Partner to the Mining Industry

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50 years of success in automation

For more than 50 years, Festo has been the brand name for automation technology and partner to numerous industry sectors. This forms the solid base on which our range of products for the process industry is built. Over 18,700 employees across the globe contribute to our substantial progress in factory and process automation, as well as in basic and advanced training in industry.

Whether you run a mining oper-ation or manufacture machines and systems for mines any-where in the world, Festo staff in 61 national companies at 250 locations in more than 176 countries can offer local support and expert, specialist advice. This guarantees optimum support during engi-neering, planning, operation and service.

Innovation is Festo’s top priority.That is why we invest 7.5% ofour turnover in research anddevelopment. With a single goalin mind: ensuring your success.

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Contents Page

Energetic minerals 4

Metallic minerals 6

Industrial minerals 8

Construction minerals 10

Extremely efficient cost structures 12

Perfect engineering 13

Procurement services 14

Installation and commissioning 15

After sales 16

World market leader in basic and advanced technical training 17

Automation concepts 18

Product overview 19

Maximum efficiency throughautomation At a time when energy costs are rising and environmentalawareness is heightened, thecoal mining industry is underimmense pressure. Coalprocessing plants must beextremely efficient in order to be able to compete withrenewable energies.

Maximum system availability istherefore an absolute must formining and processing energyminerals. Unexpected down-time, which causes high costsand losses, must be kept to aminimum. This can be achievedwith automation technology andcomponents with diagnosticcapabilities.

devices. It transmits this data to the controllers via fieldbussystems. Its modularity enablesa variety of combinations thatcan be perfectly adapted to individual processes such aswashing, crushing andscreening.

An example of this type ofcomponent is the valve terminalCPX/VTSA. Integrated diag-nostic functionalities enable theuser to retrieve valuable infor-mation about the status of thevalves. In coal preparationplants (CPP), a valve terminalcontrols all the process valvesand collects data from the field

Energetic minerals

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Control cabinet with coolingfunctionalities Reliable, even in extreme heatand harsh ambient conditions:this control cabinet with inte-grated valve terminal CPX/VTSAeffortlessly controls numerousprocess valves in a coal prepara-

tion plant (CPP) in Australia. A special ventilation system for the control cabinet ensures that heat accumulation inside the control cabinet is prevented, even in the high temperatures experienced in South Africa.

Standards-based valve terminalVTSA – maximum pneumaticfunctionality up to ISO size 2(52 mm)Ideal for maximum pneumaticand electrical function integra-tion. The possibility of mixingfour valve sizes on one valveterminal without any adapterplates is totally unique. It is

highly integratable and 100%compliant with ISO 15407-2 and ISO 5599-2. Suitable foruniversal use, including as flowrate-optimised VTSA-F for up to3,000 l/min. Hot swapping ofvalves, pressure zones, diagnos-tics and use in safety zones isalso possible.

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Metallic minerals

Overcoming extremely difficultconditions with automation Products used to extract metalores and process them intometal concentrates are subjectto extraordinarily difficult condi-tions. Particulate matter andaggressive acids form corrosiveand highly abrasive slurry, whichmeans products have to beextremely robust and reliable.

Festo’s products are thereforedesigned for resistance againstaggressive media such as acidsand alkalis. They are alsoprotected against the ingress of moisture and particles suchas dust, for example. The resultis increased reliability in thefield.

Protection to IP65 and IP66 isstandard. Products developedspecifically for mining complywith even higher protectionclasses.

Special materials, such as highalloy stainless steel or corro-sion-proof coatings, permit

use under almost all ambientconditions. The portfolio iscompleted by control cabinetsand fittings made from stainlesssteel, tubing made from tetra -fluoroethylene and special sealand scrapper materials for thedrives.

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Proportional cylinder DFPI in flotation cells To adjust the level of metal concentrate in a flotation cell the company Minera Milpo used the first series-produced DFPI in El Porvenir in the highlands of Peru. Today, the DFPI is found inmany well-known mines around the world, for example in copper

mines in Chile, silver mines in Peru and Mexico as well as gold mines in Argentina. More than 600 DFPI units have been installed in over 300 flotation cells throughout all 6 continents over the past 5 years. The proportional drive DFPI is one of Festo’s key products for mining.

DFPI – linear drive with integrated positionerAvailable in IP65, IP67, and IP69K protection thanks to its high level of integration. This makes the product virtually mainte-nance-free, even under the extremely difficult conditions associated with processing metallic minerals.

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Industrial minerals

Robust automation – worldwide Unlike metals and coal, indus-trial minerals are found almosteverywhere. That is why somany countries around theglobe process at least oneindustrial mineral, be it salt,potassium, lithium, phosphoror diamonds.

The worldwide distribution ofthese minerals calls for globallyactive companies and appro-priate extraction structures.Festo’s worldwide presence, on-site support and service make it an ideal automation partner.And its high product and servicequality as well as standardisedroutines that are easy to learnare a decisive advantage.

Processing industrial mineralsvery often produces corrosivesalts that demand robust andreliable products. Special mate-rials or coatings are essentialwhen designing individualautomation components, whileextremely abrasive media alsorequire special process valves.

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Quarter-turn actuators forprocessing lithium and magnesium Sociedad Chilena de Litio usesquarter-turn actuators fromFesto for processing lithium and magnesium in its plant inAntofagasta, Chile. Special coatings for the actuators and

special materials for the processvalves ensure system reliabilityand continuous production. Special process valves, actuatedwith pneumatic actuators, arethe right choice in most casesfor the highly abrasive mediainherent in extracting andprocessing industrial minerals.

Quarter-turn actuator DFPB –sturdy and flexible The sturdy quarter-turn actuatorDFPB with standardised inter-faces can be flexibly mountedon a wide range of processvalves. The direct connection ofsensor boxes type SRBP makesfor a user-friendly and extremelysturdy unit that can easily with-stand even dirty environments.

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Construction minerals

Managing changing situationswith modular automationThe building industry is veryclosely linked to the globaleconomy. A strong economymeans a lot of constructionactivity, which in turn creates ademand for cement, sand andother construction materials.During periods of slow growth,production is cut back and as a result demand for materialsalso drops.

These fluctuations in demandtogether with rising energycosts and worldwide competi-tion are the three reasons why it is so crucial to be able to

adapt systems for extractingand refining constructionminerals to the market situation.

Modular products that can beextended, adapted and opti-mised as needed are the idealsolution. Valve terminals fromFesto are the right product forthis market because both theirelectric and pneumatic parts are modular.

Products from Festo defy dustand heatThe atmosphere at many extrac-tion sites is saturated withextremely fine dust that impairsthe quality of the pilot air for

the drives and solenoid valvesand could therefore damagethese components. This is not a problem for our wide range of compressed air preparationdevices; with these devices, thepilot air is always clean and dry.

Festo also provides productsand solutions for applications

involving high ambient tem-peratures as, for example, in the vicinity of rotary kilnsused to manufacture cement. Examples of these includequarter-turn actuators and cylinders with special sealingmaterials designed for ambient temperatures of up to 140 °C.

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Perfect tension at the V-beltThe fluidic muscle ensures theideal V-belt tension in cementand concrete factories. Thanksto its closed system and self-cleaning function it is perfect forextremely dusty atmospheres,sometimes even with self-hard-ening slurry. Its pressure isproportional to the stroke and

is thus the best solution for this requirement.

Fluidic muscle MAS – sturdy,powerful and stick-slip freeWhether with screwed or press-fitted connection, the sturdystructure and hermeticallysealed design make the fluidicmuscle ideal for applications in

dusty and dirty environments. It has up to 10 times the initialforce of a conventional cylinderand stick-slip-free movements,even at extremely slow speeds.Diameters 10, 20 and 40 mm;nominal length 30 ... 9,000 mm; force 480 ... 6,000 N.

Reducing the total cost ofownership (TCO) throughtargeted use of Festo services

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Extremely efficient the cost structures

This efficiency is achieved byreducing your total cost ofownership (TCO).

Festo’s product and servicephilosophy is based on continu-ously analysing the valuecreation chain of a wide range of customers. Festo uses everypossible tool to design servicesspecifically for each link in the

chain. It is this win/win coopera-tion that results in a reduction ofyour Total Cost of Ownership.

One-stop shopping: fromcomponents to complexsystemsEverything from a single source.Innovative technology, such ascontrol and fieldbus systems,pneumatic or electric drives,

standard or customised products, ready-to-install orpre-assembled solutions, and modular designs offermaximum flexibility. Combinedwith market leading services,such as our comprehensiveproject support, this ensuresyou will achieve maximumproductivity – quickly and reliably.

E.g. Energy Saving Service: savings of up to 35%

E.g. ready-to-install pneumatics:savings of up to 50%

Potential savings

Cost

s

Engineering OperationProcurement AssemblyProject phases

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Perfect engineering: the basis for highly efficient systems

Production and processingsystems in mining plants areamong the biggest in the in-dustry and never stop. They consist of several con-nected, continuous processes.The huge size of the plantsdemands that they be brokendown into subprocesses or

product groups during planning.As a result, planning and engi-neering offices always work inclose cooperation.

Products and services fromFesto lighten their workload.They simplify the selection ofthe components, guarantee

their compatibility and speed up the documentation of theplants. If necessary, our engi-neers will work together withthe planners to work out theideal automation concept.

The services for faster andsimpler engineering range from:• 2D drawings and 3D models

comprising more than 20,000 components in 80 CAD

formats, directly transferablefree of charge

• FluidDRAW® for generatingpneumatic circuit diagrams on a PC without CAD

• ProPneu for simulating,selecting and configuringpneumatic drive systems

• Tubing selection program formaximum process reliabilityand productivity

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Procurement services: always tailored to your supply chain

In the mining industry, purchas -ing is usually done centrally at a company’s headquarters.Delivery, on the other hand, isdirectly to the mines, often invery remote locations. Knowingthat the right product will bedelivered in the right quantity tothe right place is therefore animportant criterion when select -

ing suppliers in the miningindustry. This is because theonly way to reduce expensivedowntimes and thereforeincrease productivity is withquick delivery directly to themines. Festo’s services forprocurement and logistics are perfectly tailored to this situation:

• Festo online shop• E-procurement• 24-hour delivery service• Express service• Customised build-up of stock• On-site delivery on request• Special manufacturing

service (SMS)• Customised packaging

systems, contracts and part numbers

On-site services for mines –

Festo has the rightequipment.

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Service packages for getting started – installation and commissioning

The installation and commis-sioning of plants signals the end of years of cost-intensivestudies and complicated engi-neering. Festo reduces theseexpensive and unproductivelead times. After all, the fasteryour plant is installed andcommissioned, the faster extrac-tion can begin and the quickeryou can get a return on invest-ment (ROI).

• Festo easy assembly service:from delivery of individualcomponents to pre-assemblyservice and turnkey pneu-matics

• Local support during commissioning

• Programming

Smooth commissioningguaranteed: installationservice by experiencedengineers from Festo

• Setup of the components and subsystems

• Integration technology• Special designs: close-to-

standard or individual• Specific training for specialists

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After sales: designing more effective processes for the long-term

Everything from a single sourceand perfectly harmonised prod-ucts and services from Festo.Take, for example, the compactflow sensors that support theEnergy Saving Services andimmediately indicate leaks orfailures. This combination ofproduct and service helps toreduce energy consumption.

Another way of identifying andimplementing savings potentialquickly and cost-effectively iswith compressed air consump-tion analyses. There is no easierway of achieving immediate andlasting cost reductions.

Our portfolio of services for themining industry includes:• Maintenance contracts for

maximum availability of pneu-matic installations

• Energy Saving Services• Compressed air consumption

analysis• Compressed air quality

analysis

• On-site consultation by Festotechnical consultants

• Spare parts and repair service• Help and hotline• Diagnostics-capable compo-

nents to support maintenanceand repairs

• Total productive maintenancesupport

Reducing energyconsumption andextending the servicelife of the productsthanks tocompressed airquality and consump-tion analysis

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Didactic: world market leader in basic and advanced technical training

Successful training throughpractical experience of processautomation is possible withindustry-oriented modelsystems. “Learning by doing”

and “process orientation” arethe best ways of teaching thedifferent critical topics ofprocess engineering. Simulatinga process engineering system

on a PC provides an opportunityto use a simulation as an actualtraining system. The processcontrol system is based on thesuccessful concept of replica-tion and simulation:• Modular station structure• With industrial components

and standards• Open interfaces

• Individually configurable and extendable

• For all types and levels ofqualification

• Stimulating project and team work

This system offers an effectivelearning environment for:• Electronic engineers,

process control engineers,

mechatronics engineers,microtechnologists

• Procedural technicians forplastic and rubber technology,glass technology and coatingtechnology

• Experts in food technology,confectionery and fruit juicetechnology

• Chemical laboratory assist-ants, chemical engineers,pharmaceutical engineers

• Experts in water supply,sewage technology, pipe,canal and industrial services

• Biological laboratory techni-cians, biotechnicians

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CPX-FEC

Stand Alone

Remote Controller Fieldbus

HMI

FED

CPX-FEC CPX-FECCPX-FB

PLC-Fieldbus

HMI-Ethernet/WebPLC-Ethernet

PC 1 PC 2

CPX-FB

PC

1

2 2 2

3

3.1

44.1

5

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3.2Notebook

Automation concepts in themining industryWith more than 30,000 cata-logue products the rightautomation concept can alwaysbe found for every applicationwithin the mining industry.An extremely wide range ofstandard solutions and manycustomised solutions coveringevery level of automationensure smooth system opera-tion in the mining industry.

Levels and depth of diagnosticsin the automation pyramid

6 Remote maintenance,remote diagnostics

5 Control system and visualisationCompressed I/O and diagnostic informationProcess visualisation

4 PLC levelCommunication, status anddiagnostic information fromseveral thousand I/Os

4.1 Visualisationby means of programming

3 Field device level64 to 512 l/Os per device

3.1 Handheld terminalDiagnostics in plain text,without any programming

3.2 CPX maintenance toolLocal diagnostics and parameterisation viaEthernet

2 Module levelDigital: 4, 8, 16 channelsAnalogue: 2, 4 channels

1 Sensor/actuator level1 sensor = 1 channel,1 valve/actuator = 1 channel

On-off valves Control valves Individual valves and sensors

Axis

Cylinder

Positioner

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Products for the miningindustry In this section Festo’s productportfolio for the mining industryis described in more detail.It covers the entire controlsequence and virtually everyprocess and requirement,whether for sturdy, resilient,stable, reliable, explosion andoverload proof or corrosion-resistant products.

Products for the Mining Industry

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Get in touch

Festo (Pty) Ltd.SA Head office 18-26 Electron Avenue, Isando,Johannesburg,South Africa, 1600(Branches nationwide)

Tel: Fax E-mail

08600 FESTO (33786) 08794 FESTO sales.za@festo.com

www.festo.co.za