indurad is a German company that has made a sizeable impact in the world of dry bulk handling. Its products are used with a wide range of commodities, from metallic ore to agricultural products. Since its founding in Aachen in 2008, indurad has branched off into all major markets and counts some of the world’s largest mines, ports and terminals as its customers.
CASE STUDIES: TECK RESOURCES
Copper and coal miner Teck Resources operates Fording River mine in southeastern British Columbia in Canada. The mine produces nine million tonnes of metallurgical coal annually, which is shipped by rail to Vancouver for export.
In 2020, indurad commissioned its iLoadout solution at one of the mine’s two train loadouts and in the following month, railcar underloading was reduced by half and tonnes shipped was increased dramatically.
The system uses indurad’s radars to determine exactly how and when to operate the chutes so that the load is maximized for each car while at the same time ensuring that no car gets overloaded and ensuring an optimal load distribution. Using iLoadout, Teck Resources has been able to cut its railcar unloading time by half. indurad’s systems halve rail loadout time, vastly increasing throughput between bogies.
The speed with which a car can now be loaded has been increased by 41.5%, reducing the total time to load a train to only two and a half hours…
In this free webinar, indurad experts will teach you how to increase the efficiency of your dry bulk handling process using indurad’s radar-based machine vision solutions.
Unleash the true potential of your conveyor belts, indoor stockpiles, reclaimers and ship (un)loaders in your dry bulk terminal.
Free registration: https://us06web.zoom.us/webinar/register/WN_YTkXz59sQYCrTNEa2_cJkA
Learn how to:
- Reduce ship loading and unloading times
- Control material inventory reliably and in real-time
- Increase reclaimer uptime and production rates
- Improve personnel safety in hazardous areas and reliably prevent collisions
Time and date: July 12th, 2022, 2 PM CET | UTC +2 Register now for free
Free registration: https://us06web.zoom.us/webinar/register/WN_YTkXz59sQYCrTNEa2_cJkA
For those who have registered but are unable to attend the webinar, a summary is available as needed.
Gain insight into how indurad’s solutions have already added value to a variety of ports worldwide by enabling automated process control, safe and fast ship (un)loading and volume monitoring.
As a foundation for consistent and reliable data generation, our solutions are based on maintenance-free radar sensors that are unaffected by environmental conditions such as dust, rain, fog or snow.
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indurad has contributed with our unique iLoadout Train Automation Solution to the Operational Operating Excellence of TECK Fording River Operations.
TECK has chosen indurad technology with
1. its broad experience in more than 30 train loading machine vision solutions in Europe, Australia and South Africa,
2. Its maintenance free1D speed 2D|3D imaging radar portfolio working in snow and fog
3. CSA/IECEx approval for its sensors to be used in hazloc zones 20|21|22.
The indurad solution has been integrated into the Rockwell Automation PLC with our Vancouver partner enCompass Solutions Group. The technology is currently in rollout based on the great teamwork with Teck.
Feel free to contact us for more information.
Usually, these mines are in remote areas that face some of the harshest conditions Australia has to offer – with regions such as the Pilbara in Western Australia recording temperatures of up to 45°c in the summer.
To complicate matters further, dust and debris can cause havoc to sensors, and could interrupt the collection of data for Industry 4.0 systems.
This problem is what German equipment manufacturer indurad set out to solve. Fabian Riedel, VP of Sales and Projects at indurad, says the company was challenged with creating a system that was proven to work in the rough conditions of the mining industry.
What the company created is the iBelt system, a volume flow measurement sensor that can be used for almost any kind of bulk materials conveying system.
iBelt measures belt load, speed and misalignment with high accuracy in real time with radar technology. The system can be installed over the conveyor belt, where it can determine the 2D load profile measurement. This can be automatically combines with a measured or fixed conveyor belt speed value to determine the load volume.
Dust, vibration and the harsh Australian sun can reduce the reliability of sensor readings, which is why indurad has designed a solution specifically for the mining industry.
The operation of belt conveyor systems in the bulk materials handling industry can cause significant challenges, such as limitation of production rate, reliability issues, safety risks like spillage and belt damage, or a high environmental impact.
Increasing the throughput on underutilized conveyors can be tough if setpoints are based on mass instead of volume flow. If the bulk density of the conveyed material fluctuates, setpoints based on mass readings (belt scale) must be set more conservatively to avoid spillage. Volume based setpoints allow a higher belt conveyor utilization.
Spillage of material due to overloaded or unequally loaded conveyors, or varying volumetric load, can be a risk for humans and machines. Material transfer points and loading and discharge points are particularly prone to spillage events. It can be a result of misaligned belts, that lead to increased wear or even belt damage. Both are critical for human safety and maintenance.
indurad iBelt-SC hardware kit
As a specialist in automation solutions and high-precision sensors for heavy industry, indurad offers products for harsh and hazardous environments. Our applications range from zone 20 dust atmospheres (Group IIIC) and zone 2 gas atmospheres (Group IIA) to underground mining (methane & coal dust, Group I). Our robust sensor solutions reduce risk, improve yield, and increase automation in potentially explosive environments.
Our sensors are IECEx, ATEX and ANZEx certified. Additionally, we offer sensor solutions for CSA/UL and are in the certification process for EAC Ex. If you are unable to find your local certification, our team of engineers can provide expert technical support to assist you with your specific requirements. We work with various certification bodies worldwide to provide our customers with high quality sensors certified in accordance with their respective local regulations.
Q How has radar use in mining changed from initial deployment in autonomous machines?
A Legacy automation systems for mining applications rely, among other perception sensors, on automotive-spec radars for medium and long distance CAS in a limited field of view per sensor. The sensors are merely protected in a more ruggedised housing. However, the sensors themselves and signal processing are conventional. Today, the automation system’s perception is based on indurad’s unique 360° radar technology scanning with up to 50 revolutions per second. indurad’s radar technology is designed for the harsh mining environment and does not compromise on point cloud imaging, unlike low-cost automotive radar sensors that rely on inaccurate digital beam forming, patch antennas and integrated MMIC chipsets. It scans the machine’s surroundings with high accuracy (sub-millimeter ranging accuracy) while being largely unaffected by environmental influences such as dust, rain, fog, or snow. Radar is the only technology that maintains its high OEE in even the harshest mining environments.
Q Can you give more detail on how radar uniquely handles mining
A Mining and tunnelling applications are characterised by extreme environmental conditions such as dust, mud, water, rain, fog and snow. Furthermore, machinery and thus its sensor technology must endure a
wide temperature ranges from -40° to +60°C at different sites. Additionally, mobile machines such as trucks and loaders components must withstand high acceleration in multiple axes. In some applications corrosive water poses another challenge to sensors. Radar is by far the most suitable technology for harsh environments due to its favorable wavelength compared to optical systems such as LiDAR or cameras. indurad’s high-precision scanning dynamic radars are specifically designed for high vibrations for a great variety of industrial applications.
Q Can radar handle mining applications on its own?
A indurad has successfully demonstrated that trackless mobile machine automation in harsh mining environments including terrestrial mapping are feasible with radar-only perception. This technology already incorporates advanced signal processing algorithms and AI approaches for more challenging object detection and mapping tasks…
indurad has successfully demonstrated that trackless mobile machine automation in harsh mining environments including terrestrial mapping is feasible with radar-only perception
We look forward to welcoming everyone to Booth 817 for some great networking, exchange of ideas and a discussion on how to best remove bottlenecks from pit to port.
Our robust, radar-based solutions reduce risk, improve yield, and facilitate automation in very harsh environments.
Automatic shiploading has always been the holy grail of the mining and bulk material handling industries, as it allows operators to tele remote the boom and spout from a safe location. iShiploader uses high precision 2D and 3D radar sensors to reliably scan for collision objects, provide position data, and measure the interior of bulk carriers in real time during loading/unloading cycles.
Most seaports experience a considerable amount of dense fog, rain, strong winds, ice, and snow. These environmental factors pose challenges for conventional optical technology like lasers which rely on favourable weather conditions to perform optimally. indurad’s sensors use the latest in radar technology, which is proven to work reliably in all weather conditions. This allows the company systems to work continuously day and night, 365 days/year with minimal maintenance.
The Germany-based global supplier of radar-based automation technology is continuously developing its solution to consider new shiploader and unloader types…
Installed iShiploader, the shiploader automation radar solution at the customer site.
Conveyor belts are often installed in environments with poor visibility, high dust loads, or exposure to rain and snow. Furthermore, they are often in remote areas that are difficult to access. This explains why optical measurement systems are often not suited to measure material across conveyor belts.
The iBelt, indurad’s radar based bulk volume scanner, addresses those problems and can help debottleneck key processes, optimize process performance, improve safety, and increase availability of critical equipment.
The solution can be deployed in mines, plants, smelters, stockyards, ports, and on balanced machines like stackers, reclaimers, shiploaders and unloaders. The solution is applicable to all bulk commodities, including, amongst others, crushed ore, coal, lignite, potash, sulphur, salt, cement, tar sand, grain or wood pellets. All indurad sensors are maintenance free, so regular cleaning is not required….
indurad’s Bulk Volume Scanner in a Chilean open pit copper mine
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For those who registered but cannot attend the webinar, a summary will be available for you to view at your convenience.
Our iSilo/iDome solutions have been adding value to a multitude of bulk material handling processes by providing precise 3D inventory control for all types of silos and domes. Growing industry requirements such as: needing to convert material level to volume or mass, accounting for specific material behavior, and operating reliably in harsh ambient conditions have proven to be too much for conventional level measurement systems. Whereas, iSilo and iDome use robust 3D sensors and cutting-edge software to confidently meet these objectives. Additionally, 3D inventory control is one of the most critical components of having a Digital Twin that allows clients to utilize the advantages of real time plant monitoring.
We will provide you with an expert view on how to make your business safer and more efficient. We are offering the opportunity to speak with the indurad team after the webinar to discuss each of your unique goals.
It is the go-to event for mining leaders to connect around the strategic priorities, emerging opportunities and technologies that are driving change for a sustainable mining future.
Meet indurad’s CEO Reik Winkel and indurad team: Nicky Suwandy and Carlo Rothschuh to discuss how our solutions can help debottleneck your operation from pit to port.
Don’t miss out one of the most important events for the mining industry in 2021. Meet us at booth: #439
- iBeltVOLUME for volume flow
- iBeltSPEED for material speed and
- iBeltALIGN for belt alignment.
Customers rely on iBelt VOLUME and SPEED to monitor their actual belt load, increasing their production rate while preventing spillage. Meanwhile, iBeltALIGN is typically used to monitor the behaviour of the belt and the material on it, allowing operations to avoid costly downtime caused by activating misalignment switches. The iBelt solution can add significant value, especially on conveyors that are a volumetric bottleneck in the supply chain. The iBelt offers a strong return on investment: after the installation of indurad’s iBelt on a bucket wheel excavator in a Greek lignite mine, operators now can remotely control the productivity of their excavator from a central control room, which has resulted in a 20% increase in the excavator production rate. Another customer in the US is using the iBelt to increase the production rates in their secondary and tertiary crushing circuit, where fluctuating material density was limiting their mass-flow controlled process. With the iBelt, the customer has achieved an estimated 500 tonnes per hour increase in production. Upon customer request, the iBelt solution also offers advanced features. Using the measured cross section, the centre of gravity and the position of the peak load of the material can be determined, which provides guidance for the customer to adjust the material transfer or feed supply to the belt. Based on the alignment measurement, the freeboard between the material on the belt and the belt edges can additionally be detected and monitored. This can help to reduce the unused space on the belt by increasing belt load while monitoring the result on the belt, or to detect a decentralized material flow. All sensors are built with a robust IP67housing and with military-proof cables and connectors. indurad ́s latest generation of iBelts also includes a weatherproof electrical cabinet (IP66) for outdoor use that includes all additional hardware items such as: an induradRadarProcessingUnit (iRPU), a 24V power supply, a fiberoptics-ready ethernet switch, and a remote access unit. iBelt represents a reliable and highly robust step towards the digitalization of mines, sophisticated process control, device optimization, and reduced belt wear. indurad has delivered over 100 iBelts to customers globally, handling typical bulk commodities like iron ore, coal, lignite, copper ore, fertilizers, tar sands or woodchips. indurad sensors operate in the harshest conditions found in heavy industry operations and have been deployed in open pit and underground mines, ports, stockyards, covered stockpiles, domes, and even on offshore vessels.
Please visit Dry Cargo International to read the article.
iBelt installation in underground salt mine in Canada.
Please click here to register.
Date: December 10th, 2020
Time: 3:00 – 3:45 PM CET | 11:00 AM BRT | 5:00 PM MSK | 4:00 PM SAST
Duration: 30 min + 15 min Q&A
For those who register and cannot attend the webinar, a recorded version of the presentation will be available to you to view at your convenience.
This free webinar will provide you with an essential overview of gathering, transmitting, and managing your machine data. Relevant data allows you to provide insight to your analytics and deliver actionable results, improving your business.
• OEE (Overall Equipment Effectiveness) of conveyor belt systems: Optimize your belt loading to increase throughput and help maximize profits
• Increase understanding of material volume to control downstream processes
• Measure material volume flow under harsh conditions
• Identify and eliminate bottlenecks
• Reduce downtime by implementing a contactless and maintenance free solution
• Accurately measure belt alignment and material freeboard to improve belt loading
• Understand the capabilities of well-managed data
• Implement a data-based solution at your operation
We will provide you with an expert view on how to make your business safer and more efficient. We are offering the opportunity to speak with the indurad team after the webinar to discuss each of your unique goals – return on invest is typically less than 1 year.
Who will be speaking?
Speaker is Johannes Hornung, Sales Manager at indurad GmbH. indurad will convey the knowledge of how the iBelt solution solves digitalization challenges being faced by mining operations and heavy industry.
Please click here to register.
Each of the three draw points inside the tunnel has been fitted with a volume scanner, supported by a material speed sensor after the last draw point.
Contact for more information on how our solutions can improve your process.
Here you can learn more about our iBelt solution.