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Keep your plant up-to-date – Revamps and modernization for longer equipment and plant lifetime

Over the lifetime of mining operations, operational parameters may differ from time to time demanding adjustments in equipment features and application planning. Quickly the request for additional or different equipment is stated from operations managers, not being aware of the wide opportunities and huge potentials in modifying the existing equipment park. Our mining revamps portfolio covers the full range of opportunities and features of mining equipment already in operation. This includes services to renew, relocate, upgrade or simply optimize existing equipment. We are your partner to understand your equipment better and lift hidden potentials.

Why Revamps? – Potentials over and over

Why consider revamps over new equipment or take a deep dive into operations? This is why:

  • Reduce Operational and Maintenance Cost
  • Extend Lifetime of Equipment for another Lifecycle
  • Increase Capacity and Performance
  • Implement additional Features and latest innovative Developments
  • React on changing Environmental, Legal or Operational Conditions
  • Relocate and rehabilitate (idle) Equipment for extend Asset Utilization
  • Limit shutdown times by revamps instead of replacement by new equipment

Especially when looking into a comparison of the cost-to-lifespan ratio between new equipment and a revamped or renewed machine the specific yearly investment offers a remarkable advantage for revamps looking into the financial metrics.

Taking a closer look into effects on operations further advantages come to light: Renewals, modernizations or also implementation of innovative new features like assistance systems on a well-established equipment with long-term operational experience has a much lower risk profile. Operations thus can remain with the same operator and maintenance teams familiar with the equipment, continue with existing spares, auxiliaries and infrastructures already in place as well as to keep mine planning considerations a fit also for the future.

What’s inside? – Revamps Portfolio

The revamps portfolio covers a wide range of measures and modifications on existing machines and equipment in the mining sphere. These can be structured in basically four streams:

  • Refurbishment
  • Relocation
  • Upgrade & Modernization
  • Health Audits & Consulting

In addition to the core revamps portfolio a close reference to upgrades and integrations of Automation & Digitalization solutions shall be taken to achieve full potential of optimizations on existing equipment as an integrated package.

How to start? – Integrated Plant Approach

To understand full potentials of revamps, especially as part of the Health Audit and Consulting offering, a push towards an assessment of not only the single machines but the complete interaction of the process stream elements shall be initiated.

Consolidating the single machine know-how with process know-how is the core competency of an OEM. This allows the development of a full and complete plant solutions to even more drive optimizations by looking out- and especially beyond-the-box.

Refurbishment

Refurbishment, also often called Renewal or Rejuvenation, extends the lifetime of machines for another lifecycle. It often appears as mid-life refurbishment after 15-25 years of operation. Typical scopes would be the integration of reinforcements or repair of structural steelworks, re-painting for protection against corrosion and checks, repair or replacement of mechanical components, especially ropes, slew bearings, bucket wheel bearings and major gearboxes.

Our Relocation services cover various approaches. On the one hand it comprises the relocation of equipment from one location within an operation to another, for instance the relocation of a semi-mobile crushing plant by transport crawler. On the other hand our services also cover the relocation from one mine or to any other location in the world – supporting with the dismantling, shipping and re-building process. In addition we assess the condition of relevant parts to replace or repair those en-route.

The scope of Upgrades & Modernization has a very wide area of applications on existing equipment. Modernization covers the replacement of components with latest technologies or new innovations from research and development. Whereas Upgrade is looking into the optimization of both, complete systems and single machines, improving energy efficiencies, increasing capacity or simply take measures for a more smooth operation like maintenance access or a more robust design to ensure availability and reliability.

Our Health Audit & Consulting services cover condition assessments of the equipment in structural steelwork, mechanical components and/or electrical installations. In addition we perform data analytics to develop concepts for efficiency upgrades to raise potentials in mutual collaboration with equipment operators.

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