Two months ago Oaky North commenced mining with two 48x152mm armoured face conveyor chain assemblies and flight bar installation provided by Becker Prûnte (KBP) through Australian agent Inbye Mining Services. In that time, Inbye said the chain had continued to perform well at the mine with minimal change in elongation.

Hunter Valley-based Inbye originally signed an agency agreement with KBP in mid-2005. The deal came about after KBP recognised it needed to diversify with a diminishing German coal industry. After first tackling the US and China, KBP wanted representation in the Australian market and approached Inbye.

As a longwall conveyor OEM, Inbye needed a chain package for installation onto its own brand of AFCs and beam stage loaders. It recognised the pedigree of KBP and its large range of mining chain and flight bars – and consequently entered the agreement.

The recent sale to Oaky North came about after KBP’s technical features were proven through trial installations of smaller chain assemblies on the mine's BSL.

The staged trial started with three flight bars, then a short chain and flight section, and eventually a full BSL chain and flight installation. Oaky North has since standardised on the KBP BSL chain arrangement after it was proven to be quieter running and long lasting.

Once the trials were complete, Oaky North went ahead and ordered the 48x52mm AFC chain and flight bar separate from its conveying equipment, making it the first 48mm installation not provided as part of a new equipment package or upgrade from DBT and Joy, Inbye said.

“Like miners elsewhere in the world, Australian customers are starting to break up OEM packages to get the best technical and commercial solution for what is basically wear parts,” the company said.

KBP's 48x152mm chain suits Oaky North's high powered longwall, which produced 4.52 million tonnes in 2006 (mine total = 4.9Mt). The 48x152mm chain suits high powered installations of greater than 2000kW, with capacity exceeding 4000 tonnes per hour.

“Oaky North previously used a 48mm chain having a patented dual pitch configuration, which resulted in them paying a heavy price for flight bars, sprockets and chain,” Inbye said.

“In reverting to the DIN standard 48x152mm configuration from KBP, Oaky North are able to buy chain and flight bars competitively on the open market.”

According to Inbye Mining Services the mine opted for KBP's product in recognition of its "commercial advantages and extended warranties". KBP warranty periods are typically 25–50% longer than competitors, Inbye said, and the warranty starts from underground commissioning.

On larger projects KBP also offers delayed progress payments linked to in-mine performance milestones of the product.

Like many manufacturers using large amounts of steel, KBP has struggled to find raw material to keep up with demand for its products.

“Supply of high quality raw material for chain manufacture is becoming critical for all chain manufacturers, leading to long lead times and increasing prices,” Inbye said.

“Through their direct purchasing arrangements KBP has ability to juggle material to help customers in need of urgent supply; however, mines making routine AFC chain purchases need to allow up to six months lead time from order to site delivery.”

In Australia, KBP products have been installed at Newlands, Oaky North, Crinum, Glennies Creek and West Wallsend.

In recent orders, Beltana has ordered a replacement 42mm AFC chain and Newlands has ordered its fourth KBP BSL chain after an excellent result with previous and current installations, Inbye said.

In China, an Oaky North style chain and flight bar package has been running for some time at a Shenhua mine. Since its first installation, Shenhua has since ordered more than 7000 bars and new 48mm chain to outfit more of its faces.

KBP also has more than 80% of the German domestic flight bar market, including a recent major order for 48mm bars for the DSK group’s DBT AFCs.

In a move to progress its range in Australia, Inbye is about to receive a batch of flight bars to suit the patented DBT dual pitch 48mm chain system, for use in PF5-1142 conveyors.