mining industry - cda · mining raw materials is becoming more challenging as mineral deposits ......

Mining industry

Brand introduction

Edition April 2016

Industries

CONTENTS

Solutions for mining applications .................................................... 4

Crushers & feeders ....................................................................... 6

Conveyors ..................................................................................... 8

Stockyard equipment .................................................................... 10

Solid/liquid separation ...................................................................12

Port equipment ............................................................................. 14

Experience ....................................................................................... 16

Our experience in mining .............................................................. 16

Experience and knowledge means ............................................... 17

Offering ............................................................................................ 18

Proposals based on engineered solutions .................................... 18

Some of our references ............................................................... 19

Rossi Special Projects ...................................................................... 20

Dedicated team + specific job = Project Management................. 20

Order phase ..................................................................................... 21

Customer order management ....................................................... 21

Quality and Products ....................................................................... 22

Helical and bevel-helical gear reducers and gearmotors .............. 22

Rossi Special Projects for mining industry ....................................22

Heavy industry products for mining industry ................................23

Drive units on swing bases ........................................................... 23

Modularity means competitiveness .............................................. 24

Example of modularity .................................................................. 25

Cutting edge technology .............................................................. 26

Quality control ...............................................................................27

Specialized housing machining .....................................................28

Test controls .................................................................................. 29

Service ............................................................................................. 30

Global partnership for local solutions ........................................... 30

Global service ............................................................................... 31

Our service centers worldwide ..................................................... 31

4

SOLUTIONS FOR MINING APPLICATIONS

With over 60 years experience in the design, manufacturing and commissioning of gear reducers and gearmotors, Rossi has become a power transmission leader in the mining sector.Rossi has forged many strategic partnerships with established mining companies and original equipment engineering firms in this sector and throughout the world. Relationships forged from Rossi’s know-how and expertise in many different industries combined together allow the company to offer turn-key solutions for nearly every mining application.Rossi’s smart solutions, thanks to product designed around modularity, robustness and reliability, help customers to minimize Total Cost of Ownership of plants, reducing maintenance costs and risk of process downtime as well as enhancing energy saving.

6

SOLUTIONS FOR CRUSHERS & FEEDERS

Rossi’s comprehensive product range offers some of the best mechanical performance in terms of torque to mass ratio, thermal capacity and reliability, enablings Rossi’s products to outperform competitors in applications such as crushers, belt feeders and conveyors. Rossi’s smart design, robustness and reliability reduce downtime, lower maintenance cost and enhance energy saving giving plant operators a low cost smart solution.

CRUSHERS & FEEDERS CONVEYORS STOCKYARD EQUIPMENT

SOLUTIONS FOR CRUSHERS

SOLUTIONS FOR BELT FEEDERS

Type: Helical gear unitsCatalog: G, H

Type: Planetary in-line gear / Combined with bevel helicalCatalog: EP, G

SOLUTIONS FOR APRON FEEDERS


STOCKYARD EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT

8

SOLUTIONS FOR CONVEYORS

Mining raw materials is becoming more challenging as mineral deposits become more remote. The distance between the mine pit and the processing plant could mean that large distances need to be spanned, while extraction times and product reliability have never been more important. Belt conveyors remain one of the most cost effective solutions as they allow for large volumes of material to be transferred across most terrains and gradients. Rossi has developed products perfectly tailored to belt conveyors for harsh applications like those in the mining sector irrespective of the conveyor or terrain they need to operate in.


SOLUTIONS FOR CONVEYORS

SOLUTIONS FOR CHAIN CONVEYORS

SOLUTIONS FOR OVERLAND CONVEYORS

Type: Bevel - helical gear units Drive units on swing base Catalog: RE

Type: Bevel helical gear unitsCatalog: G

Type: Bevel - helical gear unitsDrive units on swing baseCatalog: RE


10

SOLUTIONS FOR STOCKYARD EQUIPMENT

Stacker reclaimers, bucket wheel and circular stackers can be found in many bulk handling stock yards and mines throughout the world. Their principle function is to move large quantities of raw materials reliably, continuously and of course cost effectively. Rossi can provide specific drive solutions tailored to individual requirements such as those found in bucket wheel excavators. With its specific solution, Rossi customers can take advantage of both the benefits each type of gearing has to offer: outstanding overload capacity of planetary and the highest mechanical to thermal power ratio of bevel helical gear. The high torque to mass ratio offered by our EP series planetary gear units provide significant benefits to chains drives, conveyor belts and powertrains. Being modular they provide even more benefits when combined with Rossi’s bevel-helical gear units to form a combination drive package solution for use in high torque, high shock load applications, typical of large bucket wheels.The Rossi range allows for a high level of flexibility through optional accessories and auxiliary equipment, which means cost can be controlled and every product engineered to suit individual needs both technically and commercially.


SOLUTIONS FOR BUCKET WHEEL STACKER RECLAIMER

SOLUTIONS FOR CIRCULAR STOCKYARDS


Type: Bevel helical gearCatalog: G


12

SOLUTIONS FOR SOLID / LIQUID SEPARATION

There is a growing need to use more water through mining and other industrialization processes. However with global water reserves being put under more pressure than ever before, the need to manage waste water effectively has never been more important. Every part of the process is being tightly controlled and regulated to ensure proper environmental controls are being adhered to. From clean drinking water to the residual waste material every process requires a drive that will ensure reduced cost of ownership through every process. Today, every process is considered part of the solution as very often what was once waste is now a critical component of another process. Sewage sludge for example is an organic and renewable fuel source that can be used to power the installation energy requirements. Looking back at more than 60 years of Rossi know how and strategic partnerships in the management of waste water, Rossi is able to offer the right drive solution for almost every waste water process.


SOLUTIONS FOR FILTERS

SOLUTIONS FOR FLOATATION CELLS

Type: In line combined planetary gears Catalog: EP

Type: In line planetary gears Catalog: EP


14

SOLUTIONS FOR PORT EQUIPMENT

Port equipment from port container cranes, bulk ship loaders and various other equipment needed to manage the daily movement of import and export goods have become the gateway to individual countries economies. Without the effective management of port equipment the industrial trade between countries will become less efficient. Port authorities have limited berths within ports to enable the loading and unloading of vessels, these berths are charged per hour so the vessel operators demand that port equipment operates fast, continuously and very reliably. As a principle supplier to original manufacturers in the marine and specifically port side equipment, Rossi smart solutions, are designed around modularity, robustness and reliability, to ensure proper Total Cost of Ownership of port equipment, reducing maintenance costs and enhancing load cycle times. Thanks to Rossi’s reliable products many more vessels leave port on time.


SOLUTIONS FOR SHIP LOADERS

SOLUTIONS FOR SHIP UNLOADERS

Type: Helical - Bevel helical gears Catalog: G, H

Type: Combined units Bevel helical - Planetary gears - Helical - Bevel helical gears Catalog: EP, G, H


16

OUR EXPERIENCE IN MINING

With more than 60 years of know-how and experience in applications within the mining sector, Rossi continues to design products for use in heavy duty applications such as those found in mining, quarrying, mineral processing and other typical applications. Rossi continues to develop its working relationship with key global mining operators. This relationship is built on trust, industry know how, industry competence and continued investment in the product design and production techniques. For over 60 years Rossi has understood that experience in this sector is a key factor to develop solutions for the future.

EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

EXPERIENCE AND KNOWLEDGE MEANS...

Experience and knowledge does not only mean to know what is needed in the specific application, but also how to support customers during all design and dimensioning phases.Rossi continues to develop its experience and ensure it has the ability to share vital knowledge that is relevant to machine builders today no matter what the application is, information Rossi makes available includes - expected bearing life calculation,- Finite Element Analysis - torque calculation, and- shared design capabilities with customers Why not discuss your application with a Rossi technician and ensure you receive the benefit of Rossi experience in your application?

ORDER PHASE QUALITY & PRODUCTS SERVICE

18

PROPOSALS BASED ON ENGINEERED SOLUTIONS

A Rossi proposal is a comprehensive document, designed to answer all the questions posed through a customer enquiry and to ensure a comprehensive summary is given to all the listed parameters of the design. A proposal contains all the technical features and benefits needed to ensure a Rossi units out performs any other unit in the market as it is selected as closely as possible to the actual needs of the design. Used correctly, it answers all the questions the decision makers need when evaluating a technical and commercial proposal. Rossi believes that customers require a comprehensive list of the objectives of the needs of the enquiry, this ensures all important aspects are covered and written down form which to reference when developing a viable solution. Having the customers objectives allows Rossi to ensure all these are met and make recommendations in order of priority for every customers. With a Rossi proposal, customers get peace of mind as any service or warranty is build into the service offering. Our warranty is comprehensive and arguably one of the best on offer today. This is because we at Rossi believe in our products and believe in our ability to meet the needs of our customers and we are therefore willing to back it up.



SOME OF OUR REFERENCES

CUSTOMER NAME APPLICATION

Tenova Group Material handling conveyors Continuous ship unloadersRadial stackersCircular stockyardsBelt conveyorsPipe conveyors

FLSmidth Group Apron feedersBelt feedersOverland conveyor drivesInching Drives for MillRotary kilnRotary sluice drivesCement separator drivesTwin shaft brakersTravel drives for mobile stacking conveyor Mobile overland tripper

Metso Apron feedersPortal reclaimersSlurry pump drivesRail car positionersLinear stackersRadial stacker reclaimers

Takraf Scraper reclaimersBelt conveyors

Taim Weser Refinery machines

Thyssen Krupp Belt reel drives

END USER NAME APPLICATION

First Quantum Minerals Belt conveyorsFeeder drivesOverland conveyorsApron feeders

Anglo American Belt conveyors

Gol E Gohar Material handling conveyorsBelt conveyors

Mongolyn Alt Group Apron feedersConveyors

Ausenco Conveyors

Rio Tinto Belt conveyors

Freeport Mc Moran Apron feeders

20

DEDICATED TEAM + SPECIFIC JOB = PROJECT MANAGEMENT

Once the order is assigned, our dedicated team, named Rossi Special Projects, with specific and skilled resources, is in charge to develop the job as a project. The Team Leader compiles the Job Quality Plan (document PP28), identifies the critical phases and continues with the identification of the main responsibilities.The implementation of all the activities, as well as the collection and care of Documentation, ensures that all the phases/activities already planned are under control.


CUSTOMER ORDER MANAGEMENT

Rossi ensures that all processes within the IT platform are designed with rapid transfer of data needed for internal processes as well as for the management of the order by the customers themselves. Rossi has chosen to operate with Oracle’s JD Edwards EnterpriseOne. This facilitates order management on one platform for both the customer and Rossi staff anywhere in the world. Through a standard operating platform we are able to configure customers unique forecasting, shipping standards, transportation sequence and reporting processes in coordination with commercial contracts and associated quality control documentation – all integrated to one ERP system.


22

HELICAL AND BEVEL-HELICAL GEAR REDUCERSAND GEARMOTORS

BEVEL-HELICAL GEAR REDUCERS AND GEARMOTORS G SERIES

Size 18 sizes (40 ... 360)

Power P1 0.09 ... 160 kW

Nominal torque TN2 ≤ 87,500 N m

Transmission ratio iN 2 ... 160

HELICAL GEAR REDUCERS AND GEARMOTORS G SERIES

Size 18 sizes (40 ... 360)

Power P1 0.09 ... 160 kW




ROSSI SPECIAL PROJECTS

Power P1 according to specifi cations

Nominal torque TN2

≤ 700,000 Nm

Transmission ratio i according to specifi cations

22

ROSSI SPECIAL PROJECTS FOR MINING INDUSTRY

HEAVY INDUSTRY HELICAL AND BEVEL HELICALGEAR UNITS H SERIES

Size 11 sizes (400 ... 712)

Nominal power PN2 16 ... 3,650 kW



DRIVE UNITS ON SWING BASES

DRIVE UNITS ON SWING BASERE SERIES

Gear reducer sizes 140 ... 712

Motor sizes 132 ... 400



HEAVY INDUSTRY PRODUCTS FOR MINING INDUSTRY

HEAVY INDUSTRY PRODUCTSEP SERIES

Size 10 sizes (125…3000)

Nominal torque TN2 125,000 ... 3,000,000 Nm

Transmission ratio iN 18 ... 1,800

HEAVY INDUSTRY PRODUCTSEP COMBINED UNITS

Size 6 sizes (125…710)

Nominal torque TN2 ≤ 710,000 Nm

Transmission ratio iN according to specifi cations

24

MODULARITY MEANS COMPETITIVENESS

Modularity can be considered the foundation of Rossi. Modular products and “modular”processes allow Rossi to engineer a solution for almost every industrial application requiring a gearmotor or gear reducer. To Rossi, modularity means fl exibility, wide range of options, faster delivery, and most important of all, competitiveness. Even more it allows for assemblies in any assembly facility with almost limitless confi gurations allowing Rossi to deliver solutions, regardless if it comes to supply a standard unit or an engineered one, in a cost eff ective manner. This capability is made possible through Rossi’s ability to understand the customer’s requirements and translate the needs of that customer into a commercially and technically acceptable solution. Of course, at Rossi, our modular approach doesn’t stop at the delivery of a product or solution. For Rossi this is just the start, with strong online support systems our customers have access to leading interactive product and service care.



EXAMPLE OF MODULARITY

26

CUTTING EDGE TECHNOLOGY

When it comes to high-performance and ground precision gear manufacturing, technology and experience are everything. Cutting edge technology without experience can limit the benefit the final product has for the end user which is why Rossi continues to take pride in the fact that the ground gears the company manufactures are probably some of the best industrial gears manufactured by anyone today. Rossi believes that ground gears, be they helical gears or helical bevel gears or any other, need to be of a consistent high quality finish in order for Rossi products to maintain the reputation of quality and performance they have today. Cutting edge technology is also a fundamental corner stone of the quality control procedures needed to ensure the strict standards set as a company continue to be met and that the final product the customer sees is never compromised. Cutting edge technology can be bought, but how you control it is earned through experience.


QUALITY CONTROL

Every Rossi component machined individually or part of a production batch, follows a stringent quality control process as part of Rossi Quality management policy. This policy is mirrored in every Rossi production facility and is managed through a dedicated in house IT system, that allows the rapid flow of information at any given time. Rossi’s quality control policy, audited by TÜV Nord, ensures that the manufacturing process is controlled from the sourcing of material, all the way through the final assembly of the geared product. Continuous monitoring of the ISO 9001 manufacturing procedures and processes allows the production quality control process to eliminate excess costs that could traditionally be added to the final batch of any production run, ensuring a cost effective final product. Rossi employs some of the most modern quality control equipment needed to measure tooth profiles, surface finishes and critical dimensions of components. Rossi by employing this quality management plan, can ensure consistent product performance safe in the knowledge that Quality is the foundation Rossi products are built on.


28

SPECIALIZED HOUSING MACHINING

High performance needs to be supported with important equipment and knowledge.For this reason, Rossi dedicates special attention to machining all components, including housings for big sizes. High quality standard requirements can be reached using cutting edge technology, such as our new boring milling center.Production flow is complete with the final operation and quality check. The housings are measured using appropriate “Coordinate Measuring Machines” (CMM). One of our CMM machines can be used also as gear inspection system, offering the possibility to check parts with the following maximum dimensions: length 4000 mm, height 2000 mm, width 2000 mm.


TEST CONTROLS

Systematic, extensive controls on every stage of the process (from materials to final controls under load using computerized brakes at the end of the assembly line) and their productivity allow quality to be produced and not just achieved through selection, and permit monitoring and improving the process itself.In addition customers can trust our solutions which have been fully tested and run in our testing room, being operationally certified before on site commissioning.


30

GLOBAL PARTNERSHIP FOR LOCAL SOLUTIONS

SubsidiariesDistributors / Dealers

WHERE WE’RE LOCATED

As a result of the rapidly growing importance of the global market for power transmission systems, Rossi has set up a network of subsidiaries and dealers in nearly all industrialized countries. Support during the design phase, local availability of the required drive technology and rapid local service make Rossi a fl exible and dependable partner throughout the world. Cooperation with Rossi is especially customer-friendly and effi cient with Rossiforyou - a communication network which provides a 24/7 global coordination of the ordering, supply and service processes.



GLOBAL SERVICE

We don’t stop with the sale of our product, we provide our customers with service and back-up. Through our subsidiaries’ stocks and assembly centers worldwide we make sure that we are not only able to supply gearboxes but that we can also back them up, if need be, with the spare parts required. Our Global Service has the possibility to reach our customer’s plants quickly, in case of breakdown. Our main goal is to return our customers’ plants to operation as soon as possible and to keep maintenance overheads as low as possible.

OUR SERVICE CENTERS WORLDWIDE

AFRICA phone +27 32 815 0380AMERICA phone +1 800 931 2044

ASIA phone +86 21 3350 5345EUROPE phone +39 059 330288 OCEANIA phone +61 8 94557399

Rossi S.p.A.

Via Emilia Ovest 915/A41123 Modena - ItalyPhone +39 059 33 02 88fax +39 059 82 77 74e-mail: [email protected]

Product liability, application considerations

The Customer is responsible for the correct selection and application of product in view of its industrial and/or commercial needs, unless the use has been recommended by technical qualifi ed personnel of Rossi, who were duly informed about customer’s application purposes. In this case all the necessary data required for the selection shall be communicated exactly and in writing by the Customer, stated in the order and confi rmed by Rossi. The Customer is always responsible for the safety of product applications. Every care has been taken in the drawing up of the catalog to ensure the accuracy of the information contained in this publication, however Rossi can accept no responsibility for any errors, omissions or outdated data. Due to the constant evolution of the state of the art, Rossi reserves the right to make any modifi cation whenever to this publication contents. The responsibility for the product selection is of the customer, excluding di� erent agreements duly legalized in writing and undersigned by the Parties.

Every decision we make at Rossi impacts the world we live in. But new technologies and renewed commitment to sustainable practices have provided us with the opportunity to make environmentally friendly printing decisions. Our catalogs are printed on Forest Stewardship Council® (FSC®) certifi ed paper (1). This is our tangible commitment in terms of environment sustainability.

(1) The certifi cation means that fi nished wood-based products in the marketplace have been handled by companies that have also been certifi ed

and that the paper has been handled in an environmentally-friendly manner.

Australia

Rossi Gearmotors Australia Pty. Ltd.e-mail: [email protected]/australia

Benelux

Rossi BeNeLux B.V.e-mail: [email protected]/benelux

Brazil

Rossi do Brasil LTDAe-mail: [email protected]/brazil

China

Rossi Gearmotors China P.T.I.e-mail: [email protected]/china

France

Rossi Motoréducteurs SARLe-mail: [email protected]/france

Germany

Rossi GmbHe-mail: [email protected]/germany

India

Rossi Gearmotors Pvt. Ltd.e-mail: [email protected]/india

Malaysia

Rossi Gearmotors South East Asia Sdn Bhde-mail: [email protected]/malaysia

Poland

Rossi Polska Sp.z o.o.e-mail: [email protected]/poland

Spain, Portugal

Rossi Motorreductores S.L.e-mail: [email protected] www.rossi-group.com/spain

South Africa

Rossi Southern Africae-mail: [email protected]/southafrica

Taiwan

Rossi Gearmotors Co. Ltd. e-mail: [email protected]/taiwan

Turkey

Rossi Turkey & Middle Easte-mail: [email protected]/turkey

United Kingdom

Rossi Gearmotors Ltd.e-mail: [email protected] www.rossi-group.com/unitedkingdom

United States, Canada, Mexico

Rossi North Americae-mail: [email protected]/northamerica

Global Service

Rossi S.p.A.e-mail: [email protected]

FSC

Registered trademarksCopyright Rossi S.p.A.Subject to alterationsPrinted in Italy

mining industry - cda · mining raw materials is becoming more challenging as mineral deposits ......

Documents