Since its initial development more than five years ago, Ivanhoe Mines’ Kamoa-Kakula Copper Complex in the Democratic Republic of Congo (DRC) has relied on engineered X.e series power packs from SEW-EURODRIVE. With well over 100 units already in operation, SEW-EURODRIVE will be supplying several more units to the mining complex this year to drive conveyors, as well as planetary gearboxes for feeder applications.
At Kamoa-Kakula, the tropical climate led to specific features being incorporated into the equipment.
The Kamoa-Kakula Copper Complex is a joint venture between Ivanhoe Mines and Zijin Mining of China. Willem Strydom, Business Development Representative at SEW-EURODRIVE, says the power packs – which are integrated units comprising gearbox, coupling and motor – will be part of the Phase 3 expansion. Through all phases of the development of the mining complex, SEW-EURODRIVE has worked closely with Ivanhoe Mines and the engineering, procurement and construction (EPC) contractor.
“As in previous phases, our robust, high quality power packs will provide reliable solutions in on-site applications such as conveyors, agitators, and slurry pumps,” Strydom says. “The size range in the order makes use of our ability to provide a total solution, ranging from 55 kW units to 500 kW units.”
The latest order includes several X.e Series power packs for conveyor applications, planetary gearboxes for feeder applications, and spare gearboxes. The equipment will be delivered in a sequence of shipments this year. Although the mine usually undertakes the installation of the equipment, SEW-EURODRIVE sends technical teams to site to check final alignment and overall installation parameters.
Over recent years, the company has expanded its after-sales service teams, enabling it to support the growing base of its equipment throughout Africa. Its projects and engineering teams have also grown – developing a depth of experience to assist customers from the design phase onwards.
In addition, Strydom notes that SEW-EURODRIVE has developed its infrastructural foundation in South Africa significantly and, going forward, plans to develop physical representation in over 23 other African countries. As the DRC is a priority country for the company, it plans to have a representative office there this year. Field service teams from South Africa are often on site at Kamoa-Kakula to assist with servicing of the power packs already in operation there.
“Our local assembly capability at our new facility in Johannesburg – combined with our ability to source from the group’s other global operations – has allowed us to meet the tight delivery deadlines for this substantial order of equipment,” Strydom says. “We have the capacity to deliver faster than most players in our field, and this is often an important factor for our market.”
Until recently, SEW-EURODRIVE imported the larger X.e Industrial gearboxes from Germany – and it can now assemble these at its expanded South African facility. As part of its service for the project, the company will also handle the logistics of getting this large volume of equipment to site. It has provided training on the equipment and its maintenance at its Johannesburg Drive Academy.
Andreas Meid, Head of Engineering at SEW-EURODRIVE, highlights some of the specific requirements for the equipment supplied to the Kamoa-Kakula project. He says the tropical climate was an important factor in the design. This required the inclusion of certain cooling and paint specifications in the contract. In addition, special breathers were incorporated into the design to address the high humidity levels – and serve to ensure moisture is excluded from the gearboxes. In outdoor applications where sun exposure is high, covers are included to reduce heat build-up. Cooling fans are also optimised in certain cases to ensure optimal performance.
He highlights that Kamoa-Kakula is one of many projects in Africa where the installation of monitoring equipment on the power packs has been requested. This facilitates real-time monitoring, using specialised sensors to measure key indicators like vibration and temperature from anywhere in the world.
“It allows the operator to monitor the equipment remotely, receiving early warnings of any issues in performance,” says Meid. “The operator can then respond in good time to prevent serious damage or unplanned downtime.”
As a preferred supplier for the mine, SEW-EURODRIVE delivered the first X.e Series power packs between 2019 and 2021 for the initial development phase. Motors ranging from 7.5 kW to 500 kW as well as planetary gearboxes were supplied for feeder applications, together with several spare gearboxes.
For the Phase 2 expansion of the mining complex, which doubled capacity of the concentrator plant, SEW-EURODRIVE supplied standard X.e Series power packs for the conveyors as well as planetary gearboxes for the feeders.
For more information visit: www.sew-eurodrive.co.za
