.

Service and maintenancePerfectly managed

Operational support – so that production continues

If you consider maintenance to be part of your core process and have a competent maintenance team, then our operational support will complement your own per­sonnel optimally.

Service contracts

From a simple on­call service to the as­sumption of operator risks, Siemens of­fers a wide spectrum of contract options. The aim of all our contracts is to work in close cooperation with our customers to achieve a competitive edge together. The experts in our global Support Centers are available around the clock. Along with providing phone support for the operation

and maintenance of your equipment, we also keep a pool of qualified staff avail­able for service visits at short notice, and offer suggestions for optimizing your sys­tems and increasing availability. A further component of our service contracts can be online data capture, processing, and analysis. This allows a detailed diagnosis of the actual conditions of the compo­nents monitored and a sound assessment of improvement potentials.

Spare parts and components

The spares and components team special­izes in the accurate and timely supply of top­quality spare parts and components, in product quality improvement and pro­duction cost­saving packages.

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Maintenance

Consulting and training

Our offer covers sound analysis, consult­ing, and integration services, targeted to your processes. Together with your specialists, we increase the transparency of your processes and identify and evalu­ate potential areas for improvement. The services range from maintenance process analysis and corresponding optimiza­tion programs to assumption of these processes. To meet the challenges, the customer’s staff are trained in individu­ally tailored courses on systems similar to those of the customer.

Maintenance services – provable and measurable

A contract in which we assume respon­sibility for a freely definable scope of plant maintenance contains not only clear agreements on the measures to be per­formed, but also on the measurement criteria. These include, for example, the following:

K Plant reliability

K Plant availability

K Operating costs

Upgrading and modernization

Throughout the lifetime of a plant, we at Siemens are constantly seeking to improve the performance and production time of our customers’ plants. To meet steadily rising demands in terms of cost and prod­uct quality, it’s crucial to install state­of­the­art equipment, process models and automation solutions to stay competitive and successful in the market.

The upgrades mainly consist of component replacement by state­of­the­art design. Siemens supplies upgrading packages for automation systems which can be inte­grated into existing software configura­tions without the need to replace entire automation systems. Thus major perfor­mance improvements can be achieved with little investment.

Upgrading your equipment and automa­tion system gives you access to a number of new functions and interesting features that can boost the performance of your process. In this way, you can ensure that your plant is consistent, easily expand­able, and advanced. Our comprehensive capability minimizes downtime and risks during the upgrade process.

In this way you can quickly assess whether our maintenance performance has achieved its – and your – goals or if and where there’s still room for improvement.

Plant modernization and optimization

Modernizing your plant extends its work­ing life. Technological updates not only increase availability and productivity, but lower operating and maintenance expenditure and thus ensure a rapid return on investment. As a technology leader, Siemens offers you modernization solutions tailored to your needs.

Migration packages

As the original supplier of many automa­tion systems in the mining industry, Siemens has developed system migrations as a cost­effective method for improving system performance and maintaining the value of the asset. Plant automation systems based on Siemens SIMATIC and SIMADYN allow migration through the application of standardized packages during operation or with limited down­time. As a result, the working life of your system can be extended with significant improvements in maintainability and per­formance.

Engineering &purchasing

Coldcommissioning

Start-up

Productionoptimization

Commercialproduction

Projectphases:

– Classroomtraining

– Site installation,infrastructure

– Setup ofmaintenance organization

– Personnel recruiting

– Maintenance managementsystem

Training forone localcommissioningengineer

On-site support forsix months duringoptimization phase

Teleservicefor one year

Siemensservices:

Example: Service concept for gearless drive package. Service is 100% included in our solutions.

99% availability: No unplanned shutdowns in any of the 31 Siemens gearless drive mills now in operation

It’s all about you.Solutions, partnership, commitment – worldwide.

Siemens is located in 190 countries worldwide, including all major regions of coal and ore excavating, handling, and beneficiation. Here is a brief pro-file of our company, showing the strengths you can benefit from – and our commitment to being a reliable partner throughout the entire life cycle of your plant, right from the beginning.

Installed base

Europe and Russia: 49 excavators 1 shovel/dragline 4 trucks 61 conveyors 12 mills 81 winders

North America and Central America: 20 excavators56 shovels/draglines 89 trucks 19 conveyors 4 mills 4 winders

South America: 21 excavators 45 shovels/draglines 128 trucks 11 conveyors 36 mills 3 winders

Africa: 55 excavators 36 trucks 13 conveyors 4 mills 18 winders

Asia: 139 excavators 23 shovels/draglines 39 trucks 87 conveyors 2 mills 70 winders

Australia: 58 excavators 5 shovels/draglines 54 trucks 6 conveyors 13 mills 7 winders

Siemens is present locally in 190 countries in the world – wherever mining is carried out.

Status: 12/2007

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19�0 19�0 1970

19�8Delivery of electrical equip-ment for a cross-pit spreader

1940First control station for a cross-pit spreader for open-cast mining (Böhlen)

1950

1955First bucket wheel excavator with Leonard drives and controllers

1960First stationary control center in open-cast mining (Fortuna, Rheinbraun)

1960

1965First bucket wheel excavator with 1/cos adjustment setting for slow drive

1970Launch of stationary power convert-ers for main drives of bucket wheel excavators

1977Launch of PLC sys-tems in the mining industry

1985First gearless drive for conveyors

1980

Milestonesfor better performance

In globalized markets, there is no alternative to the continual optimization of productivity and efficiency in production lines.

To offer the best solutions, you first need to invent them. Constant innovation is what makes Siemens the world’s largest provider of technical services. And it’s what makes us the perfect partner for every­one in the mining industry who wants to be one step ahead: because that’s what we’ve always been.

1940

1969Launch of dual-starter technology for wound-rotor motor drives for conveyors

1975Launch of DC braking for wound-rotor motor drives for conveyors

1976First application of AC drive technology on a shovel (Bucyrus Erie, USA)

1980First mine hoist with AC cyclocon-verter driveFirst microprocessor based mine hoist com-puter for jerk limited acceleration and de-celeration at any point of the hoisting cycle

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Ausklappseite (2 mm verkürzt) innen

1985First gearless drive for conveyors

1987Launch of Frozen Charge Protection for mill drives

1980

1988Launch of AC trac-tion combined with a digital control sys-tem for large exca-vators in open-cast mining

199�Launch of operator assistance modules for excavators in open-cast mining

1994First bucket chain excavator with gear-less drive in open-cast mining at LAUBAG, Welzow

Milestones

1990First in-tegrated mine winder (Romberg, Germany)

1990 �000

1999New pellet process to increase productivity at L-GOK First speed-controlled downhill conveyor generating approx. 17 MW of electrical power (Los Pelambres, Chile)

1996First application of the oven model for a pelletizing plant in Russia First AC drive for the ultra-class mine trucks (400 tons)

199�Launch of quality management systems for the supply of coalfield power plants

�000Launch of material and quality management system for coal minesFirst MES in open-pit mining (Niederaußem, Germany)

�001First SIRAS (remote access) system on Bucyrus machines, Access Direct, was commissioned on a shovel in Boliden, Sweden

�00�First Access Direct systems, for draglines in Queensland, Australia

�004Frozen charge shaker for grinding mills

�005Complete electrical package for CTE coal terminal (Europoort, Rotterdam)

�006Largest slurry pump (6 MW) ever supplied to a mine at Erdenet, MongoliaFirst gearless drive for grinding mills in Brazil at Rio Paracatu Mineração

1998First gearless drive (20 MW) for SAG-Mill at Orange, Australia

Launch of DC braking for wound-rotor motor drives for conveyors

First mine hoist with AC cyclocon-verter driveFirst microprocessor based mine hoist com-puter for jerk limited acceleration and de-celeration at any point of the hoisting cycle

�007Gearless drives came into operation first time for Dragline at Zhungeer coal mine, ChinaPneumatic spray-in flotation cells for Molybdenum plant at Mineria Los Pelambres, Chile

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Installed base

Starting operation – the professional way

With Siemens, partnership starts much earlier than with engineering machines, vehicles and plants. For example, we de­velop customized financing solutions that perfectly fit your strategy while at the same time minimizing economic risks.

To optimally prepare equipment and plant operation, we offer training for opera­tors, service technicians and maintenance staff – for a quicker mastery of the tasks and processes to reduce downtime. And plant modernization with Siemens helps you keep pace with technological prog­ress. We make sure that your investments achieve the required success – from re­placing an individual drive group to mod­ernizing complete plant systems.

At the leading edge – in any phase of the life cycle

With Siemens, you can always make use of the latest innovations – leading to higher production output, reduced ener­gy costs, and minimized operation costs.

Our people have set the pace in the mining industry for decades. Milestones within the last 30 years range from the introduc­tion of AC technology to the launch of quality management systems to the first gearless draglines. The introduction of cutting­edge technologies is the logical result of our cross­area network, with 47,000 people working on research and development alone. So wouldn’t you like to share this spirit with Siemens?

Relying on expertise – with a large installed base

With Siemens, you can rely on profound expertise proven in practice. Having equipped some 350 excavators, 150 winders, and 250 trucks – to name just a few examples – we have an excellent basis to provide the best solution for your mine. Including the complete mechanical and electrical engineering, enriched by leading technological solutions.

A large installed base throughout the entire process chain in mining industry – on all continents: This is Siemens’ expertise, which you can take advantage of.

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Completely Integrated Solutions with SIMINECIS

Integrated offerings for increased plant performance

End-to-end process optimization

We create the foundation for optimized processes with our engineering services and with leading automation, drive and energy supply products for all steps in the process – from extraction to material logistics to final processing.

At their core, these products are built on proven Siemens standards. We use this basis to set the benchmarks for efficiency and ergonomics through continual inno­vation and new technologies. Examples range from the world’s first gearless drag­line (SIMINECIS DRAG) and our ring motors for processing plants (SIMINECIS MILL) to completely new processes for pelletizing plants (SIMINECIS Pellet).

Further solutions round out our portfolio for everything from water and sewage needs to power supply and other infra­structure projects, including all aspects of security for your mine.

Higher availability

Measurable process improvement

Greater productivity

Integrated information technology

Reduced life-cycle costs

Maximum protection of your investment

Efficient process control

Competitive processes also hinge on the quality of information processing. Data from various process steps must be con­densed and compared against planning data to ensure an optimal process flow.

Siemens solutions in the areas of IT and MES (Manufacturing Execution Systems) lead the field for the mining industry, providing full transparency from the pro­cess to the planning and management level. Patented solutions produce system­atic quality assurance, efficient logistics, flexible production and schedule plan­ning, as well as end­to­end tracking and tracing from extraction to the processed material and back – such as SIMINECIS MAQ for creating the optimal quality mix.

Maximized life-cycle return

Siemens services help your mine achieve high profitability throughout its entire life cycle. We start in the planning, approval and financing phases, setting the course for a rapid, on­time start­up of operations.

Efficient service measures and a reliable supply chain for spare parts ensure high availability of your equipment during active operation.

Last but not least, we ensure timely mod­ernization so that your mine remains competitive while complying with strict environmental regulations. Every product in the SIMINECIS portfolio is equipped for a smooth hardware and software migra­tion – so you benefit from current inno­vations while protecting the value of your investment.

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Perfect integration of every aspect

Completely Integrated Solutions with SIMINECIS

There are three primary aspects to increas-

ing productivity and minimizing costs in

the mining industry: raising the potential

in each individual process step, optimizing

the entire process chain to fully exploit

synergies, and ensuring competitive per-

formance throughout the entire life cycle.

Our Completely Integrated Solutions

cover all these aspects. The name SIMINECIS

stands for a coordinated spectrum of prod-

ucts, services and expertise. From engi-

neering to the implementation of leading

electrical technology, from IT solutions for

optimized process control to equipment

modernization – SIMINECIS is your single

source for optimizing production and

logistics processes.

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www.siemens.com/mining

For further information contact:

Siemens AG Industry Sector Industry Solutions Mining Technologies

Schuhstr. 60 91052 Erlangen, Germany

E-mail: mining@siemens.com

The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of 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 re-spective characteristics shall only exist if expressly agreed in the terms of contract.

Order No.: E10001-M5-A5-V2-7600

Printed in Germany

Dispo No.: 21662 K No.: 28400

GB WS 10083.

Subject to change without prior notice

© Siemens AG 2008. All rights reserved.

SIMINE is a trademark of Siemens AG.CIS = Completely Integrated Solutions