Complete Reconstruction of Reclaimer А2RsВ12500 at Mini Maritsa Iztok
As part of its investment program, Mini Maritsa Iztok EAD has entrusted Rotek Ltd. with a complete modernization of the control system and operational cabling for reclaimer А2RsВ12500 at the “Troyanovo-North” mine. The project represents a full-scale upgrade, delivering a modern automation solution built on world-class industrial standards.
Turnkey Engineering Project
The scope of the project includes:
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Development of a detailed electrical design;
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Delivery and installation of all control equipment;
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Execution of functional and load tests (including a 72-hour run);
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On-site training and certified center-based technical courses.
Allen-Bradley PLC at the Core
The control system is based entirely on Allen-Bradley programmable logic controllers (PLC), chosen for their:
Robust design suitable for harsh, high-vibration environments; Protection rating up to IP54 and compliance with DIN VDE, IEC, ISO, and SIL standards; Native support for decentralized Fieldbus architecture over ControlNet and Ethernet/IP; Real-time diagnostics, remote access, and HMI integration.
Smart Control of Industrial Power
The new system includes:
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Replacement of thyristor rectifiers and variable frequency drives;
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HMI operator terminals with Bulgarian SCADA interfaces;
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Comprehensive monitoring: temperatures, currents, inclinations, conveyor slippage, etc.
Each drive group is independently monitored, and emergency operation modes are available in case of motor or component failure.
Rotek Ltd. – Trusted Engineering and Delivery Partner
In addition to supplying Allen-Bradley hardware, Rotek Ltd. performs:
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Full system design tailored to site conditions;
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Programming and integration of all software;
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SCADA visualization and commissioning;
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Training of 6 electricians and 3 automation engineers;
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Delivery of complete technical documentation and diagnostics tools.
Safety, Performance, and Reliability
The system offers:
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Emergency and repair operation modes;
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UPS-powered backup for the entire control infrastructure;
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Alarms and system logs saved for over 30 days;
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Compliance with all safety, fire, and vibration protection requirements.
Conclusion
This project showcases how Allen-Bradley’s advanced automation platform, combined with the proven expertise of Rotek Ltd., can transform critical mining infrastructure into a smart, safe, and sustainable system. The А2RsВ12500 reclaimer now stands as an example of world-class automation applied in Bulgarian industry.