Mining industry Brand introduction

Transcription

1 Industries Mining industry Brand introduction Edition April 2016

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3 CONTENTS Solutions for mining applications... 4 Crushers & feeders... 6 Conveyors... 8 Stockyard equipment Solid/liquid separation...12 Port equipment Experience Our experience in mining Experience and knowledge means Offering Proposals based on engineered solutions Some of our references Rossi Special Projects Dedicated team + specific job = Project Management Order phase Customer order management Quality and Products Helical and bevel-helical gear reducers and gearmotors Rossi Special Projects for mining industry...22 Heavy industry products for mining industry...23 Drive units on swing bases Modularity means competitiveness Example of modularity Cutting edge technology Quality control...27 Specialized housing machining...28 Test controls Service Global partnership for local solutions Global service 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. 4

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6 CRUSHERS & FEEDERS CONVEYORS STOCKYARD 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. 6

7 EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT SOLUTIONS FOR CRUSHERS SOLUTIONS FOR BELT FEEDERS SOLUTIONS FOR APRON FEEDERS Type: Helical gear units Catalog: G, H Type: Planetary in-line gear / Combined with bevel helical Catalog: EP, G Type: Planetary in-line gear / Combined with bevel helical Catalog: EP, G

8 CRUSHERS & FEEDERS CONVEYORS STOCKYARD 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. 8

9 EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT 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 units Catalog: G Type: Bevel - helical gear units Drive units on swing base Catalog: RE

10 CRUSHERS & FEEDERS CONVEYORS STOCKYARD 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. 10

11 EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT SOLUTIONS FOR BUCKET WHEEL STACKER RECLAIMER SOLUTIONS FOR CIRCULAR STOCKYARDS Type: Planetary in-line gear / Combined with bevel helical Catalog: EP, G Type: Bevel helical gear Catalog: G

12 CRUSHERS & FEEDERS CONVEYORS STOCKYARD 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. 12

13 EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT SOLUTIONS FOR FILTERS SOLUTIONS FOR FLOATATION CELLS Type: In line combined planetary gears Catalog: EP Type: In line planetary gears Catalog: EP

14 CRUSHERS & FEEDERS CONVEYORS STOCKYARD 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. 14

15 EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT 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 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS 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. 16

17 ORDER PHASE QUALITY & PRODUCTS SERVICE 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?

18 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS 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. 18

19 ORDER PHASE QUALITY & PRODUCTS SERVICE SOME OF OUR REFERENCES CUSTOMER NAME Tenova Group FLSmidth Group Metso Takraf Taim Weser Thyssen Krupp APPLICATION Material handling conveyors Continuous ship unloaders Radial stackers Circular stockyards Belt conveyors Pipe conveyors Apron feeders Belt feeders Overland conveyor drives Inching Drives for Mill Rotary kiln Rotary sluice drives Cement separator drives Twin shaft brakers Travel drives for mobile stacking conveyor Mobile overland tripper Apron feeders Portal reclaimers Slurry pump drives Rail car positioners Linear stackers Radial stacker reclaimers Scraper reclaimers Belt conveyors Refinery machines Belt reel drives END USER NAME First Quantum Minerals Anglo American Gol E Gohar Mongolyn Alt Group Ausenco Rio Tinto Freeport Mc Moran APPLICATION Belt conveyors Feeder drives Overland conveyors Apron feeders Belt conveyors Material handling conveyors Belt conveyors Apron feeders Conveyors Conveyors Belt conveyors Apron feeders

20 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS 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. 20

21 ORDER PHASE QUALITY & PRODUCTS SERVICE 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 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS HELICAL AND BEVEL-HELICAL GEAR REDUCERS AND GEARMOTORS BEVEL-HELICAL GEAR REDUCERS AND GEARMOTORS G SERIES Size 18 sizes ( ) Power P kw Nominal torque T N2 87,500 N m Transmission ratio i N HELICAL GEAR REDUCERS AND GEARMOTORS G SERIES Size 18 sizes ( ) Power P kw Nominal torque T N2 87,500 N m Transmission ratio i N ROSSI SPECIAL PROJECTS FOR MINING INDUSTRY ROSSI SPECIAL PROJECTS Power P 1 according to specifications Nominal torque T N2 700,000 Nm Transmission ratio i according to specifications 222

23 ORDER PHASE QUALITY & PRODUCTS SERVICE HEAVY INDUSTRY PRODUCTS FOR MINING INDUSTRY HEAVY INDUSTRY PRODUCTS EP SERIES Size 10 sizes ( ) Nominal torque T N2 125, ,000,000 Nm Transmission ratio i N ,800 HEAVY INDUSTRY PRODUCTS EP COMBINED UNITS Size 6 sizes ( ) Nominal torque T N2 710,000 Nm Transmission ratio i N according to specifications HEAVY INDUSTRY HELICAL AND BEVEL HELICAL GEAR UNITS H SERIES Size 11 sizes ( ) Nominal power P N ,650 kw Nominal torque T N2 630,000 N m Transmission ratio i N DRIVE UNITS ON SWING BASES DRIVE UNITS ON SWING BASE RE SERIES Gear reducer sizes Motor sizes Nominal torque T N2 630,000 N m

24 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS 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 flexibility, 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 configurations allowing Rossi to deliver solutions, regardless if it comes to supply a standard unit or an engineered one, in a cost effective 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. 24

25 ORDER PHASE QUALITY & PRODUCTS SERVICE EXAMPLE OF MODULARITY

26 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS 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. 26

27 ORDER PHASE QUALITY & PRODUCTS SERVICE 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 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS 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. 28

29 ORDER PHASE QUALITY & PRODUCTS SERVICE 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 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS WHERE WE RE LOCATED Subsidiaries Distributors / Dealers GLOBAL PARTNERSHIP FOR LOCAL SOLUTIONS 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 flexible and dependable partner throughout the world. Cooperation with Rossi is especially customer-friendly and efficient with Rossiforyou - a communication network which provides a 24/7 global coordination of the ordering, supply and service processes. 30

31 ORDER PHASE QUALITY & PRODUCTS SERVICE 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 AMERICA phone ASIA phone EUROPE phone OCEANIA phone

32 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 ) certified paper (1). This is our tangible commitment in terms of environment sustainability. FSC (1) The certification means that finished wood-based products in the marketplace have been handled by companies that have also been certified and that the paper has been handled in an environmentally-friendly manner. Australia Germany South Africa Global Service Rossi Gearmotors Australia Pty. Ltd. info.australia@rossi-group.com Rossi GmbH info.germany@rossi-group.com Rossi Southern Africa info.southafrica@rossi-group.com Rossi S.p.A. aftersales@rossi-group.com Benelux India Taiwan Rossi BeNeLux B.V. info.benelux@rossi-group.com Rossi Gearmotors Pvt. Ltd. info.india@rossi-group.com Rossi Gearmotors Co. Ltd. info.taiwan@rossi-group.com Brazil Malaysia Turkey Rossi do Brasil LTDA info.brazil@rossi-group.com Rossi Gearmotors South East Asia Sdn Bhd info.malaysia@rossi-group.com Rossi Turkey & Middle East info.turkey@rossi-group.com China Poland United Kingdom Rossi Gearmotors China P.T.I. info.china@rossi-group.com Rossi Polska Sp.z o.o. info.poland@rossi-group.com Rossi Gearmotors Ltd. info.uk@rossi-group.com France Spain, Portugal United States, Canada, Mexico Rossi Motoréducteurs SARL info.france@rossi-group.com Rossi Motorreductores S.L. info.spain@rossi-group.com Rossi North America info.northamerica@rossi-group.com 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 qualified 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 confirmed 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 modification whenever to this publication contents. The responsibility for the product selection is of the customer, excluding different agreements duly legalized in writing and undersigned by the Parties. Rossi S.p.A. Via Emilia Ovest 915/A Modena - Italy Phone fax info@rossi-group.com Registered trademarks Copyright Rossi S.p.A. Subject to alterations Printed in Italy