Bogatyr, Kazakhstan's largest open-cast coal mine, has turned to Vollert's technology to automate and speed up its rail loading operations. Vollert has introduced five new tandem shunting robots that are Wi-Fi controlled and capable of pulling trains up to one kilometer long and weighing up to 6,900 tonnes. This innovation ensures 24/7 rail loading on four parallel tracks, significantly increasing the mine's production capacity. The rail loading system began full operation in mid-2023.
To meet the increasing demand for coal, Bogatyr has embarked on a modernization project to raise its annual production capacity from 32 million to 40 million tonnes. Collaborating with ThyssenKrupp, the mine installed an automated coal wagon loading system, which utilizes Vollert's DER 300 shunting robots to move trains efficiently. With a diesel-electric drive, a tractive force of 300 kN, and a service weight of 150 tonnes each, these shunting robots handle the seamless movement of trains, enabling rapid loading.
The extreme environmental conditions of the open-cast mine posed a significant challenge to using the technology. Temperatures ranging from -30°C to +30°C and drastic temperature fluctuations required robust and proven technology. Vollert's shunting robots, equipped with heated components, diesel tanks, automatic couplings, and sanding systems, adapted to harsh climatic conditions and met all scheduled commissioning requirements.
Operating in manual mode with mobile radio remote control, the shunting robots precisely deliver empty freight trains to the loading siding. When they reach the loading building, the loading process is initiated via Wi-Fi. Coal is loaded into the wagons at a continuous rate, completing the process within three hours. Once loaded, the mainline locomotive takes over for transport to the customer, while the shunting robot prepares for the next train, ensuring an uninterrupted loading process.
Vollert's delivery of the tandem shunting robots to the Bogatyr mine covered 6,000 km, involving road, water, and rail transport. The robots travelled from Germany to Kazakhstan on heavy-duty flat-bed trailers carrying the ten tandem parts, weighing 750 tonnes.
