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K-UTEC AG Salt Technologies „Cum grano salis sano“ „Salt – vital to your health!“
K-UTEC AG Salt Technologies„Cum grano salis sano“
„Salt – vital to your health!“
Contacts
Executive DirectorDr. Heiner Marx Telefon +49 (0) 36 32.610 100 [email protected]
Executive DirectorDr. Volker Asemann Telefon +49 (0) 36 32.610 101 [email protected]
SecretaryChristiane Lücke Telefon +49 (0) 36 32.610 102 [email protected]
Executive Boardof K-UTEC AGSalt Technologies
Over 50 years of experience with salt …… Does not appear over night. Since the 1950s the mining of potash and rock salt has been researched and developed in Sondershausen in Northern Thuringia. As an integral part of the state owned Potash Company, which had up to 32,000 employees, the Potash Research Institute at the time inherited all associated tasks of development within the former state owned Potash Company of the German Democratic Republic. K-UTEC AG Salt Technologies has continued with this tradition since the reunification of Germany. Privatised since 1992, a public company since 2008, today the business advises, examines, plans and researches for the salt mining and processing industries throughout the whole world, undertaking projects and tasks of every size. We strive to develop a solution for all salts and every type of deposits. We are able to answer any questions that the miners have as well as any procedural, analytical, geotechnical and geophysical questions. This concentration on the salt itself, the year long experiences, many successful projects around the world, but above all the highly qualified employees, have helped to create the current reputation of K-UTEC AG Salt Technologies.
A Treasure trove of experience
Range of services
Process designKnowledge and experience in the areas of process development and process evaluation
Implementation of asset development projects
Special experience with the processing of inorganic salts according to industrial standards
Pilot tests to model all typical potash process steps
Pilot tests on solar evaporation of brine (sea water), water from salt lakes, industrial water
Calculation of evaporation areas and pond designs
Assessment of raw materials and production technologies
Mass balances for complete processes
Block and process flow diagrams (BFD, PFD)
Site plans
Preparation of equipment lists
Regulations on measuring, construction and control technology, infrastructure, health, safety and environmental protection
StudiesProject feasibility evaluations
Comparison between process variants
Scoping studies
Feasibility studies
Estimate of investment and operating costs (CAPEX / OPEX)
Basic engineeringBasic engineering for process plants for the extraction of inorganic salts
Detailed process description for the individual process stages and for all process flows
Selection and calculations for suitable equipment and machinery
Sample planning, instructions on sample preparation, analysis and evaluation
Special rules for turnkey plant assembly
Piping and instrumentation diagram / P&ID
Ansprechpartner
Department of Chemical and Physical EngineeringDipl.-Chem. Stephan KapsTelefon +49 (0) 3632.610 [email protected]
Department ofChemical and PhysicalEngineering
Achieving the best for our customers …… Is always our aim. For us the best means creating conditions which allow the highest possible amount of the desired salt material to be produced in the highest quality, with the lowest manufacturing costs and of course causing the least possible damage to the environment. The department of Chemical and Physical Engineering possesses, with its longstanding expertise and own technological centre, the ideal requirements for the qualified development of complete processing machinery of different mineral salts, oxides and hydroxides, above all potassium and magnesium compounds. However, the business activities reach much further afield.
Process development for the production of fertilisers and industrial saltsRaw materials
Mined rock salts (marine evaporite), industrial salt crystallisation, natural brine, bittern, seawater
Solutions from brine extraction
Suitable waste water, refuse
Products
Potassium chloride and potassium sulphate as fertiliser or industrial salt (sylvite, MOP, KCl99, SOP)
Potassium and magnesium salts
Magnesium compounds (MDH, CCM, DBM)
Sodium chloride, sodium sulphate
Calcium carbonate, calcium sulphate
Aluminium hydroxide, aluminium oxide, alum, aluminate
Boric acid, pentaborate, borax
Lithium salts
Extraction of reusable materials from wasteRecycling process for the recovery of:
Nickel-cobalt mixtures and rare earths from scrap NiMH batteries
Nickel and chromium from hydroxide sludge
Potassium from spent electrolytes in the electrolysis of magnesium
Magnesium dross
Plant design, assistance with construction and commissioningDescription of plant functions, measuring and control functions, and automated processes
Description of machinery and equipment
List of fittings
Preparation of tender documents
Project control / project management
Monitoring of commissioning
Performance tests
Training and instruction for customer staff
Technical equipmentJaw crushers, roll mill, disc mill, impact mill, sieves
Stirring reactors of various sizes with double shells and with different fittings (loop reactors)
Evaporation plant
Vacuum cooling system
Solar pond simulation
Flotation cell
Thickeners, purifying funnel, band filter or centrifuge
Roller compactor, granulating drum, pan granulator, mixer
ESTA (electrostatic separator), magnetic separator
Range of services
National
DEUSA International GmbH
K+S KALI GmbH
EBNER GmbH & Co. KG
ERCOSPLAN Ingenieurbüro Anlagentechnik GmbH
Xstrata Zink GmbH
MSE - Magnesium Solutions Europe GmbH
Maschinenfabrik Köppern GmbH
International
Sinohydro Mining Corp., People’s Republic of China
Sinochem Corp., People’s Republic of China
Archean Chemical Industries Pvt. Ltd., Republic of India
Cementos Pacasmayo, Republic of Peru
Salmueras Sudamericanas S. A., Republic of Peru
Cleveland Potash Ltd., United Kingdom of Great Britain and Northern Ireland
ICL Fertilizers, State of Israel
ICL Fertilizers Iberpotash s.a., Kingdom of Spain
Jacobs Engineering Group Inc., United Kingdom of Great Britain and Northern Ireland
The Bangchak Petroleum Publik Company Ltd., Kingdom of Thailand
ALKIM ALKALI Kimya Anonim Sirketi, Republic of Turkey
Salinen Austria AG, Republic of Austria
Quiborax S.A., Republic of Chile
IMIDRO, Islamic Republic of Iran
NEDMAG Industries, Netherlands
VARTA AG - European Portable Battery Association, Federal Republic of Germany/ Swiss Confederation
TATA - Chemicals Ltd., Republic of India
Multiplex Constructions Pty Ltd., Commonwealth of Australia
Hatch, Canada
Societe Chimique Alkhimia, Republic of Tunisia
Selected Customers
Salt analysis and mineralogySalt analysis
All types of salts and minerals
Salts of natural and industrial origin
Analysis of lyes and concentrated salt solutions
Mineral analysis
Salts of saline origin
Salts from industrial processes
Products from the processing of saline salts
Industrial crystalline waste (e.g. filter dust)
Equipment and methods
ICP-AES, AAS, elemental analyser XRF, XRD
Ion chromatography
Mineralogical analysis with X-ray diffractometer, polarising, phase contrast and stereo microscopes
Environmental and mineral analysisAnalysis of complex matrices and mixtures of substances
Analysis of main components using wet chemical process
Routine trace analysis for inorganic parameters
Routine trace analysis for organic parameters
Equipment and methods
ICP-AES, AAS, ion chromatography, voltammetry, GCMS, GC, HPLC, XRF, XRD
Sampling of solid, liquid and gaseous substances
Testing for heavy metals, sum parameters (TOC, EOX/AOX, COD/BOD, TNb), organic matter (PAC, PCB, VOHC, BTEX, OHC), etc.
Range of services
Contacts
LaboratoryDr. Dipl.-Chem. Oliver Braun Telefon +49 (0) 36 32.610 154 [email protected]
Mineralogy|MicroscopyDr. Dipl.-Krist. Joachim Schaal Telefon +49 (0) 36 32.610 152 [email protected]
Waste Management and BackfillingDipl.-Chem. Dittmar Lack Telefon +49 (0) 36 32.610 142 [email protected]
Department ofChemical and PhysicalAnalytics
We want to know precisely, very precisely …… As only exact knowledge about the materials creates the foundation of well grounded decisions for processes, technology and investment. In the laboratories of K-UTEC AG solid and liquid samples are analysed and evaluated, chemically and mineralogical, for customers from all over the world, specifically for salt chemistry and waste analytics. Also incorporated in this field of work is the analysis of underground gas samples, as well as finding solutions to complex, analytical questions in the area of method development and validation. The reliability of our testing methods is guaranteed by regular audits in accordance with DIN EN ISO 17025.
If technology no longer helps …… Then experience is the only answer. The determination of the actual mineralogical compound of a sample can often only be identified with the help of microscopy, which also supports the X-ray diffraction phase analysis. And with mineral elements of less than 1% a high degree of experience and expert knowledge is just as important.
At K-UTEC we have both.
National
K+S KALI GmbH
Asse-GmbH - Gesellschaft für Betriebsführung
und Schließung der Schachtanlage Asse II
Ercosplan - Group of Companies
UGS - Untergrundspeicher- und Geotechnologiesysteme GmbH
Menteroda Recycling GmbH
BfS - Bundesamt für Strahlenschutz (Federal Office of Radiation Protection)
Research Partners:
AiF e.V. - Arbeitsgemeinschaft industrieller
Forschungsvereinigungen “Otto von Guericke” e.V.
BioPlanta GmbH Leipzig
Local facilities:
Envinronmental Agencies, Sewage treatment plants, etc.
International
Jacobs Engineering Group Inc., United Kingdom of Great Britain and Northern Ireland
Elemental Minerals Ltd., Commonwealth of Australia
Eramet Research, Republic of France
Selected Customers
R&D activitiesSpecialist areas and competencies
Mining: Analysis of gases, lyes, salts and minerals
Experience and expertise in the areas of calculations, evaluation and consulting
Pollutants in the workplace, in the home or in the environment (pesticides, herbicides, insecticides, asbestos, PCB, wood preservative)
Development and validation of methods
Calculation of ionic balances and mineral compositions
DAKKS accreditation
The specialist department for Chemical and Physical Engineering is a test laboratory accredited to DIN EN ISO 17025. A dedicated team of chemists, analysts and mineralogists guarantees a high level of reliability with determining, evaluating and interpreting analytical data.
Officially recognised wastewater testing laboratory pursuant to Art. 8 Regulation of the Free State of Thuringia on Wastewater Self-monitoring (ThürAbwEKVO)
Officially recognised waste and residual waste testing laboratory pursuant to Art. 7 Law of the Free State of Thuringia on Waste and Residual Waste (ThAbfAG) in conjunction with Art. 3 par. 1 Regulation of the Free State of Thuringia on Landfill Self-monitoring (ThürDepEKVO)
Analysis of:
Salts and their lyes Water / wastewater / sludge / sewage sludge / sediments Waste and recycling materials Soil / contaminated soil Gases and air Oils and fuels Building materials and work materials
Range of services
Contact
Disposal and Filling MaterialDipl.-Chem. Dittmar LackTelefon +49 (0) 36 32.610 142Mobil +49 (0) 160.788 25 [email protected]
Department fordisposal and fillingmaterial technology
Suitability testing of industrial waste for backfilling and landfillExpert reports
Mine suitability reports for the recycling of industrial waste as backfill material
Expert evaluation of waste for storage in an underground landfill
Preparation of the necessary documents to apply for approvals for backfill materials pursuant to Art. 4 Health Protection in Mining Regulation (GesBergV)
Consultancy and general services
Advising on mine backfills and underground landfills with regard to the safe recycling and disposal of waste
Long-term proofs of safety for the storage of chemotoxic waste in salt rock
Assessing the nature of the waste
Preparation of safety data sheets, operating instructions
Classification of waste in accordance with the German Regulation on Hazardous Substances (Gefahrstoffverordnung)
Environmental impact assessments
Formulation development for mining mor-tar, backfill and dam construction materialsFormulations for backfilling materials for hydraulic and mechanical processes (hydraulic, pump, drop and big-bag backfilling)
Preparation of processing technology parameters
Proof of the structural suitability of waste and backfill materials
Proof of host rock tolerance
Evaluation and investigation of gas emission performance
Mortar systems based on different saline solutions and binding agents (with a focus on MgO)
Particle-free supersaturated saline solutions and salt hydrate melt as injection media
Dam construction materials with and without expansion properties
Construction materials with deposit character as advance working elements for dam construction sites
Range of services
When a mine’s productive life is at an end …… it is usually a long time before the follow-up work is fully completed. As well as recultivating the areas and slag heaps above ground, and sealing shafts, an important issue is to secure underground cavities to avoid the risk of gradual or sudden subsidence of the surface. In such cases, the cavities are filled with backfill, material either from the mine itself or elsewhere. The Disposal and Backfilling Material Technology department assists the operators of backfill mines or successor companies, and also operators of active mines with backfilling obligations or backfilling operations, to increase the use of deposits with a comprehensive range of services relating to formulation development, testing the minability of waste material, process development of backfilling material.
Special problems call for individual solutions.In particular, this applies to mining in saline horizons. Standard construction materials, for example based on cement or gypsum, fall down here because of their limited or total lack of stability under a very wide range of saline conditions. In addition, the construction materials used must be compatible with the mineral salt outcrops and should not damage the latter during installation or in their hardened state The Construction Materials unit within the specialist department for Disposal and Filling Material Technology develops and supplies special construction materials for civil engineering applications and solution mining in line with the requirements of the disposal site concerned for dam constructions, flow barriers, shaft seals, injection work, temporary or permanent sealing of bore holes, and other construction and protective measures.
National
DMT GmbH & Co. KG
GTS Grube Teutschenthal Sicherungs GmbH & Co. KG
GSES - Glückauf Sondershausen Entwicklungs- und Sicherungsgesellschaft mbH
IBeWa - Ingenieurgesellschaft für Bergbau, Wasser- und Deponietechnik Wilsnack& Partner
IfG - Institut für Gebirgsmechanik GmbH
K+S Entsorgung GmbH
MINERALplus GmbH
Minex GmbH
MMG Mitteldeutsche MONTAN GmbH
NDH Entsorgungsbetreibergesellschaft mbH
Styromagnesit Steirische Magnesitindustrie GmbH
Wacker Chemie AG Salzbergwerk Stetten
Bauhaus-University Weimar
Brandenburg University of Technology Cottbus
University of Applied Sciences Nordhausen
Ruhr University of Bochum
Freiburg University of Mining and Technology
Clausthal University of Technology
University of Leipzig
MUEG - Mitteldeutsche Umwelt- und Entsorgung GmbH
Zimmermann Sonderabfallentsorgung und Verwertung GmbH & Co. KG
International
Akzo Nobel Industrial Chemicals B.V., Netherlands
Cleveland Potash Ltd., United Kingdom of Great Britain and Northern Ireland
Sinohydro Mining Corp., Democratic People’s Republic of Laos
CIMM Chilean Research Center for Mining and Metallurgy, Republic of Chile
Selected Customers
Process development and plant designRecycling of waste material, either from the mine itself or elsewhere, in mines and caverns (hydraulic and pump backfill), as well as waste in drop and big-bag backfilling
Manufacture of backfill products and granulated and compacted backfill materials
Basic engineering
Preparation of application documents for environmental approval process
Support with environmental approval process
Technological assistance with the commissioning of backfilling plants
Concepts for erecting sealing structures in the saline formation
Planning, support and monitoring of dam structures
Backfill and construction material testing laboratoryFocus areas of testing
Particle size distribution using sieving, laser particle analysis and photo-optical particle analysis
True, gross, bulk and tapped density, density of liquids, Proctor density
Pressure and tensile strength testing
Measurement of elasticity modulus
Pressure compaction behaviour (accelerated and extended time tests)
Oedometric test, setting behaviour, swelling and shrinkage behaviour
Rheological measurements (viscosity, flow characteristics)
Measurements on the pump test rig (pipe viscometers)
Determination of gas emissions (quality, quantity)
Thermal analysis (DTG, DSC)
Climatic tests
Abrasion measurements on granulates
Static strength of individual grains
Range of services
Investigation and project evaluationExploration
Planning of exploratory measures
Geological and hydrogeological tests
Feasibility studies
Geological modelling and reserve estimates
CAPEX/OPEX cost estimates for underground and solution mining, and processing of rock salt
Environmental impact assessments
Project evaluations
Technical and economic assessments for greenfield and brownfield projects
Risk assessments
Profitability studies
Mine planning and consultingMine planning
Planning for underground and solution mining
Extraction planning and dimensioning
Planning of backfill measures
Planning the recycling of mine waste and industrial waste (underground backfill)
Planning of backfill and pillar deconstruction measures
Planning of underground landfills
Consulting
Geotechnical monitoring and support
Geological investigation and analysis
Geomechanical expert reports, verification of stability
Evidence protection process
Backfill evaluation for underground backfills and underground landfills
Concept and implementation planning for sealing structures in shafts and drifts
Risk assessments for montane gases and influent solutions
Range of services
Contacts
Geotechnics/GeomechanicsDr.-Ing. Axel StäubertTelefon +49 (0) 36 32.610 [email protected]
International MiningDr.-Ing. Thomas FlißTelefon +49 (0) 36 32.610 [email protected]
GeologyDipl.-Geol. Anne Allendorf-SchichtTelefon +49 (0) 36 32.610 [email protected]
Department ofGeomechanics and Mining
“Better safe than sorry”This proverb has a very special relevance in the field of mining. The risks to miners from the surrounding rock mass, and also the risks for investments in mine workings and equipment, are often serious and difficult to foresee. The field of geomechanics creates a basis for determining the geomechanical status of mine workings. Complex status analyses for the rock are prepared and continually updated, based on data derived from technical measurements (e.g. rock stresses, lateral strains on pillars, seismic monitoring, backfill quality tests, etc.) and incorporating customer data (e.g. occurrences of surface subsidence, geological fissures, etc.). In addition, answers are also found to unique issues relating to rock mechanics in the saline formation.
Like a Swiss army knifeThe Mining department has just about as many functions and applications as a Swiss army knife: there are many different tasks and projects extending to the four corners of the globe: deposit modelling, mine planning steps for underground extraction operations or for solution mining, maintenance concepts for abandoned mines, including securing of abandoned shafts, technical feasibility studies with varying degrees of detail, with CAPEX/OPEX cost calculations, production of customised measurement technology for solution mining, geological mapping, and much more besides.
National
Wacker Chemie AG Salzbergwerk Stetten
SWS - Südwestdeutsche Salzwerke AG
NDH Entsorgungsbetreibergesellschaft mbH
GSES - Glückauf Sondershausen Entwicklungs- und Sicherungsgesellschaft mbH
BfS - Bundesamt für Strahlenschutz (Federal Office of Radiation Protection)
DBE - Deutsche Gesellschaft zum Bau und Betrieb von Endlagern für Abfallstoffe mbH
GVV - Gesellschaft zur Verwahrung und Verwertung von stillgelegten Bergwerksbetrieben mbH
TLBA - Thüringer Landesbergamt
(State Mining Office of Thuringia)
PtJ - Projektträger Jülich / Forschungszentrum Jülich GmbH
KIT - Karlsruher Institut für Technologie
(Karlsruhe Institute of Technology)
IfG - Institut für Gebirgsmechanik GmbH
Technische Universität Bergakademie Freiberg
(TU Bergakademie Freiberg)
International
Akzo Nobel Industrials Chemicals B.V., Netherlands
The Bangchak Petroleum Plc. Ltd., Kingdom of Thailand
Cleveland Potash Ltd., United Kingdom of Great Britain and Northern Ireland
Sinochem Corp., People’s Republic of China
Sinohydro Mining Corp., Democratic People’s Republic of Laos
SIMBALIK Group InversionsLimitada, Republic of Chile
CementosPacasmayo S.A.A, Republic of Peru
North American Salt Company, United States of America
Monitoring, safekeeping and renaturationMonitoring
Planning, construction, installation and support with geotechnical and hydrological measuring systems
Fluid and solid content in shafts
Solution content and density measurements in flooded mines
Inflow monitoring equipment
Planning, construction, installation and supervision of seismic monitoring equipment and systems for flood monitoring and cavity surveillance
Maintenance
Planning for post-operational phases
Maintenance concepts, subsequent usage options, risk assessments and valuations
Planning and implementation of investigation measures in shafts (drilling investigation and on-site exploration) and in abandoned mines
Stability estimates and risk assessments for abandoned mines, solution inflows and gas inlets
Concept and implementation planning for shaft and mine maintenance, including construction support and supervision
Renaturation
Planning of renaturation of mine locations and slag heap recultivation
Rehabilitation of disused mines
Range of services Selected Customers
Geophysical explorationMethods
Geoelectric sounding, mapping, 2D/3D tomography
Surface and bore hole radar
Seismic reflection and refraction, surface wave seismology
Bore hole seismology, VSP measurements
Seismic and electromagnetic tomography
Sonar investigation
Measurements of bore hole deviation
Camera inspections
Gravimetry, magnetics and VLF measurements
Application
Cavity investigation
Deposit exploration
Hydrogeological and geohydraulic investigation
Investigation of layer boundaries and geological structures
Preliminary survey of the route
Locating pipes and cables
Seismological monitoringConception, development and surveillance of seismic monitoring equipment and measures
Operation of seismic monitoring systems
Long-term monitoring of parameters
Localisation of seismic activity and qualification of seismic events (determination of the strength/magnitude, epicentre, etc.)
Interpretation based on the geological and local characteristics
Issue of alerts in accordance with specific customer guidelines
Combination of seismic monitoring equipment and shock measuring points according to DIN 4150
Range of services
Contacts
Geophysical MonitoringDipl.-Geophys. Astrid GessertTelefon +49 (0) 36 32.610 [email protected]
Geophysical InvestigationDipl.-Geophys. Thomas SchichtTelefon +49 (0) 36 32.610 [email protected]
Department ofGeophysics
And yet it moves!This apocryphal remark by Galileo also applies to what is beneath the earth: to the many small and medium movements within mine workings, which characterise the additional geomechanical dynamics of horizons that are used for mining. It is the job of the Geophysics specialist department to record and localise these movements, calculate their epicentre and magnitude, and finally to draw the right conclusions from them. The department’s tasks include the development of hardware and software, conception and plant engineering, erection and operation of facilities on behalf of the customer, including daily evaluation and alerts, along with seismic measurements. Customers who require stationary or temporary seismic monitoring equipment include mine operators, cavern operators, geothermal power plants, abandoned mines, etc.
Making visible what was previously invisible …… is the ambitious aim of our experts in the field of geophysical exploration. A wide range of geophysical measuring methods, the latest technology, decades of expertise, particularly in the fields of potash and salt mining – from these components, we produce the data that the customer requires concerning deposits, subsoil, dikes, open pit dumps, etc., which then serve as a basis for making decisions about additional measures. We make visible what was previously invisible, whether it is above ground on saline deposits, or by investigating cavities close to the surface, conducting close inspections underground in the bore hole, or calculating stratigraphic horizons using seismic, geoelectric or radar-assisted methods.
National
GVV - Gesellschaft zur Verwahrung und Verwertung von stillgelegten Bergwerksbetrieben mbH
LMBV - Lausitzer und Mitteldeutsche Bergbauverwaltungsgesellschaft mbH
NDH-E - NDH Entsorgungsbetreibergesellschaft mbH
Helmholtz Association of National Research Centres, Karlsruhe Research Centre
Rheinkalk GmbH - Lhoist Group
BfS - Bundesamt für Strahlenschutz (Federal Office of Radiation Protection)
DBE - Deutsche Gesellschaft zum Bau und Betrieb von Endlagern für Abfallstoffe mbH
GSES - Glückauf Sondershausen Entwicklungs- und Sicherungsgesellschaft mbH
K+S AG
esco - european salt company GmbH & Co. KG
International
ICL Fertilizers Europe, United Kingdom of Great Britain and Northern Ireland
CementosPacasmayo S.A.A, Republic of Peru
SALSUD - SalmuerasSudamericanas, Republic of Peru
North American Salt Company, United States of America
Kopalnia Soli Klodawa S.A., Republic of Poland
Selected Customers
Shock measuring pointsIndividual measuring points for mobile or permanent monitoring
Combination of measuring points to monitor large areas
Application in mines, quarries
Application in the field of oil and gas production
Application to monitor gas storage facilities
Construction site monitoring/documentation
Monitoring/documentation of blasting operations
Monitoring of shock-sensitive machinery and equipment
Certification and qualificationA team composed of qualified geophysicists and experienced engineers guarantees the efficient execution of projects, from preparation of the concept and planning, through to implementation.
The specialist department for Geophysics is
certified to DIN EN ISO 9001:2008
Registered quality geophysics company according to the Professional Association of German Geoscientists (BDG)
Officially registered pursuant to Art. 26 Federal Pollution Control Law (BImSchG) for the performance of shock measurements
Range of services
K-UTEC AG Salt TechnologiesAm Petersenschacht 7 | D-99706 SondershausenPhone +49 (0) 36 32.61 00 | Fax +49 (0) 36 32.61 01 05E-Mail [email protected] | Web www.kutec.de
