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VOLUME 27, ISSUE 1 | JANUARY/FEBRUARY 2022
In this issue: Keeping belts clean Bulk handling ports Packaging systems
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Oli Vibrators .....................................................................23
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CONTENTS JANUARY/FEBRUARY 2022
20
28
31
54
6 Industry news
30 Reaping the benefits
18 Busting automation myths
34 Bulk packaging sorted with Oli Vibrators
20 indurad sees iBelt radar solution
44 BULKtalk: Finding the right solutions
22 What goes into making a fan?
48 Dry bulk trade and the importance of bulk solids handling in ports
24 Managing all the risks 26 Transmin and Thermo Fisher Scientific still going strong
BELT CLEANERS 36 Expanding horizons for TS Global 38 Kinder Australia’s finger on the pulse 40 Brushing up on belt cleaners
54 Bridge and culvert inspection requirements for mines and ports 58 Member Profile: Stephan Hötte
28 Humanitarian food relief increased more than sevenfold with bulk handling system
BUSTING MYTHS ABOUT AUTOMATION When it comes to new technologies, early adopters will often face higher risks, as bugs, glitches and inexperience can disrupt the previous way of doing things. These risks are not without rewards. Braden Goddin, Sales and Marketing Manager at Aurora Process Solutions, says that while robotics may sound futuristic, the first movers are already well-established automators.
For the full story, see page 18.
Australian Bulk Handling Review: January/February 2022 І 3
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AUSTRALIA
EDITORIAL
AUSTRALIA
REVIEW
Published by:
REVIEW
Keeping conveyors clean 11-15 Buckhurst St South Melbourne VIC 3205 T: 03 9690 8766 www.primecreativemedia.com.au Publisher Christine Clancy E: christine.clancy@primecreative.com.au Editor William Arnott E: william.arnott@primecreative.com.au Business Development Manager Rob O’Bryan E: rob.obryan@primecreative.com.au Client Success Manager Janine Clements E: janine.clements@primecreative.com.au Design Production Manager Michelle Weston E: michelle.weston@primecreative.com.au Art Director Blake Storey Design Kerry Pert, Aisling McComiskey Subscriptions T: 03 9690 8766 E: subscriptions@primecreative.com.au
www.bulkhandlingreview.com The Publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from the advertisers and contributors against damages or liabilities that may arise from material published. © Copyright – No part of this publication may be reproduced, stored in a retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.
4 І Australian Bulk Handling Review: January/February 2022
As with most things, machinery will begin to break down over time – especially in the tough conditions that bulk handling equipment often finds itself in. There are, however, plenty of ways to slow this process, such as using wear pads for brakes, or using high quality materials, but, eventually, things will degrade. Over time, this can lead to serious problems. When a component breaks or fails in unexpected ways, it can lead to further unforeseen and often expensive consequences. Proper maintenance is an important part of the industry for this reason, as it allows the site to spot potential problems early and fix them before they can snowball. In this edition, Steve Davis, Senior Bulk Handling Expert at Advisian, explains how to spot these issues early in his BULKtalk column, discussing the first steps that are often taken to solve these problems. Keeping components clean is also a key part in ensuring a system remains operating as it should. A diverse range of cleaners have been developed to keep up with the unique needs of countless conveyor combinations. DYNA Engineering’s Managing Director, Thomas Greaves, explains some of the benefits of brush cleaners – a specialised cleaning device that uses large bristles to sweep the surface of a belt to remove excess carryback. In addition, Kinder Australia has recently launched its novel belt cleaner for cleated conveyors, which uses a finger-shaped design to reach into the spots that more conventional cleaners have trouble getting. With such harsh conditions at Australian mines, cleaners often need to be built tough to survive. Graham Holford, Director at TS Global, tells ABHR about the company’s new designs that can survive these conditions while improving the manual handling aspects. In the next edition of the magazine, we will be featuring articles about belts, rollers, and automation. If you would like to get involved, please get in touch.
William Arnott Editor - ABHR
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ACROSS 121 COUNTRIES OVER 10,000 SILOS 25 MILLION M/T CAPACITY Contact APAC@aggrowth.com
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NEWS
Land purchased for $300M alumina plant construction
Alpha HPA’s project will support around 120 new, regional jobs.
MINERALS COMPANY ALPHA HPA plans to build a $300 million high purity alumina industrial plant on a recently purchased, 9.2-hectare site in the Queensland Government’s State Development Area. Queensland Premier Annastacia Palaszczuk says supporting more jobs in more industries was an important part of Queensland’s plan for economic recovery. “Supporting projects like this means more opportunities for secure, high-skilled jobs across Queensland,” she says. Regional Development and Manufacturing Minister Glenn Butcher says the extensive infrastructure and port facilities in the Gladstone region, an established industrial sector and
skilled workforce all helped attract Alpha HPA to the Gladstone. “Gladstone is a world-best location for existing industries with a proven track record of growing successful new industries – like the emerging green energy manufacturing sector,” he says. “Alpha HPA are joining other global companies, who have also recently chosen Gladstone to establish their manufacturing hubs and create local jobs.” Deputy Premier and State Development Minister Steven Miles says Gladstone is fast becoming a world-leading manufacturing hub drawing on the world’s demand for renewable energy to inspire new industry growth. “Alpha HPA’s project will support
6 І Australian Bulk Handling Review: January/February 2022
around 120 new, regional jobs in a new emerging industry with global demand,” Miles says. “High purity alumina is used in items such as LED lights, lithiumion batteries for electric vehicles, solar battery storage and consumer electronics, and synthetic sapphire which is used in watches and smartphone camera glass. “These are high-technology items with rising consumer demand, particularly in China and Europe. Energy, Renewables and Hydrogen Minister Mick de Brenni says these opportunities were a result of the Palaszczuk Government’s investment in making sure the world knows Queensland is the place to be for renewable energy and decarbonising industry. “Renewables are a massive opportunity to decarbonise industry and bring manufacturing back to Queensland,” de Brenni says. “Queenslanders know how to build a new industry from the ground up and nowhere more so than in Gladstone. “We are making sure we are grabbing this opportunity with both hands and creating these decent, secure jobs for Queenslanders.” Rimas Kairaitis from Alpha HPA says it’s an exciting time for the Australian Company as it fast tracks construction of its Stage 1, Precursor Production Facility (PPF). “We’ve operated a Brisbane demonstration plant since July 2019, and we are confident in the demand for high purity alumina,” Kairaitis says. “Stage 1, which is fully funded, will enable us to commence commercial production from August 2022, tapping into this demand quickly. “Stage 2, the full scale project, will commence in parallel with Stage 1, and is scheduled to be commercially operating by 2024”.
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NEWS
Mount Isa mine to be powered by solar The project aims to boost employment and the local economy, with a goal of hiring employing around 300 people during peak construction.
A NEW SOLAR FARM WILL POWER Mount Isa’s North West Minerals Province under a two staged plan with an initial investment of more than $80 million. APA has announced it will commence building the 44 megawatt stage one of the Mica Creek Solar Farm. Deputy Premier and State Development Minister Steven Miles says the project is an excellent example of the demand for renewable energy, from all sectors of business and industry. “The North West region is a significant part of Queensland’s resource-based economy and, with its endowment of new economy minerals, will play an important part in helping propel the boom in emerging technologies,” Miles says. “A mining customer of APA were seeking a renewable energy solution
as they move to reduce their reliance on gas and transform their business to meet greenhouse gas reduction goals. “This has led APA to a long term lease for 198 hectares of industrial land from the Queensland Government to develop a solar farm, with Stage 1 capacity of 44 megawatts and Stage 2 Capacity of an additional 44 megawatts, taking both stages to 88 megawatts.” The project also aims to boost employment and the local economy, with a goal of hiring employing around 300 people during peak construction, with an ongoing workforce of one to five people. APA CEO and Managing Director Rob Wheals says APA was pleased to have signed a 32-year lease with the Queensland Government for the Mica Creek site. “APA has been working with Economic Development Queensland in
8 І Australian Bulk Handling Review: January/February 2022
relation to a lease to support the solar farm, and are very pleased to work with the Queensland Government to continue our strong relationship and support the ongoing development of the North West Minerals Province,” Wheals says. “The site is perfect because it is adjacent to APA’s existing gas and power generation assets, which delivers reliable and affordable power to the region. “APA has proudly invested more than $1 billion in energy assets in the North West Minerals Province, underscoring our commitment to delivering safe, reliable and affordable energy security to the region.” The first stage of the solar farm is expected to be operational by the first quarter of CY2023, while APA is in advanced discussions with several customers to commit to the development of stage two.
NEWS
Oliver Rubber’s OM-2000 cement has arrived in Australia OLIVER RUBBER INDUSTRIES, A major manufacturer of conveyor belt vulcanising, splicing and maintenance products, has begun exporting its Cold Vulcanising Glue OM-2000 Rubber Cement to Australia. The rubber cement is used in some of the most demanding mining environments to help maintain rubber conveyor belts to improve cost effectiveness, reduce shutdown times and avoid breakdowns. The product is mainly use for cold and hot vulcanising methods.
The rubber cement has an unlimited shelf life, is nonflammable and carries a 100 per cent guarantee for non-failures of belt joints made using it. Other products the company is now exporting to the Australian market also include an energy saving pulley lagging rubber sheet. The ‘Energy Saving’ pulley lagging rubber sheets have wavy top and button top patterns. They reduce around 50 per cent of installed conveyor belts without the need for scrapers.
The rubber cement is used in some of the most demanding mining environments for cold and hot vulcanising methods.
10 І Australian Bulk Handling Review: January/February 2022
It also provides the I-BOND EZEE Instant Repair Kit, which can repair the damaged conveyor belts within five minutes – without needing hot vulcanising machinery. The company designs products that provide solutions for belt slippage, belt misalignment, bel elongation, and sticky materials. Its vulcanising materials can also be more beneficial when compared with mechanically fastened splices, as mechanical fasteners often cannot produce as smooth a surface at the splice.
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NEWS
QLD copper mine waste could create cobalt Director of the University of Queensland’s Sustainable Minerals Institute Professor Neville Plint and Minister for Resources Scott Stewart. Joined by (L-R) the University of Queensland’s Professor Rick Valenta, and the Department of Resources’ Dr Helen Degeling and Tony Knight.
COBALT, A KEY INGREDIENT FOR
battery manufacturing right here
battery technology, could be retrieved economically from old copper mine tailings. A three-way research agreement between the Queensland Government, Japan Oil, Gas and Metals National Corporation (JOGMEC) and the University of Queensland will examine whether cobalt can be retrieved from mine waste. The study will involve researchers’ samples from the tailings of Copper Resources Australia’s Rocklands copper mine near Cloncurry in north west Queensland. Samples will be studied at the University of Queensland’s Sustainable Minerals Institute and at JOGMEC’s laboratories in Japan with results shared between all three parties. Queensland Resources Minister Scott Stewart says the research could help unlock the state’s potential as a major global supplier of ethically sourced cobalt and
in Queensland. “Australia and Japan have a strong trade partnership and the Palaszczuk Government is proud to be working with JOGMEC and the University of Queensland,” Stewart says. “Cobalt is a highly sought-after new economy mineral that is a key component in lithium-ion batteries used in electric vehicles and battery storage systems. “Queensland is renowned for having a large endowment of cobalt, however extracting and processing this mineral is often difficult due to costs and resources. “It could also revolutionise how Queensland copper mines operate by turning their waste into a revenue stream.” The project is the first joint venture between the Queensland Government and JOGMEC. In 2019 Premier Annastacia Palaszczuk re-signed a Memorandum of Understanding with JOGMEC whilst
12 І Australian Bulk Handling Review: January/February 2022
on a trade mission in Tokyo which included continued co-operation in the fields of coal, minerals and hydrogen. JOGMEC Chairman & CEO Tetsuhiro Hosono says the latest joint research project formed part of JOGMEC’s Carbon Neutral Initiative. “It is a great honour to be collaborating with the Queensland Government and University of Queensland on this exciting project,” he says. “Through this joint research, we aim to promote the effective use of unrecovered cobalt resources in Queensland and other parts of the world. “This could contribute to the stable supply of minerals that are needed for a carbon-neutral society. “Should this project yield notable results, there is potential for the technology to be shared and used in other countries and regions.” University of Queensland’s Sustainable Minerals Institute Director Neville Plint says reducing mine waste was a key challenge for the mining industry. “As the industry seeks to reduce its environmental footprint there is growing interest in reusing mine waste as a secondary resource” Plint says. “Through this research agreement, we have the opportunity to explore the potential to extract important critical metals from mine waste.” “We are proud to be working with the Geological Survey of Queensland and an internationally-respected group like JOGMEC to take this opportunity forward.” The study is expected to be completed by 2024 with a public report and data set.
Free whitepaper download ‘Reaping the benefits’ Learn how a collaboration between Kilic Engineering and SEW-EURODRIVE has changed the game for grain handling in Australia.
THIS WHITEPAPER DISCUSSES: • Challenges of the grain industry – staff shortages and disruptions to the supply chain • The importance of high quality equipment to last through harvest • How the Kilic Engineering Bunker Stacker equipment is specifically designed to address challenges and unique Australian conditions • How the partnership between Kilic Engineering and SEW-EURODRIVE has meant the equipment is truly fit for purpose and supply of componentry is secure • How the collaboration has helped customers such as The Manildra Group achieve vertical integration with custom-made Bunker Stacker machinery that optimises grain storage
To read more, scan the QR code and download this free resource from ABHR!
A supportive partner According to Craig and Susan the assurance of support they receive from SEW-EURODRIVE is comparable to KE’s approach to customers.
Engineered to SEW-EURODRIVE: 24/7 SERVICE AND address challenges of implied or intuited understanding,” Robert enthuses. “That comes from trust, and often we can anticipate their needs successfully.”
SUPPORT CAPABILITIES
As a leading global manufacturer renowned for reliability in drive technology around the globe, SEWEURODRIVE backs this up with local, highend service and support with centres in Adelaide, Brisbane, Mackay, Melbourne, Perth and Sydney. All these centres are well-stocked in parts and provide a 24/7 breakdown service to customers.
Reaping the benefits
From the KE perspective, whilst they value “We’re a family company, and our the face-to-face customer service they values are aligned with those that a receive from SEW-EURODRIVE, they also family have – we don’t sell machines to take advantage of the online support. our customers and leave it at that, we provide end-to-end solutions and support How a collaboration between “We access CAD drawings online and when that begins with the initial consult and we need with gearbox SEW-EURODRIVE continues well beyond the saleKilic so that Engineering we we figure out whatand Key attributes: ratios, torque and power, we will enter can guarantee the machinery is working has that changed the game for grain • Quick turnaround – The modular nature information and share our design how it should,” explains Susan. “SEWof the units combined with investment with SEW,” explains in Craig. “They will then EURODRIVE are similar in this regard. handling Australia into spares means modern replacement check that information – make changes or Even though they are a global company units can be built and dispatched in a and can draw from a breadth of technical recommend alternatives if required – and short time. come back to us with a file which we can expertise and product knowledge, they • Experts – The 1300 363 432 customers to build aand stack makes Since itsus inception 45 years ago, regularly with on ourhand stakeholders to discuss provide with a highly personalised, put in our software seethat exactly how after-hours or hotline is 24/7 with technical optimal usemodel of their Adelaide-based equipment manufacturer new technology changes to existing local service. There has never been a that motor is storage going tocapacity.” work.” expertsthat available around clock. Kilic (KE), has building technology what we couldthe adopt to time Engineering when we haven’t feltbeen supported.” machines have been popular among bespoke handling solutions that are explicit The improve the equipment.” For the BunkerStacker equipment, KE use • Team approach – Over 40 sales and grain handlers, farmers andgearmotors, truck drivers to Australian challenges. Robert pointsconditions out that hisand company’s engineering people available across standard SEW-EURODRIVE alike are so efficient. OftenAustralia, the primary objective of updating providing support for the life attitude towards support is that it should whichbecause have thethey advantage of a compact “The founder of the company, Tony Kilic, and modular design. the technology is to improve product. the safety of every SEW-EURODRIVE be personal. “They’re designed to minimise spillage is a mechanical engineer who had a of the machinery. For example, the KE • Predictive maintenance – SEWwhich we is a major pain point – vision hard-working machinery “There BunkerStackers have features such “There to is create a set theme at SEW-EURODRIVE areknow thousands of potential EURODRIVE’s future-forward approach to multi-directional chute and large bed that the safety, reliability the as hydraulic jacks, automated takewhichwould is thatimprove we are never far away mounting shaft and power configurations, keeping drives in optimal working order. ensures they canthey getare thebacked most grain and of Australian materials up systems, on-board compressors, fromproductivity our customers,” he says. “We have with these and by into • Online support – Online support each stack without the need for sweeping handling explains General pendant controls, shade canopies andis centralisedoperations,” manufacturing in Germany but relatively short lead times and assembled offered so customers can track and shovelling up spilled product,” says Manager Craig Dennis.here “Thatin vision has easy now access ramps. decentralised assembly Australia, to order locally in Australia,” adds Robert. quotes and orders, access CAD files, Susan Collier, who is the KE Operations been realised with KE’sis expertise meaning that the stock where ourin “They also have ingress protection and installation manuals and more. With Manager. “Truck drivers delivering from the “Our aim is to make these machines providing that are service truly fitand for customers solutions are, and so is the meet international standards in terms now having farms love the BunkerStackers because purpose.” user SEW-EURODRIVE friendly and safeproducts for seasonal technical expertise.” of being explosion-proof, which can be a QR code customers also scan they have long, gently sloped ramps and workers,” stresses Susan.can “The more the a hazard in grain handling applications and access a wealth of information provide a large target zone for the efficient machine can do automatically, and with The KE BunkerStacker The relationship that KEagricultural and SEWwhere there is a lot of dust.” from the code link. dumping of grain. Drivers will go the extra simplistic controls, the less stress that equipment exemplifies EURODRIVE range have developed hasthemeant mile to offload at a BunkerStacker because puts on workers who aren’t necessarily company’s ability tohave tackle the paina points the two companies developed type the more loads they can do, the bigger experienced in using grain handling felt among grain handling operations. of ‘shorthand’ when it comes to drive their pay packet.” equipment.” Designed for rapid intake, these requirements. self-propelled machines speed up the While KE’s first BunkerStacker came to offloading of grain for storage in a Importantly, the BunkerStacker equipment “A long-term benefit of our collaboration market in 1999, the equipment has had user-friendly, safe way. uses reliable, quality componentry such as is that we’ve both come to understand and multiple upgrades since then. SEW-EURODRIVE gearmotors. draw from the other’s knowledge, expertise “A lot of Australia’s grain is exported and and competencies, which also extends to “It’s important to point out that not only the challenge during harvest season is to “Grain handlers prefer our machines how we communicate – there is a type is each machine unique and exclusive to store this product until it can be shipped because they see the SEW-EURODRIVE every customer, butharvests, every iteration comes of overseas. InWith warmer regions, the grain is drive technology and they recognise that the Australian grain industry experiencing record the performance grain handling equipment has listening to difference our customers,” Susan usually stored in bunkers, whichimportant appear – it from these machines giveharvest. them the best become increasingly can make all the to an operation’s productivity levelswill during elaborates. “We those have in post-harvest reviews as big pilesYet or despite stacks covered large being productive for the whole bumper by crops and promising forecasts, the sector have had tochance contendofwith other challenges customers give us feedback on of equipment tarpaulins,”that explains Craig. “Like the harvest,” says Craig.and “Drive motors are threaten their livelihood. Thesewhere challenges include a disrupted supply componentry, labour machine performance, and often they namesake, deficiencies, the BunkerStacker critical components in this equipment, both ofmachines which have been compounded by the global pandemic. provide us with a wish list of features are built to make that process easy and and the fact that we use SEW-EURODRIVE they’d like with to see or have upgraded. efficient. A This key shared feature of this those challenges drive more technology helps when we put out whitepaper discusses a particular focus on how smarter, efficient machinery assist meeting production demand. It highlights unique collaboration proposals between local OEM Kilic customer – it Depending how viablethe these suggestions equipment can range is theindischarge chute to a prospective Engineering andtoSEW-EURODRIVE in achieving that goal bythem bringing handling solutions tothat we’re going to are, we will incorporate into bespoke the next grain which can be manipulated shoot grain gives them confidence the Australian market that address distinctive native conditions and challenges. Additionally, it provides generation of equipment. We also meet in virtually any direction. This enables deliver a quality product.”a case study example of how the custom-built BunkerStacker machinery, supported by SEW-EURODRIVE drive technology, has helped agribusiness The Manildra Group achieve success in its vertical integration.
Introduction
www.bulkhandlingreview.com.au/reaping-thebenefits-with-sew-eurodrive-and-kilic-engineeirng/
Scan the code to download the whitepaper
www.bunkerstacker.com www.kiliceng.com.au www.sew-eurodrive.com.au
NEWS
Nyrstar to build facility to reduce fugitive lead emissions METALS PROCESSING COMPANY Nyrstar will build a product recycling facility at its Port Pirie smelter to significantly reduce fugitive lead emissions and improve the long-term health of the Port Pirie community. The South Australian Government will provide a $7 million grant, with Nyrstar to pay for the rest of the $23 million total cost of the facility. SA Premier Stephen Marshall says he is proud that the company and the State Government have joined forces to take action to deal decisively with lead emissions and improve the health of the children of Port Pirie. “This outstanding initiative will create 75 jobs at the peak of construction and sustain hundreds of jobs over the life of the project, delivering a significant economic boost for Port Pirie’s economy,” Marshall says. Currently, materials are processed
in an open-air environment. This area will be enclosed by a large facility that will reduce lead in air emissions by up to 25 per cent. The new 6850 square metre structure will store and transport feedstock materials along a covered conveyor belt to the furnace. The facility aims to eliminate dust generated from exposed material stockpiles and in handling and transporting materials at the site. The facility will also be negatively pressured to contain fine dust particles. Housing the storage and transport of materials in an enclosed facility prevents fine lead containing dust particles from escaping and affecting community health. Preliminary works are expected to commence in early 2022. From approval the construction of the facility is expected to take less than
Materials processing will be enclosed by a large facility that aims to reduce lead in air emissions by up to 25 per cent.
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30 months to complete. Nyrstar’s Vice President Australian Operations, Dale Webb, thanked the State Government for its support of its actions to make a significant and sustained reduction to lead in air concentrations in the community. “We value the partnership approach to improving the health of the local community which we see as vital to securing a stronger future for metal processing in South Australia,” Webb says. SA Energy and Mining Minister Dan van Holst Pellekaan says the recycling facility is a significant investment to reduce lead in blood levels of children in Port Pirie. “Despite the previous Labor Government promising that lead issues would be a ‘thing of the past’, it’s clear their efforts were not effective,” van Holst Pellekaan says. “Reducing lead in air requires a comprehensive approach that involves Nyrstar, the local council and the community working with the State Government to deliver a multipronged solution. “We have listened to the community and improved the governance of Targeted Lead Abatement Program (TLAP) by including representation from the local council and a TLAP community reference group.” Last month, van Holst Pellekaan announced that Nyrstar and the State Government have agreed to extend TLAP to 2034. The SA Government also announced a $2.5 million program to upgrade 43 Housing SA dwellings with young children in the areas of Port Pirie at greatest risk of exposure. Remediation works are tailored for each property and may include sealing the homes and improving outdoor areas to remove legacy lead.
CBH helps conduct Australian-first biofuel trial
CBH Marketing and Trading shipped 30,000 tonnes of sustainably certified malting barley to Vietnam, aboard the Edwine Oldendorff.
THE CBH GROUP HAS PARTNERED with dry bulk operator, Oldendorff Carriers, to conduct the biofuel trial on a grain vessel exporting from Australia. CBH Marketing and Trading shipped 30,000 tonnes of sustainably certified malting barley to Vietnam, aboard the Edwine Oldendorff. The vessel will be bunkered with a biofuel blend for the trial, supplied by integrated energy company BP. The biofuel blend is estimated to produce about 15 per cent less greenhouse gas emissions for this journey than conventional fossil fuels. CBH Chief Marketing and Trading Officer Jason Craig says the cooperative was proud to be pioneering efforts, alongside two of its global partners, to explore ways to reduce its carbon footprint along the supply chain. “Customers across the world are increasingly seeking to source
sustainable products, including sustainable grain,” Craig says. “It is our role, as Australia’s leading grain exporter, to take the necessary steps to lower carbon emissions along our supply chain. “Biofuel is one low-carbon option that could be part of the solution to reducing emissions in the shipping industry.” The malting barley, which is accredited as sustainable under the International Sustainability and Carbon Certification program, is set for Vietnam’s leading malting company, Intermalt. Intermalt services several brewing customers, the largest being Heineken, which has set a target of a carbon neutral value chain by 2040. “We need to meet the growing market demand for sustainable or carbon reduced grain by being proactive, practical and
adapting,” Craig says. “By doing this, we are making sure we can continue to keep our WA growers competitive.” The trial aims to provide information on how the vessel engine responds to biofuel, its speed and efficiency, and measure the emissions it produces. “We are excited to be working alongside our key global partners to conduct this trial, which will provide valuable information and help pave the way for a more sustainable grain industry,” Craig says. Managing Director at Oldendorff Carriers Melbourne, Ben Harper, says the company is very pleased to be collaborating with CBH to trial biofuel in its vessel, Edwine Oldendorff. “Collaboration is crucial for us all to learn and share information about the best paths in our efforts to decarbonise the supply chain,” Harper says.
Australian Bulk Handling Review: January/February 2022 І 15
NEWS
Queensland changes freight entry requirements Drivers must continue to monitor symptoms, and stay home if unwell, have tested positive, or have been deemed a close contact of a confirmed COVID-19 case.
QUEENSLAND HAS REMOVED THE requirement for freight workers and truck drivers to provide a negative COVID-19 polymerase chain reaction (PCR) test to enter the state. Drivers must continue to monitor symptoms, and stay home if unwell, have tested positive, or have been deemed a close contact of a confirmed COVID-19 case. If a driver develops symptoms while in Queensland, they must immediately undertake a COVID-19 test and not continue their journey until they have a negative result. Transport and Main Roads Minister
Mark Bailey says the change follows a decision out of national cabinet. “We thank all truckies, freight drivers, and the industry for their cooperation and patience over the last year,” Bailey says. “There is no longer any requirement for freight and truck drivers to provide a negative COVID-19 PCR test to enter Queensland. “We have implemented a new F border pass for freight workers and truck drivers, which will still need to be completed to cross the border.” Bailey says other freight border entry requirements will
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remain, including vaccination. “Drivers will still need to provide proof they are fully vaccinated against COVID-19 and complete the F border pass” he says. “Freight workers and truck drivers are absolutely essential to keeping food on the table and rebuilding our economy, and I cannot thank them enough for their efforts over the last two years. “We understand it has been a challenging time for the industry and will continue to support the industry as we have done throughout the pandemic.
Ahrens helps deliver Gepps Cross extension
Cavpower sells, maintains and repairs a range of Caterpillar equipment.
CAVPOWER, THE OFFICIAL Caterpillar dealer for South Australia, partnered with Ahrens to expand and upgrade its Gepps Cross facility. Cavpower sells, maintains and repairs an expansive range of Caterpillar equipment for the mining, construction, energy and transportation sectors, including new and used machines, work tools and power systems Ahrens used its range of inhouse capabilities and own structural steel to deliver a variety of works for the Gepps Cross location, spanning across two levels, including a standout laboratory, store room, open plan office, meeting rooms and all
other associated amenities. Ahrens completed 1000 square metres worth of work, which aided in relocating key components of the Cavpower business from Enfield to their new headquarters in Gepps Cross, a site Ahrens has been developing for several years. The team has supported Cavpower for many years and has delivered onsite works for as the Service Operations Centre, Truck Shop and Component Rebuild Centre. Ahrens’ diverse range of capabilities, teamed with proven experience and a national footprint, has allowed it to become a one-stop-shop
for the bulk handling sector. Delivering design and construction solutions for leading Australian businesses is Ahrens’ bread and butter, as it looks to strengthen the nation’s bulk handling capacity.
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Australian Bulk Handling Review: January/February 2022 І 17
COVER STORY
Busting automation myths Braden Goddin, Sales and Marketing Manager at Aurora Process Solutions tells ABHR some of the common misconceptions about automation and robotics for smaller bulk handlers. Robots are suited for boring, repetitive and physically intense jobs.
WHEN IT COMES TO NEW technologies, early adopters will often face higher risks, as bugs, glitches and inexperience can disrupt the previous way of doing things. These risks are not without rewards. In 1947, Ford started up its first automation department. Now, the technology is commonplace in the automotive industry, driving productivity to new heights. Braden Goddin, Sales and Marketing Manager at Aurora Process Solutions, says that while robotics may sound futuristic, the first movers are already wellestablished automators. “Larger corporations and industrial manufacturers had the privileged position to take on more risk with robotic technology and now they are reaping the benefits,” he says. “However, because these larger companies have been the main adopters of automation, there is a misconception that robotics are only for massive
multinationals. That’s no longer the case.” Aurora Process Solutions specialises in providing robotic equipment for smallto-medium bulk product manufacturers, particularly in rural areas. Its range of robots can semi- or fully automate the packaging, conveying, conditioning, palletising and wrapping processes. The New-Zealand based company’s targets first time automators, working with them to bring operations into the 21st century. Goddin says one major misconception around installing automated bulk equipment is the difficulty. “We talk to a lot of small to medium businesses, and often need to drill into what is causing any underlying anxieties or what misinformation they may have heard,” he says. “Some believe that automation is overkill, but others may not be comfortable with new technology – in a lot of cases if a person doesn’t understand
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the office suite on their computer, they think a robot would be even more complex.” To help smaller businesses get started, Aurora works closely with them to get a feel for what the process will look like. According to Goddin, there are plenty of case studies that were going through similar discussions a few years ago. Aurora can show new automators around equivalent-sized facilities and helps them connect with business owners and staff to see what it’s like. Aurora’s team also makes sure to use plain, easy to understand language that is devoid of buzzwords and complicated terminologies. Afterwards, the company will sit down with the client and its accountants to collect more information about the site, the production rates, number of manual labour units employed, amount of product rejection and cost of production to determine the return on investment (ROI). In most cases, the ROI is around two
Aurora helps connect new customers with other automators to see what it’s like.
to three years. Goddin says if the numbers don’t stack up, then at least Aurora has helped do its due diligence. “We understand how a small to medium enterprise works and have spent countless hours observing and even getting involved with the packaging as well,” he says. “It’s not uncommon for our engineers to do some of the bagging while at a site to better understand the process. It helps us find out what the requirements are for a client – you can’t just pull an automated system off a shelf and expect it to work.” Human error is one of the factors that leads to costs in manual systems. Humans are complicated creatures – workers can get tired during a shift, could have an injury, or not be available to work during peak times. Manual labour around machinery also brings with it health and safety risk. If people lose concentration, even for just a moment, it can spell disaster. Goddin says that some tasks shouldn’t have a human involved at all. “Moving pallets and bags is boring, repetitive and physically intense. It doesn’t make much sense to have a person those kinds of jobs, especially when they could be adding value to the process elsewhere,” he says. “Logistics, for example, is a task that remains very much manual. Coordinating deliveries is even more important now,
“Moving pallets and bags is boring, repetitive and physically intense. It doesn’t make much sense to have a person those kinds of jobs, especially when they could be adding value to the process elsewhere.” following major disruptions to global supply chains. Other roles that are better suited for humans are engineering roles, or roles that help optimise the use of machinery. “These jobs often get minimal attention, and as a result, packaging lines don’t run as efficiently. With manual labour units freed up from the boring
tasks, suddenly you can put more time and effort into improving your systems.” Goddin says another hidden benefit to automation is reducing the workload of the business owner themselves. A surprising amount of time is often spent managing manual labour and the day-today business. Clients that have adopted automated machinery often have more free time to focus on new ways of growing the business. “Ultimately, we want to automate the inhuman, and provide businesses the means to both de-risk their operations, build resilience and increase their competitiveness in domestic and international markets,” Goddin says.
Aurora’s robots can semi- or fully automate the packaging, conveying, conditioning, palletising, and wrapping processes.
Australian Bulk Handling Review: January/February 2022 І 19
SENSORS
Indurad sees iBelt radar solution
The iBelt system can be installed over a conveyor belt, where it can determine the 2D load profile measurement.
Dust, vibration and the harsh Australian sun can reduce the reliability of sensor readings, which is why indurad has designed a solution specifically for the mining industry. TO SURVIVE IN THE MINING industry, equipment needs to be made tough. Heavy machinery moves millions of tonnes of abrasive, and often hefty, materials from the mines. Usually, these mines are in remote areas that face some of the harshest conditions Australia has to offer – with regions such as the Pilbara in Western Australia recording temperatures of up to 45°C in the summer. To complicate matters further, dust and debris can cause havoc to sensors, and could interrupt the collection of data for Industry 4.0 systems. This problem is what German equipment manufacturer indurad set out to solve. Fabian Riedel, VP of Sales and Projects at indurad, says the company was challenged with creating a system that was proven to work in the rough conditions of the mining industry. What the company created is the iBelt system, a volume flow measurement sensor that can be used for almost any kind of bulk materials conveying system. iBelt measures belt load, speed and misalignment with high accuracy in real time with radar technology. The system can be installed over the conveyor belt,
where it can determine the 2D load profile measurement. This can be automatically combines with a measured or fixed conveyor belt speed value to determine the load volume. To find the load speed, an indurad Doppler velocity radar is installed with a clear view above the material stream. This captures both the low and high speeds and can distinguish between the load and speed of the belt, which can be especially important on steep conveyors. An indurad Linear Dynamic Radar sensor can also be installed as part of the iBelt solution, to measure the distance between the belt edges to detect misalignments in seconds. “The need arose for close range industrial imaging radar. At the time, the only methods that were easily available were optical sensors, which can’t provide real time control information when covered in mud and water,” Riedel says. “There are also a lot of airborne particles in mining environments, which can interfere with optical systems. “These kinds of radar systems already existed in the defence industry, so we set out to develop the technology to be cost effective in the mining industry.”
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Because the iBelt sensors use radar technology, they will work in almost any situation – rain, snow, heatwaves, or dust storms. When it comes to dust, the sensors can still get accurate readings while being covered in debris. Florian Schwarz, Head of Product Management at indurad, says that having constant, direct feedback is vital for not only the operators, but the entire downstream process. “Stockyard machines running autonomously will have the information they need to implement the right levels of process control. Without that constant data, you wouldn’t be able to run machines autonomously at all,” Schwarz says. “For plant automation, reliability is often more important than pinpoint accuracy. Autonomous machinery requires a confident understanding of exactly how much material needs to be moved.” The iBelt sensors use robust housings, with all the electronic components selected for reliability in these environments. The sensors are also tested in indurad’s climate chambers, as part of its research and development process. Other testing ensures the devices can
handle the heavy vibration of massive mining machinery without needing to be recalibrated. The iBelt sensors are also designed to have as little failable components as possible to keep everything simple. The technology has been installed in systems around the world, with some operating for more than 10 years in the field. There are numerous applications the system can be used for, such as bucket wheel volume measurement, detecting the flow direction on reversing conveyors, or ensuing material flow on a shiploader is properly monitored and controlled. Schwarz says the technology has been consistently developed over time and is plays a vital role in combination with most Industry 4.0 technologies. “It can interface with all common programmable logic controller (PLC) environments, where it offers some of the most important values for the system to calculate,” he says. “Automated machinery can make
The iBelt can be installed on bucket wheels for volume measurement or ensure material flow on a shiploader is properly monitored and controlled.
use of its real time data, the history of which is stored to provide insights about the bulk materials handling system as a whole.” Riedel says the iBelt comes with its own webserver, which lets the owner check the data remotely. “Once it is hooked up to the remote diagnostics server, data can be stored on the cloud and the status of the system
monitored constantly. It also allows indurad to go into the system and provide troubleshooting if required,” he says. indurad has offices across the globe, including in Australia, where the technology has been rolled out across the Pilbara. The company plans to extend its presence in the region and bring the technology proven in the mining industry to other sectors as well.
Innovation is our
Motivation...
find out more @ kinder.com.au Australian Bulk Handling Review: January/February 2022 І 21
GRAIN HANDLING
What goes into making a fan? ABHR speaks to Victor Stiller, General Manager at Kotzur Bulk Solids Handling, about how the company designs and manufacturers its aeration equipment.
Silo aeration helps prevent mould, impedes insect development, maintains seed viability, and reduces grain moisture.
AERATING GRAIN HAS FOUR MAIN purposes for silo operators. It prevents mould, impedes insect development, maintains seed viability, and reduces grain moisture. The process typically uses centrifugal fans that blow air into and through perforated ducting. The air moves up through the grain and out of the silo roof through sealable roof vents. The size of the silo, type and quality of grain stored (particularly moisture content) all lead into the calculation of total airflow and subsequently, the size and number of fans required for the silo to effectively store the grain. The Kotzur Group, a familyowned business based in Walla Walla and Toowoomba, manufactures these components to support its customers in the grain handling sector.
Victor Stiller, General Manager at Kotzur Bulk Solids Handling, says the company provides silos and other equipment such as screw conveyors, drag conveyors, fans and everything needed to support the product. “The fans are something we make up here in Toowoomba. It can get fairly specific when it comes to the design, as the level or airflow and back pressure need to be correct for an aeration system to work properly,” he says. The two most common types of fans are axial (propellor) fans and centrifugal fans. Centrifugal fans are better at handling back pressure than axial fans. The applications Kotzur uses fans for typically have higher back pressures, such as moving air through a grain column, and so all fans produced by Kotzur are centrifugal.
22 І Australian Bulk Handling Review: January/February 2022
There are some variations in the impellors within the centrifugal range depending on the specific application. One example is for grain aspirators, which are used for cleaning the dust and husks out of grain. Typically used in preparation of stock feed rations to clean the grain prior to wetting, these units enable continuous grain flow through the system to reduce downtime. The fans are used to move the air at specific velocities through the controlled grain stream to pick up the lighter dust materials while leaving the whole grain. The dust is then removed from the air using a cyclone system. While not always the case, it is quite common to ‘pull’ the dust through the fan which can introduce high rates of wear to the fan impellor. To reduce this, abrasive resistant material is used to manufacture
the impellor in this application. Stiller says that due the available options, as well as the very specific requirements of given airflows at certain backpressures, it is essential that the fan designs are proven in a test environment prior to being put into service. “The output of the testing is a fan curve, which graphs the performance of the fan for airflow and power requirement (current draw) at different back pressures. These fan curves can then be used to determine which model fan best suits the application and how many are required. We also perform the tests if there is a modification or revision to a fan for some reason to prove the fan curves are still valid,” he says. The process for testing the fans is to bolt the fan onto a test rig which is essentially a long tube that has a mechanism on the output end that can vary the opening to adjust the back pressure in the tube. The fan is run at different backpressures and the current draw of the motor, air velocity within
the tube and the tube pressure are measured and recorded. The velocity is used to calculate the airflow and results are plotted. “The testing process gives us a very good feel for how much air is being circulated through the grain in a silo and confidence in what that can achieve with preventing mould, inhibiting insect development, maintaining seed viability and reducing grain moisture,” Stiller says. Kotzur also employs an inhouse engineering team, made up or structural, civil, and mechanical engineers, to help handle the complex design requirements of a bulk handling project. After a design is determined, the business can then fabricate it locally. Most of the work is handled in-house, using Kotzur’s own manufacturing facilities. In addition, the company’s maintenance services division helps commission and maintain the equipment as well.
Kotzur has its own manufacturing facilities in Toowoomba and Walla Walla.
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Australian Bulk Handling Review: January/February 2022 І 23
SAFETY
Managing all the risks When it comes to disruptions to a bulk handling system, there are many that are outside of an organisation’s control. Spencer Wakelam, an independent Security consultant, explains how planning for only maintenance related disruptions can leave operations exposed. Bulk handling sites are by definition hazardous environments.
CONDITION MONITORING PLAYS a vital role in preventing catastrophic machine failure, but it is just one of several elements that contribute to the overall resilience of a bulk handling operation. The Prevention, Preparedness, Response and Recovery (PPRR) model is a widely recognised and applied method in risk management. However, to plan only for maintenance-related disruptions, rather than take an allhazards approach, is to leave operations exposed to a wide range of risks. Enterprise Risk Management and Supply Chain Security can mitigate the
risks presented by indirect geopolitical, economic, and logistic issues that are often beyond the control of the organisation. But what of the direct threat posed by a determined or malicious human actor? It is noteworthy that multiple categories of risk event can originate from a security breach. One of the key security threats currently facing the mining and resources, freight and bulk handling industries in Australia is that of Issue Motivated Groups (IMGs) such as Frontline Action on Coal (FLAC), Extinction Rebellion (XR) and Blockade Australia, to name but a few.
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Since 2014, activists have conducted non-violent direct action at bulk handling facilities at Whitehaven and Port of Newcastle in New South Wales, several Queensland coal terminals, and the mine and its associated rail construction project in Carmichael. Protests have involved scaling machinery and disabling conveyor systems by locking-on and activating emergency stop buttons. In two weeks alone in November 2021, two activists lockedon to conveyors at both Hay Point and Abbot Point, and protesters conducted more than twenty separate actions targeting the Port of Newcastle and the
rail infrastructure that services it. This type of illegal activity presents several significant risks. The first and foremost is to the safety of the protesters themselves, and the safety and wellbeing of site employees, including mental and emotional wellbeing in the unfortunate event of an incident. The prevention of a safety incident must therefore always be the primary aim. Thereafter, the priority of the risks will depend on the nature of the site, but will certainly include operational, financial, and reputational damage, with the possibility of regulatory non-compliance resulting from failure to take sufficient measures to prevent the activity occurring. There are several strategies and controls that can be implemented to mitigate the risk of unauthorised entry leading to safety hazards and operational disruptions. Arguably the most obvious would be physical security measures. However, at large sites installing physical barriers and security systems can be costly, and still fail to prevent access being gained by determined intruders. Therefore, the single most valuable element of a protective security profile is a positive security culture. Positive security culture can be embedded through employee training, innovative internal communications, and promotion of security risk
awareness. A characteristic of such a culture is employees who feel a sense of personal responsibility for security and safety in the workplace. Whenever positive security culture examples are set by employees, they should be recognised and positively reinforced, because employees are more likely to reflect positive peer group behaviour than follow ‘examples’ set by senior leadership. Knowledge of supportive legislation is another important risk mitigation approach, and therefore a healthy relationship with the organisation’s legal team is essential. Advance understanding of sections of relevant law – for example the Mining Act 1992 and Crimes Act 1990 (NSW), the Summary Offences Act 2005 (Qld), and the WA Criminal Code (Prevention of Lawful Activity) – can empower an organisation to better formulate its security strategies based on prevention and recognition of illegal protest activity. Being targeted by IMGs, and the organisation’s public response, can have a significant impact on brand and reputation. It should be assumed that all protests will be photographed, filmed and live streamed to social media, as this is how IMGs gain widespread coverage and support for their ideological cause. For this reason, employee behaviour
must be exemplary and focus upon the safety and wellbeing of the protester until such time that emergency services can respond (or the protester voluntarily ceases the activity). During or after a protest, a large organisation portraying itself as a victim, or issuing statements containing overtly negative sentiments about the groups or individuals responsible, is unlikely to win sympathy outside of those already supportive of the organisation and may even have adverse reputational consequences. Safety must always be the number one consideration in the prevention of, planning for, response to and recovery from IMG activity at bulk handling sites, which are by definition hazardous. The mitigation of security risk will reduce the likelihood of a safety incident and the risk to business continuity.
Spencer Wakelam is an independent Security Risk and Resilience consultant based in Queensland. He has over thirty years’ experience gained from both military and police service, and in corporate and government roles across three continents. He holds a Master’s Degree in Security and Risk Management from the University of Leicester.
One of the key security threats currently facing the mining, freight and bulk handling industries in Australia is Issue Motivated Groups.
Australian Bulk Handling Review: January/February 2022 І 25
SENSORS
Transmin and Thermo Fisher Scientific still going strong After signing a distribution agreement more than seven years ago, Transmin and Thermo Fisher Scientific continue to successfully serve the Australian mining industry. ABHR speaks to Robert Engelbrecht from Transmin and Maren Krakau from Thermo Fisher Scientific to learn more about the partnership. Transmin supplies Thermo Scientific bulk materials handling equipment, which includes tramp metal detectors, belt scales and integrators.
ON A BUSY MINE SITE, THERE are plenty of ways unwanted metal could enter the material stream. Tools can fall onto a conveyor, teeth on shovel equipment could snap and other scrap metal can enter the process stream. This metal can cause millions of dollars of damage in lost productivity and equipment repair, which is why many major miners ensure they use a tramp metal detector. Robert Engelbrecht, a product specialist at Transmin, says very few large conveyor systems would operate without a tramp metal detector, and one of the most popular systems is the Thermo Scientific Ramsey Oretronic IV. “It can detect all types of metallic scrap, including bucket teeth, manganese steel mantles, bore crowns, car scrap chains, tools and more,” he says. “Because the Thermo Scientific Ramsey Oretronic IV tramp metal detector is insensitive to materials with high magnetic permeability and electrical conductivity, it can be used in applications where conventional metal detectors produce an unacceptable false alarm rate, even if the tramp metal is buried in wet conductive material.” Thermo Fisher and Transmin have worked closely with each other since 2014, when the companies signed a distribution agreement for Australia. Transmin supplies all states and territories with the Thermo Scientific bulk materials handling portfolio, which includes tramp metal detectors, belt scales and integrators. Transmin has been supplying the Australian mining industry with bulk handling equipment since 1987, and during that time has developed a wide range of products. Engelbrecht says
Transmin is known as a one stop shop for equipment in the mining industry for engineering, manufacturing, parts, and service. Through Transmin, Thermo Fisher has greater exposure in the industry, making it a natural fit for both businesses. Engelbrecht says the wellestablished equipment is robust and reliable, with Transmin keeping a complement of spares on hand to ensure turnaround times are as quick as possible. “The quality of the product build, combined with Thermo Fisher Scientific having many years of experience, makes their solutions a benchmark for the mining industry,” he says. “There’s proven, long-term reliability and access to plenty of spares for the equipment ensuring customers can continue their operations smoothly and with confidence. “Thermo Fisher’s electronics and sensors under the Thermo Scientific brand are high quality, providing extreme accuracies and reliability.” This accuracy is the result of decades of research and development. Maren Krakau, ANZ Sales Manager at Thermo
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Fisher Scientific, says the company is committed to developing leading solutions to enable its customers to make the world healthier, cleaner, safer. “When it comes to tramp metal detectors, the market isn’t massive, but there are a lot of competitors. Our research and development, along with our proven track record, help us to stand out,” she says. The agreement with Transmin is an excellent example of how a good collaboration can accelerate the adoption of our bulk material handling solutions in Australia, says Krakau. “We work with partners to best focus on and serve our customers in each area and state. And they can help with servicing as well, which ensures rapid response time and onsite support,” she says. “We want to work more closely as the borders begin to open. Our manufacturing centre is in South Australia, and I look forward to joining them for customer site visits when we’re able to again.”
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If you need a better way to store dry bulk solids, Nelson can deliver it. Nelson are totally committed to innovative design and product development, and are now engineering silos with a proven 4-leg base design mounted on load cells. This unique Nelson design development ensures accurate weight measurement. For grain, legumes, sugar and flour, and plastic granules, Nelson 4-leg design silos are available in pre-painted steel. For flour, sugar, plc and industrial powder, Nelson are building fully welded stainless steel silos, also with the proven 4-leg design, mounted on load-cells. With the Nelson CAD programme, we have the capacity to develop a cost effective design package to meet the needs of the industry. We can then engineer your order in our own complex -with a fixed price that will save you up to 50% of the cost of on-site construction. And Nelson can deliver, install and commission purpose-built silos, with an absolute minimum of lead time.
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PACKAGING
Humanitarian food relief increased more than sevenfold with bulk handling system A Texas-based humanitarian relief meal company produces more than a 1.5 million meals per day after installing an automated bulk handling system. dischargers, and then positions a bag lifting frame immediately above the bag, allowing an operator to slide the bag’s four lifting straps into Z- CLIP strap holders affixed to the lifting
Two flexible screw conveyors move lentils from the two bulk bag dischargers outside to a transition hopper.
BREEDLOVE FOODS, INC PRODUCES nutritious food products for humanitarian relief in the aftermath of hurricanes, earthquakes and other catastrophic events. The non-profit company produces shelf-stable packages of ingredients such as lentils, rice, soy protein, dehydrated potatoes, onions and carrots. Packaged in one kilogram, 500 gram and 130 grams sizes, Breedlove’s food products require only water and 30 minutes of cooking time. The company installed an automated bulk handling system that boosted production of its Lentil and Vegetable Blend product more than sevenfold while improving worker safety. Two Flexicon
BULK-OUT BFF bulk bag dischargers and six interconnected flexible screw conveyors distribute dehydrated lentils to four mixers, followed by packaging. Purchasing lentils in bulk bags reduces ingredient costs, while discharging from bulk bags relieves workers of heavy lifting. Wesley Sloan, Breedlove’s Maintenance Team Lead, says operators were manually lifting five, 45.4 kilograms bags of lentils and adding them to the mixers.
Automated bulk bag discharging of lentils A forklift now delivers a 908-kilogram bulk bag of lentils from the warehouse to either of two side-by-side bulk bag
28 І Australian Bulk Handling Review: January/February 2022
frame. The forklift then raises the frame with suspended bag, and places it into receiving cups on the top of the discharger frame’s posts. The operator then secures the clean side of the bag spout to the clean side of a SPOUT-LOCK clamp ring positioned atop a TELE-TUBE telescoping tube, which applies constant downward tension as the bag empties and elongates, to completely discharge lentils into the 566-litre capacity hopper below. Spring-loaded POP-TOP extension arms on the discharger posts raise the bag as it lightens, further promoting discharge. “With two bulk bag dischargers, we run one until it gets low and then run the other one,” Sloan says. “While number two is running, operators are refilling number one and there’s never downtime replacing product. Even with the 908-kilogram loads in the work area, dust is not a problem.”
Lentils move from dischargers to mixers via flexible screw conveyors From each discharger’s floor hopper, a six metre long, 114-millimetre diameter flexible screw conveyor moves the lentils through an opening in the wall into the Packaging Room where they discharge into a 28.3 litre capacity transition hopper atop a diverter valve that directs lentils into the four interconnected flexible screw conveyors feeding the four mixers. The conveyors, with lengths varying from three to 4.5 metres, consist of a
System operates under loss-of-weight control
speed as material is discharged into a designated mixer. The PLC steps down the conveyor feed rate to dribble as the target weight is approached, stopping the conveyor once the precise batch weight has been lost from the discharger. “We’re getting excellent results from the system and are achieving our goal of below one percent for weight variants,” Sloan says. “Our rates are extremely accurate.” Blended batches are discharged into a hopper that feeds its respective packaging machine, which outputs the various packages. Breedlove CEO Bill Miller says that before the packaging upgrades, Breedlove’s daily production averaged between 200,000 and 500,000
At the control panel, the operator sets weight specifications and routing to a specific mixer. The batching system operates under loss-of-weight control whereby load cells supporting each discharger transmit weight loss data to a PLC, which runs a conveyor at high
meal servings a day. “Now, we can approach 1,500,000 meal servings a day. We have produced more than 22 million food servings for COVID-19 food relief and the upgrades we completed played an integral part in that response.”
Interconnected flexible screw conveyors, under PLC control, deliver precise weights of lentils to four mixers.
polymer tube enclosing a flat wire spiral driven by a 2.25-kilowatt motor beyond the discharge point, preventing material contact with seals or bearings. Lentils exiting the conveyor are gravity fed through downspouting to one of four mixers where operators manually add minor dry ingredients, including rice, soy protein, potatoes, and onion. “Some recipes include 272 kilograms of lentils from the bulk bag discharger, while many recipes and
production runs are approximately 45.4 kilograms,” Sloan says.
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GRAIN HANDLING
Reaping the benefits A collaboration between Kilic Engineering and SEW-EURODRIVE has changed the game for grain handling in Australia. WITH THE AUSTRALIAN GRAIN industry experiencing record harvests, the performance of grain handling equipment has become increasingly important – it can make all the difference to an operation’s productivity levels during harvest. Agriculture’s contribution to the Australian economy – when factoring in all farm production inputs – accounts for an estimated 12 per cent of the gross domestic product, with the wheat industry alone valued at $8.5 billion. Despite bushfires, drought, COVID-19 and global trade disruption, the sector has seen substantial growth, especially in cropping. The Australian Bureau of Agricultural and Resources Economics and Sciences (ABARES) attributes the volume growth and improved productivity seen in cropping partly to the adoption of new technologies and management processes. The sector has also enjoyed back-toback bumper harvests. The 2020-2021 marketing year reported the second largest wheat crop ever on record. Forecasts predict the 2021-2022 season will fall just two per cent shy of that figure but achieve 25 per cent more than the five-year average. In fact, the September 2021 ABARES agricultural overview report determines that Australia’s total agricultural production will surpass the $70 billion mark for the first time due to a combination of high commodity prices and optimal seasonal conditions.
Threats to productivity Regardless of these favourable conditions, labour shortages and border restrictions have threatened agribusinesses’ ability to deliver on the bumper season. While the sector has lacked skilled workers for the past decade, demand for unskilled labour is now considerably elevated adding additional pressure on businesses looking to secure seasonal workers. The Federal Government announced a new agricultural visa in late 2021 but conceded that overseas workers would
unlikely be available for immediately upcoming harvests. In some instances, where labour had been obtained from Pacific nations, workers were unable to enter Australia due to differing state quarantine controls and caps. Disruptions to the global supply chain have also proven to be a serious roadblock in the availability of harvesting and commodity handling equipment and parts. Demand has surged in tandem with heightened cropping volumes, but many agribusinesses have gone without muchneeded equipment for lengthy periods.
Engineered to address challenges Since its inception 45 years ago, Adelaide-based equipment manufacturer Kilic Engineering (KE), has been building bespoke handling solutions that are explicit to Australian conditions and challenges. Craig Dennis, General Manager at Kilic Engineering says the founder of the company, Tony Kilic, is a mechanical engineer who had a vision to create hardworking machinery that would improve the safety, reliability and productivity of Australian materials handling operations. “That vision has been realised with KE’s expertise in providing solutions that are truly fit for purpose,” he says. The KE BunkerStacker agricultural equipment range exemplifies the company’s ability to tackle the pain points felt among grain handling operations. Designed for rapid intake, these self-propelled machines speed up the offloading of grain for storage in a userfriendly, safe way. “A lot of Australia’s grain is exported and the challenge during harvest season is to store this product until it can be shipped overseas. In warmer regions, the grain is usually stored in bunkers, which appear as big piles or stacks covered by large tarpaulins,” Dennis says. “Like the namesake, the BunkerStacker machines are built to make that process easy and efficient.
30 І Australian Bulk Handling Review: January/February 2022
A key shared feature of this equipment range is the discharge chute which can be manipulated to shoot grain in virtually any direction. This enables customers to build a stack that makes optimal use of their storage capacity.” The machines have been popular among grain handlers, farmers, and truck drivers alike because they are so efficient. Susan Collier, KE Operations Manager, says they’re designed to minimise spillage which is a known pain point. “The multi-directional chute and large bed ensures they can get the most grain into each stack without the need for sweeping and shovelling up spilled product,” she says. “Truck drivers delivering from the farms love the BunkerStackers because they have long, gently sloped ramps and provide a large target zone for the efficient dumping of grain. Drivers will go the extra mile to offload at a BunkerStacker because the more loads they can do, the bigger their pay packet.” While KE’s first BunkerStacker came to market in 1999, the equipment has had multiple upgrades since then. “It’s important to point out that not only is each machine unique and exclusive to every customer, but every iteration comes from listening to our customers,” Collier says. “We have post-harvest reviews where customers give us feedback on machine performance, and often they provide us with a wish list of features they’d like to see or have upgraded. Depending how viable these suggestions are, we will incorporate them into the next generation of equipment. We also meet regularly with our stakeholders to discuss new technology or changes to existing technology that what we could adopt to improve the equipment.” Often the primary objective of updating the technology is to improve the safety of the machinery. For example, the KE BunkerStackers have features such as hydraulic jacks, automated takeup
systems, on-board compressors, pendant controls, shade canopies and easy access ramps. “Our aim is to make these machines user friendly and safe for seasonal workers,” Collier says. “The more the machine can do automatically, and with simplistic controls, the less stress that puts on workers who aren’t necessarily experienced in using grain handling equipment.” Importantly, the BunkerStacker equipment uses reliable, quality componentry such as SEW-EURODRIVE gearmotors. “Grain handlers prefer our machines because they see the SEW-EURODRIVE drive technology and they recognise that these machines will give them the best chance of being productive for the whole harvest,” Dennis says. “Drive motors are critical components in this equipment, and the fact that we use SEW EURODRIVE drive technology helps when we put out proposals to a prospective customer – it gives them confidence that we’re going to deliver a quality product.”
A collaboration driven by shared values A commitment to quality and customerfocussed support are values that KE and SEW EURODRIVE share. For KE, working with SEW-EURODRIVE gives them peace of mind that the drive technology will perform to its optimum. “As we’re custom-building these large, complex machines, we try to strategically reduce risk around the critical componentry, and that’s what we’ve done through our partnership with SEW-EURODRIVE,” Dennis says. “We can effectively rely on their
expertise, safe in the knowledge that when we get the drive to fit, it will deliver the required amount of power and torque. We don’t have to worry, meaning we can focus on other aspects of the machine such as the belts, idlers or mechanical design.” The collaborative relationship KE have built with SEW-EURODRIVE – which began when the global drive manufacturer opened its facility in Adelaide over 13 years ago – also affords them security when it comes to parts supply. This has proven beneficial to KE’s customers throughout the pandemic disruptions. “We share a high level of trust and transparency with SEW-EURODRIVE and they’ve been able to advise us regarding stock, including keeping reserves of particular componentry in store for us,” Dennis says. “As a result, we’ve been able to maintain production and supply machinery to customers such as TPorts and The Manildra Group during COVID-19.” The fact that SEW-EURODRIVE has approximately $35 million AUD worth of local stock holdings has certainly aided their ability to meet KE’s requests. Robert Justice, the State Manager for SEWEURODRIVE in South Australia, says it’s a major point of difference with SEW. “We’re very much in a league of our own when it comes to stock holdings and componentry,” Justice says. “Because of the modular nature of our units, many of the parts are interchangeable, so together with the company’s heavy investment into spares, we’re able to provide customers such as KE with the security of available stock and short lead times.”
A supportive partner According to Kilic Engineering the assurance of support it receives from SEW-EURODRIVE is comparable to the company’s approach to customers. “We’re a family company, and our values are aligned with those that a family have – we don’t sell machines to our customers and leave it at that, we provide end-to-end solutions and support that begins with the initial consult and continues well beyond the sale so that we can guarantee the machinery is working how it should,” Collier says. “SEWEURODRIVE are similar in this regard. Even though they are a global company and can draw from a breadth of technical expertise and product knowledge, they provide us with a highly personalised, local service. There has never been a time when we haven’t felt supported.” Justice says his company’s attitude towards support is that it should be personal. “There is a set theme at SEWEURODRIVE which is that we are never far away from our customers,” he says. “We have centralised manufacturing in Germany but decentralised assembly here in Australia, meaning that the stock is where our customers are, and so is the service and technical expertise.” The relationship that KE and SEWEURODRIVE have developed has meant the two companies have developed a type of ‘shorthand’ when it comes to drive requirements. “A long-term benefit of our collaboration is that we’ve both come to understand and draw from the other’s knowledge, expertise and competencies, which also extends to how we
In warmer regions, grain is usually stored in bunkers, which appear as big piles or stacks covered by large tarpaulins.
Australian Bulk Handling Review: January/February 2022 І 31
GRAIN HANDLING
communicate – there is a type of implied or intuited understanding,” Justice says. “That comes from trust, and often we can anticipate their needs successfully.” KE values the face-to-face customer service they receive from SEWEURODRIVE and take advantage of the online support. “We access CAD drawings online and when we figure out what we need with gearbox ratios, torque and power, we will enter that information and share our design with SEW,” Dennis says. “They will then check that information – make changes or recommend alternatives if required – and come back to us with a file which we can put in our software and see exactly how that motor model is going to work.” For the BunkerStacker equipment, KE use standard SEW-EURODRIVE gearmotors, which have the advantage of a compact and modular design. “There are thousands of potential mounting shaft and power configurations, with these and they are backed by relatively short lead times and assembled to order locally in Australia,” adds Robert. “They also have ingress protection
The agriculture sector accounts for an estimated 12 per cent of Australia’s gross domestic product.
and meet international standards in terms of being explosion-proof, which can be a hazard in grain handling applications where there is a lot of dust.”
Leveraging global export-ise SEW-EURODRIVE’s drive technology is built to meet global standards and requirements. “While we provide a standard gearbox range for the Super Roo BunkerStackers, we provide a wide range of products to KE for their different machinery that includes geared motors, geared reducers, AC motors, VSDs and motor controllers,” Justice says. “In some applications we supply our Generation X.e heavy industry gear
BunkerStacker machines have been popular among grain handlers, farmers, and truck drivers alike because they are so efficient.
32 І Australian Bulk Handling Review: January/February 2022
motors. What all our products share, however, is increased energy efficiency, and this is complemented by an in-depth understanding of energy regulations across the globe.” This has been especially useful in instances where KE have had orders from overseas. “We have relied on SEW-EURODRIVE significantly when it comes to exporting our machines to countries such as Japan and Qatar where we had no clue as to what the electrical regulations or voltages were in those countries, or what was required on the nameplate to clear customs,” Dennis says. “We leaned heavily on SEWEURODRIVE and they helped us straight away. As a global company that moves motors and gearboxes on a daily basis around the world, they knew exactly what documentation and nameplate insignia to supply. Also, their motors are built for global use, and they just had all that information available and made it a seamless process.” Without SEW-EURODRIVE’s expertise, Susan says KE would’ve struggled to calculate and deliver the machinery to exact requirements. “Our biggest nightmare is to send a machine across and have it fail to clear customs, or find out that it is not compliant when it’s on the water – it’s not just the financial expense of doing that, but the potential damage to our reputation and brand,” she expands. “SEW-EURODRIVE give us absolute confidence that the power outputs are correct and that we are delivering the right amount of torque on the machines supplied. Honestly, they’ve been immeasurably helpful and just being affiliated with their company and brand has made the whole export process from our perspective very smooth so far.”
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PACKAGING
Bulk packaging sorted with Oli Vibrators Mark Thompson, Director at Oli Vibrators, explains how industrial vibrators can help reduce waste and improve consistency on packaging lines.
Oli’s product range is rated at a T4 Temperature Rating and are IECEx and IP66 rated.
AN AUSTRALIAN BISCUIT company faced a dilemma. It was producing an enormous amount of waste due to product degradation during the packaging process. As the biscuits were straightened to line up in the package, many would break. To solve the problem, the company reached out to vibration specialists, Oli Vibrators. Mark Thompson, Director at Oli Vibrators, says after installing Oli’s vibrators, the company was able to save almost 98 per cent of what used to become waste. “When it comes to packaging, customers are looking for two main things: reasonably high, reliable speeds and accuracy,” he says.
“Our vibrators can be used to help straighten products before they go into a bag or box, or to consolidate light and fluffy products such as flour before they are packed into a bag.” Because packaging is a broad industry, Oli Vibrators are used across many industries. Thompson says the vibrators have been used to line up metal tops for cans, help thread prawns onto skewers, and help pack icing sugar. With so many different products and industry, the company works closely with its customers to learn as much as they can about the process. Often the customer will provide a checklist of important information along with some technical drawings to get started. Knowing he characteristics of
34 І Australian Bulk Handling Review: January/February 2022
the material is also vital for success, as different bulk densities, weights, stickiness, and temperature can change the parameters of what is needed. With that information, the company’s engineers will usually find a solution that will work for the customer within 24 to 48 hours. Thompson says it’s important to install the right tool for the application, as not all vibrators will do the job a customer wants. “We once had a customer who wanted the biggest vibrator we had. We told them that they could get what they were looking for out of a smaller vibrator that was half the size. Using the larger vibrator could have done damage to the machine – bigger
isn’t always better,” he says. “Knowing what the process is also keeps maintenance to a minimum. If a vibrator is being used move 800 kilograms of materials instead of the 600 kilograms it was designed for, it won’t be as effective.” One specific task that vibrators can assist with is microbatching. This is where gentle vibrations are used to ensure the screws on a screw conveyor are full, to prevent bridging. This helps to keep the feed rate reliable and effective. Oli Vibrators ensures its own equipment can be relied on with rigorous testing at the company’s global manufacturing facilities. Oli Vibrators’ parent company, Oli SpA, recently opened its new headquarters in Medolla, Italy, which will be used to coordinate the firm’s international branches. The new facility features advanced manufacturing equipment and uses high quality materials to provide assurances of reliability to its customers. Its product range is rated at a T4 Temperature Rating and are IECEx and IP66 rated. In addition, all its equipment has a two-year warranty, which includes full replacement or repair. Thompson says the manufacturing process for the vibrators uses state-ofthe-art technology and testing. “We claim to have a price to performance ratio that is second to none,” he says. “It’s part of our goal to
The company supplies vibrators that offer three kilograms of force up to 26,000 kilograms.
Vibrators have been used to compact icing sugar into bags.
“They’re also virtually maintenance free and easily replaced. Once fitted, they go about their business based on the operation. They can be programmed to work in conjunction with the process and are energy efficient.” remain affordable and available.” The company works closely with the bulk handling industry to supply vibrators that offer three kilograms of force, up to 26,000 kilograms. Its
equipment is used on hoppers, bins, feeders, chutes and conveyors for several reasons. The company has operated in Australia for more than two decades and has built up expertise in providing the right tools for the job. Thompson says Oli Vibrators’ staff are knowledgeable about its products and know how to apply them to all kinds of situations. “They’re also virtually maintenance free and easily replaced. Once fitted, they go about their business based on the operation. They can be programmed to work in conjunction with the process and are energy efficient.” Oli Vibrator’s mission statement is ‘when you need it, where you need it’. To deliver on that, the Australian business keeps plenty of spares on hand if required and can call upon the global company’s trading subsidiaries. Thompson says the Australian branch has stocked up significantly for the new year and have several new products they are working on for its electric and pneumatic range. “Oli Australia is here to help with any vibration problems and have a good team of engineers ready to assist,” he says. “We’ve made sure to increase our local stock holding to ensure we have adequate supplies.”
Australian Bulk Handling Review: January/February 2022 І 35
BELT CLEANERS
Expanding horizons for TS Global Australian-owned TS Global has expanded significantly over the past 12 months. Graham Holford, the company’s director, tells ABHR about how its new facilities are supporting the mining industry. AUSTRALIAN MINES ARE MASSIVE infrastructure systems, built tough to handle the harsh conditions and high throughputs. To remain as durable as possible, bulk handling equipment tends to be heavy. As a result, installing a new belt cleaner could require two tradespeople moving a 70-kilogram piece of equipment up a gantry that could be covered in dust or debris. Graham Holford, Director at TS Global says these are the kinds of problems that the company tackles when designing its equipment. “The business has been built around practical people. Most of us are tradespeople who have been dealing with these problems and have firsthand experience with the challenges that our clients face,” he says. “It’s why we design serviceable, highperformance products that eliminate potential risks.” One of the main design focuses for TS Global’s belt cleaner range is to improve the manual handling. The new design aims to eliminate pinch points, which can crush fingers, and to split the weight of the cleaners in half through retractable cartridges. This means that when working on a site with rotable spares, maintenance staff can remove the cartridge and slot in a new on in less than half an hour. They can then service the worn cartridge offsite, improving safety significantly. As part of the installation package, TS Global also aims to reduce dust emissions with its cleaners. Instead of creating another potential way for dust to escape, the company’s installation teams will often add an inspection door to trap as much dust withing the chute itself. Holford says customisation has become more prevalent since the business first began more than 30 years ago. “Given the importance of safety issues
TS Global aims to offer a competitive price and fast response for servicing.
or environmental issues like carryback entering nearby waterways, mine sites are pushing harder to ensure everything is optimised,” he says. “Customisation is the way to do that, you can’t just throw the same thing at dozens of different problems.” TS Global has grown significantly to meet the needs of the modern mining industry, and has built a new facility in Tomago, New South Wales. The facility is the company’s new central headquarters for the business, located next to the existing TS Global workshop and warehouse. The expansion has helped the business to improve efficiencies, cutting down travel times between TS Global’s sites and created a business hub for the company. In addition, it has opened a new
36 І Australian Bulk Handling Review: January/February 2022
office in Perth that initially started as a one-person operation. The team has grown over the past year to eight people, with plans to hire around 10 to 15 new service specialists. Other branches have been set up in strategic mining areas around the country, to allow TS Global easier access to blue chip mining companies such as Rio Tinto or Glencore. Holford says the local support allows TS Global to offer a competitive price and fast response for servicing. “At the end of the day, it is critical to be responsive to our client needs,” he says. “Having people in the nearby area is necessary for that.” “Our clients are in the business of mining, not in maintaining belt cleaners. That’s why we’re building more service hubs around the country.”
In November 2021, Holford announced that TS Global had won a three-year contract for the Conveyor Components and Associated Maintenance by Rio Tinto Iron Ore. TS Global’s range of belt cleaning and conveyor products, coupled with its locally based product support and service team were seen as a valuable partnership for Rio Tinto. “This partnership with Rio Tinto is an exciting opportunity to work with one of the largest mining operators in Australia with shared desire to collaborate in achieving high performance belt cleaning systems,” Holford says. “We are extremely grateful for Rio Tinto deciding to support a privately owned Australian business such as TS Global.” TS Global’s specialised service team will provide support to Rio Tinto’s asset management team with the focus on driving innovation, standardisation, and optimisation of all belt cleaning systems.
TS Global has set up branches in strategic mining areas around the country.
“We’ve embraced the opportunity to build the partnership between us and Rio Tinto and have dedicated resources to work closely with their asset maintenance team” The company aims to continue
expanding in 2022, especially into Queensland and Western Australian marketplace. Holford says the goal it to eventually start moving into international markets – specifically in the United States and Asia.
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BELT CLEANERS
Kinder Australia’s finger on the pulse Kinder Australia has brought a novel belt cleaner for cleated conveyors down under. Charles Pratt, Operations Manager at Kinder Australia, explains how a trip to Spain resulted in the valuable finding. WHILE ON A BUSINESS TRIP to visit a business partner in Spain, Charles Pratt, Operations Manager at Kinder Australia, was shown a unique innovation for belt cleaning. The Spanish company had been using a belt cleaner that has a unique “finger” shape that could effectively contour to the belt’s surface as it moved, with a flicking motion. “I’d never seen anything like it in Australia, it was completely unique. I loved how simple the concept was,” Pratt says. The belt cleaner was originally designed by a company in the United Kingdom, after an engineer had been tasked to find a way to improve the cleaning processes of a Chevron conveyor belt. When the engineer ran his fingers down the belt, it inspired him to design a cleaner that used polyurethane strips to reach the difficult areas on a cleated belt. Pratt says that while the cleaner had proved itself internationally, there was a major gap in the Australian market. “The only other suitable cleaner for cleated belts is a brush cleaner, which some customers find too expensive and require too much to set up. Often an electrician is required to properly install as well,” he says. “We were surprised to hear from the company in the UK that they had no customers in the Southern Hemisphere. We have an extensive distribution network in Australia, Asia Pacific, Indonesia, South Africa and South East Asia, so it was a good fit for us. “We made a few phone calls and within a week, we had a contract signed to be the exclusive distributor.” The cleaner, now called the K-Cleatscrape, can be fitted in any
The belt cleaner has a unique finger-shaped design that contour to belt’s surface as it moves.
The cleaner can be fitted in any position from the snub drum backwards and reach the entire width of the conveyor belt.
38 І Australian Bulk Handling Review: January/February 2022
position from the snub drum backwards and reach the entire width of the conveyor belt. Various durometer cleaner blade formulas are available to suit a variety of needs, with the addition of stainlesssteel tips or optional tungsten for further robustness if required. The K-Cleatscrape Duplex Belt Cleaners will work on cleated belts up to 100 millimetres in height. The proprietary finger design ensures optimal and even belt scraping with a double row of off-set combs, to accommodate these extreme ridges. The design is a good option to ensure old and worn belts are not damaged, as the cleaner is forgiving when it comes up against mechanically fastened splices, belt cover gouges or other belt damage imperfections. Pratt says the inexpensive, yet effective cleaners have been a godsend for bulk handlers with cleated belts. “Cleaning a cleated belt wasn’t easy or previously affordable for some, which meant people had been putting up with excessive spillage,” he says. “Spillage can cause occupational
The K-Cleatscrape Duplex Belt Cleaners will work on cleated belts up to 100 millimetres in height.
health and safety issues, increase cleanup costs and cause premature roller or tracking failures.” The cleaner requires very little upkeep, as the only moving parts are designed to be flexible. Due to the construction of the ‘fingers’, they don’t need to be recalibrated. The blades are simple to replace. Kinder has already air freighted the first two shipments of the product into Australia, which sold out within the first two weeks. Pratt says the cleaners have
created a stir in the sector, and plenty of customers are looking to get them. “We’re going to be setting up a virtual demonstration in our display area and train all of our distributors and field specialists,” he says. “We want to be able to educate the end users about how effective they can be and provide a demonstration. “Kinder’s also busy working on new technology for conveyor transfer points and developing our presence in the United States.”
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Solids \ Powders \ Conveying \ Processing \ Storage Australian Bulk Handling Review: January/February 2022 І 39
BELT CLEANERS
Brushing up on belt cleaners Thomas Greaves, Managing Director of DYNA Engineering on the benefits of brush cleaners for conveyor systems. or by some adhesive properties of the material. They are particularly suited to conveyors transporting fine particle materials such as mineral sands, cement, salt, sugar, fertiliser, dust, wood chips and other fine powders. Brush cleaners are ideal for belts which do not have flat surfaces. They are also suitable for reversing belts. Normal scraper cleaners are not effective in both these cases.
Some examples of non-flat conveyor belts are: • • •
A Chevron rubber conveyor belt.
CONVEYOR BELT CLEANING cleaning equipment today is a diversified range of specialised types of cleaning devices. Each has been designed to be effective for the material being conveyed. This ensures it will deliver the best result in removing carryback and fugitive material from the belt before it causes excessive wear or damage to the conveying system.
used on all conveying applications, they are most effective when the material being conveyed is dry and granular, or where the material may be sticking to the belt surface by way of static charge
Brush cleaners As the name suggests, a brush cleaner is a conveyor cleaning product designed to clean conveyor belts with a sizeable brush. It is usually connected to a gear box and motor which causes it to consistently rotate. It can be driven in either direction to provide the best clean possible with its large bristles which sweep the surface of the belt to remove excess material. Although brush cleaners can be
40 І Australian Bulk Handling Review: January/February 2022
Grooved rubber belt Cleated rubber belt Mechanically joined conveyor belt (the metal clips can get caught in conventional scraper cleaning products) • Chevron rubber belt The bristles on a brush cleaner are able to weave in and out of troughs and up and down raised sections of non-flat belts without increasing the wear or reducing the service life. The bristles are supple and able to clean without becoming caught on anything and potentially damaging the conveyor belt. They can be used in conjunction DYNA Engineering brush cleaners are spiral bound, providing superior cleaning efficiency compared to other types of brushes.
Brush cleaners can be rotated in either direction, depending on the best cleaning action.
with a primary scraper when the initial material may be too high for the brush cleaner alone. Unlike conventional belt scrapers, brush cleaners can handle metal-clipped belts, as well as worn or repaired belts, without suffering loss of brush life. This results in lower maintenance costs and shorter planned shutdown times. Another situation which brush cleaners are suited to is in confined space applications. When space is limited and conventional cleaning products such as scrapers and spray bars are difficult to install and maintain, brush cleaners can be a simpler and less expensive solution. They are easy to install and can be designed to fit in just about any space.
Locally made DYNA Engineering’s brush cleaners are designed and fabricated at the company’s workshops in Bayswater, Western Australia, so long and costly shipping times and unexpected delivery delays, as can be encountered with imported ones, are never a problem. Quality is also guaranteed as all the steelworks in DE brush cleaners are fabricated “in-house” and the brush/bristles componentry is closely checked for consistence in maintaining or exceeding Australian standards. This doesn’t always occur with imported units.
Additional features DYNA’s Brush cleaners can be fitted with many types of bristles for a large range of applications. This includes hard, soft, short, long, anti-static, natural fibre and even wire. Match these with different directions and speeds, and the variants are endless. Another feature is that brush wear can be adjusted by the built-in adjuster mechanism. DYNA Engineering has been specializing in the design and manufacture of quality conveyor components since 1986. The company’s key business focus now is on innovations for bulk material companies to be able to operate their conveyor systems while improving the environmental impact of their operations.
Fast Fact DYNA’s Brush cleaners can be fitted with many types of bristles for a large range of applications. This includes hard, soft, short, long, anti-static, natural fibre and even wire. Match these with different directions and speeds, and the variants are endless.
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talk Finding the right solutions Every bulk material handling system will eventually begin to wear and encounter problems. Steve Davis explains how to take the first steps to solve these issues.
STEVE DAVIS In his regular BULKtalk column, Steve Davis considers the basics of bulk handling that sites often struggle with. Steve has worked in bulk handling for 30 years, for both resource companies and professional engineering firms, in Australia, South Africa, the Middle East and Canada. His experience encompasses such commodities as iron ore, coal, potash, phosphates, petcoke, sulphur, sands and grain.
THERE IS ONE ISSUE THAT IS common to all bulk materials handling systems. From the moment we start to use them they begin to wear out. In my experience the systems also experience different types of failure and damage that is unrelated to wear. The type and speed of wear is very much a result of the design and
44 І Australian Bulk Handling Review: January/February 2022
selection of components and materials. Failure and damage are more complex, may be related to design and selection, but operation and maintenance becomes part of the equation. As an example, assume that a system was fully defined during concept, prefeasibility and feasibility, and that the operating parameters for all
components were defined, the components were specified and purchased accordingly and installed according to supplier recommendations. After six months of operation there are a high number of idler failures. What is the next step? I offer a few of my observations over the years. Perhaps these scenarios ring some bells? Equipment failure and damage can be hard to find and lead to more obvious issues in the system.
Scenario 1. Idlers are replaced as a matter of course in our facility, and no-one takes notice unless the number becomes ridiculously high, or the time to replace becomes a production issue. They are cheap and disposable and go to scrap. No records are kept of which are replaced and after some time this becomes a planned maintenance issue. After a few years a keen procurement person sees a cost saving by buying cheaper idler rolls and the situation gets worse. Scenario 2. The failure rate is noticed, and an instant cause is postulated. This will be something like poor cleaner performance, poor belt tracking, incorrect belt tension or other. We rush off and change belt cleaners, add tracking idlers, add, or change belt tension and often do not monitor the outcome. It takes a few months to realise the situation has not improved so we add another unrelated solution and carry on. After a few years we have
tried multiple solutions, none of which work, and the problem remains. Scenario 3. The failure rate is noticed, and the response is to commence a trial-and-error replacement using different idlers from other suppliers. After all, the originals can’t be any good, can they? The replacement continue until a different idler performs better. We don’t really know why, but these must be “ok”. We don’t even keep records of the replacements. Scenario 4. The failure rate is noticed, and the original equipment manufacturer (OEM) is called in to explain. The OEM completes an analysis and identifies the cause as being incorrectly specified for the duty or the result of a separate issue such as high spillage. We move on to the previous solution because the OEM is just making excuses. Scenario 5. The failure rate is noticed. We have a maintenance
monitoring system that records details of each failure, the location and time, and this is correlated with operating parameters such as loading, spillages and clean ups and the like. We start a Root Cause Analysis (RCA) process to identify the cause of the high failure rate. The OEM is involved, as are maintenance and operations and the design basis. Idlers are monitored for a period to assess whether the failures are random in location or focused, whether they are of the same type or different, and we complete some analysis of the failures. We methodically go through the design basis and confirm or otherwise whether the correct item was specified and supplied. We methodically go through the operational history to confirm or otherwise whether we were operating according to design. In most cases it will be relatively easy to identify the root cause(s) of the failures and to find a solution. The outcome from the above is
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that we need to identify problems and want a solution that fixes the problem. We need a system that allows for identification and recording of problems in sufficient detail to provide data for analysis. There are several systems available, but these are of little benefit if the users do not get sufficient training and the data entered is not
complete and consistent. I analysed a set of records recently that had almost 100 different descriptions for idler failure, from failed or broken through to seized. Less than 10 percent of problems had a location or description. Meaningful data analysis was not possible. When an anomalous issue has been Poor belt tracking is often easy to notice, but its cause can be hard to spot.
identified we can then use the data to identify the root cause and propose a solution that removes the problem or reduces it to an acceptable level. There are many methods available. Jumping to a conclusion or making a low-cost fix may improve matters but may not give the best solution. When idlers are underspecified due to design base or different operating parameters or undersupplied, we can spend a little more for the correct items and save on the associated downtime and labour cost of replacement. In most cases the downtime cost far exceeds any additional component cost. If a change is made, ensure that there is follow up to confirm the outcome. Key to success in this instance is an update of procurement records so the next batch will be correct. For idlers that are damaged from external cause there are solutions available when the cause has been identified. The other situation is in older plants. Something is changed or upgraded or downgraded and there is a knock-on effect. Many times, a plant has been operating well for years, and then there is a sudden change. It can take some time to realise that a problem has occurred. I am amazed how often this type of occurrence does not generate an RCA, and conclusions are made that defy logic. Typical scenarios follow. A conveyor had been operating well for many years when almost overnight the four highest tension pulley bearings started to run hotter than before. The immediate thought was bearing failure, although four at the same time is unlikely. Multiple vibration analyses and lube samples later and no evidence, so water and air were used to cool the bearing housings. No-one considered whether something else had changed. A quick review of history showed the temperature changed when the grease supplier changed, and RCA showed that the oil viscosity in the new grease was lower. Conveyors had been operating well for many years and it was noted that the belt wear rate had increased significantly. It took three belt changes to notice this. RCA was used to identify that the supplier had changed and
46 І Australian Bulk Handling Review: January/February 2022
An idler buried in spillage.
interpreted the specification differently to previous. The specification did not give sufficient detail. Alumina belt feeders had been operating well for many years using the OEM recommended belts. The life of the belts after a regular change out reduced by 75 per cent and splices were not lasting. It took three replacement belts before RCA was used to identify that procurement had opted for a cheaper belt based on an incomplete specification. Alumina attacks the surface of certain belt materials. An inclined bauxite conveyor was operated for many years with extremely erratic tracking. Many assessments had been undertaken and every time a different type of tracking idler was installed. This was considered an apt and low-cost solution. The tracking idlers did not work. The root cause of the tracking was easily seen and caused by heavy spillage which was not regularly cleaned. The belt tracked off towards which of the sides were most buried in spillage and where the carry idlers were either rotating slowly or stopped due to the resulting contact. Another conveyor developed tracking problems overnight. The team defaulted immediately to installation of tracking idlers. When this did not fix the tracking, some digging into the operations before
and after found that a trestle had been bent from contact with a vehicle. The bent trestle changed the alignment of the idlers and caused mistracking. A belt weigher after a crusher consistently read 10 per cent less than the weighbridge before the crusher. Several assessments of the belt weigher and weighbridge fixed the issue for a short while, after which the disparity returned. The problem turned out to be the trucking contractor who ran every ninth truck through the weighbridge twice before dumping and was smart enough to stop when the assessments were being done. A fluid coupling on the drive of an inclined conveyor “exploded”. The immediate response was to try to find fault with the coupling and the OEM. The coupling had been in service for some time. After looking at the history it was found that the holdback had been disabled and the brake was not functioning well. The conveyor had run back under load and oversped the coupling and it exploded. An overland conveyor had an issue since new in that occasionally the belt would track off so much that the contents were dumped. This issue corrected itself in minutes and the conveyor generally operated well. The construction of the support structure
“There are few failures or problems in materials handling systems that cannot be defined and rectified given data and analysis. In Australia we have more experience and better components available than most locations and should have some of the highest productivities so why do we keep guessing when things go wrong?” prevented any significant damage. The cause was assumed to be some unknown oddity in the conveyor and irregular enough that it was ignored. Although not conclusive, analysis of records showed the events matched times when high winds were recorded in the area, and it is assumed that the wind force was sufficient to push the belt sideways under load. Another belt that had been running for some time started tracking off. The team considered belt damage, idler failure, adding tracking idlers but did not look at the obvious cause that tracking started at the load point and was due to an altered trajectory from a deflector that had worn through and been modified when repaired. There are few failures or problems in materials handling systems that cannot be defined and rectified given data and analysis. In Australia we have more experience and better components available than most locations and should have some of the highest productivities so why do we keep guessing when things go wrong? To be able to complete a good RCA we need several things. First, we must have history of the operation before and after a problem has been discovered. Second, we must understand the problem and its potential causes and not be diverted by the quick and easy “instant” solutions. Understanding a problem may require some forensic analysis of failed components. Third, we need a focused team that is inclusive of relevant persons to assess and recommend. Finally, support for the recommended action and follow up to confirm outcomes.
Australian Bulk Handling Review: January/February 2022 І 47
PORTS
Ports are a central part of the Australia’s supply chain, responsible for 98 per cent of its trade.
billion), Japan (AUD 34 billion), South Korea (AUD 23 billion), India (AUD 12 billion) and the UK (AUD 10 billion).
Current trends and typical handling challenges in ports
Dry bulk trade and the importance of bulk solids handling in ports TUNRA Bulk Solids’ engineer, Dr Priscilla Freire, looks at some current trends in maritime trade of dry bulk and typical issues encountered in the storage and handling of bulk solids. ACCORDING TO THE UNITED NATIONS Conference on Trade and Development (UNCTAD) Handbook of Statistics [1], a total of 7.9 billion tons of dry bulk cargo were loaded and 7.7 billion tons were unloaded world-wide during 2019. In the same year, Australia occupied the 20th position in terms of number of port calls, with 66,076 calls. As an island nation, ports are a central part of the Australia’s supply chain, responsible for 98 per cent of its trade. Commodities such as iron ore, coal, bauxite, aluminium oxide and concentrates in general are amongst the highest tonnage exports; however, dry bulk ports are also central to the country’s domestic activities, connecting the west and east coasts or the mainland and Tasmania. Australia has long held the position of world’s largest iron ore exporter,
with 828 million tonnes exported in 2017, followed by Brazil (approximately 420 Mt) and China (about 200 Mt) [2]. With the majority of its iron ore originating in the Pilbara region, Port Hedland, Dampier and Cape Lambert occupy the highest position in iron ore exports in Australia. Similarly, some of the largest coal ports in the world are also located in Australia, including the Port of Newcastle, Port of Hay Point and Port of Gladstone, among several other ports of major international relevance, totalling about 390 million tonnes of coal being exported in the coal terminals in NSW and QLD in 2019-2020 [3]. Regarding the destination of Australia’s export, the Office of the Chief Economist [4] has reported that the five key destinations of Australian resources and energy-based exports in 2020-2021 were China (AUD 149
48 І Australian Bulk Handling Review: January/February 2022
The storage, handling and transportation of bulk solid materials are major activities for a variety of industries not only in Australia but worldwide, and efficient bulk solids handling operations are of vital importance in the supply chain. This becomes even more evident in ports, where the larger throughputs and number of materials often present unique challenges. From environmental and safety concerns such as dust emissions, risk of liquefaction, selfheating or explosions, to unplanned maintenance stops potentially leading to excessive demurrage costs, appropriate design of bulk handling equipment is the key to ensure operational efficiency. The following trends have been observed in recent years in relation to international dry bulk trade, which naturally affect handling and storage operations [5]: - The average deadweight of dry bulk carriers is increasing: for Handymax vessels, it increased from 24,100 deadweight tons (dwt) in the 80s to 28,100 dwt in 2016. Panamax vessels increased from 67,800 dwt to 74,600 dwt in the same period, whilst Capesize and Ultra Large Capesize increased from 117,000 dwt to 196,000. This is not to mention the advent of the Valemax ships, which started being produced in 2011 and whose capacity ranges from 380,000 to 400,000 dwt. - Further to the increase in average deadweight, there has also been a shift to using larger ships as opposed to smaller: in 1980, handy size vessels used to account for 54.3 per cent of bulk fleet capacity worldwide, whilst Capesize ships only accounted for 14.7 per cent. In 2000, these figures were close to 50 per cent, with an accelerated shift in carrying capacity in the past decade: In 2016, Handy size vessels accounted for approximately 17 per cent while
Capesize corresponded to 38 per cent. Such shifts mean that loading/ unloading efficiency is growing in importance, as well as stockyard capacity and, in some cases, the increase in transhipment operations where ports do not have the infrastructure and size to handle large vessels. Furthermore, dry bulk typically has low value/volume ratio compared with other cargoes, such that the transport efficiency has great impact in the added value. With more than 45 years of experience, TUNRA Bulk Solids has done its fair share of projects associated with bulk solids handling in ports, both in Australia and overseas. A recent example includes the redesign of a problematic shiploading spout/chute with excessive dust generation in a grain handling terminal: with the use of multiple analysis techniques such as the continuum mechanics approach and Discrete Element Modelling, combined with a prototype, the proposed modified design was based on minimising impact angle and maintaining dust encapsulated within a fast-moving material stream. The design was endorsed by operators, with visible dust reduction reported. Another challenge often observed in ports is the design of transfer chutes able to efficiently handle multiple materials at very high throughputs. This is the case in several of Australia’s mining ports, which export ore or coal from various different mines, whose materials often behave very differently. In such cases, material characterisation, coupled with advanced engineering practices such as computational modelling, becomes even more essential for effective design.
Bringing the Industry Together In December 2021, TUNRA Bulk Solids’ specialists and guest speakers presented a 1-day workshop for industry on the typical handling challenges encountered in ports. The event took place online and attracted over 40 delegates from Australia and internationally, including participants from Brazil, Peru, Canada and China. The technical event started with
a keynote presentation by Associate Professor Dingena Schott, from Delft University of Technology, where participants had the opportunity to hear about “Increasingly Sustainable Bulk Handling Operations”. The research led by Dr Schott mostly focuses on machine-cargo interaction for logistics, with four main aspects being discussed: 1. P ort accessibility: with a focus on more efficient material handling operations, increasing uptime (decreasing downtime) and overall reduction of time at port; 2. E nergy Transition: new fuels and design of infrastructure, industry adapting to new energy carriers (both liquid and granular), nonfossil cargo fuels; 3. P rocess control and Design: industry 4.0 including Internet of Things and increasing inter connectivity at ports; system and equipment control; development of fast and accurate models (metamodels) for cargo behaviour; focus on higher degrees of autonomy; 4. E nvironmental sustainability: search for more energy-efficient systems; reduction in air, water, land and noise pollution; health and biodiversity. Among several areas of interest, the research conducted by Dr Schott’s group includes the MAGPIE Project (sMArt Green Ports as Integrated Efficient multimodal hubs), which is coordinated by the Port of Rotterdam and involves 45 partners, including TU Delft. In 2021, the project was awarded nearly 25 million euros of funding by the European Union to be used in 10 pilot projects and demonstration projects focusing on sustainable and smart logistics in port operations, mainly in relation to the use of new fuels and energy carriers not yet tested in practice [6]. Some examples include an electric battery-powered locomotive that uses power from an overhead line for both motive power and for recharging its battery, allowing it to work in areas that lack an overhead line such as marshalling yards, for instance. Other examples of projects include bunkering ammonia as a transport fuel,
or electrical power from shore for ships moored offshore to a mooring buoy. The consortium will also aim to design and implement digitalisation and automation solutions in the context of the energy transition [6]. Even though the primary focus of the MAGPIE research is on container terminals, it is believed that the outcomes of the research will also be of great relevance to dry bulk handling terminals worldwide. Dr Schott’s presentation was followed by Dr Jayne O’Shea and Dr Dave Bradney, two of TUNRA Bulk Solids’ consulting engineers, who presented on material characterisation and dust respectively. Dr O’Shea introduced the typical flow properties characterisation techniques available with a focus on efficient design of materials handling facilities such as transfer chutes, bins, hoppers and belt conveyors, all of which of critical importance in dry bulk handling ports. Dr Bradney’s presentation consisted of specific characterisation and modelling techniques with a focus on dust control. The topic is of special relevance given that port facilities are typically situated in close proximity to the general public, and exposure to dust is a risk both from a health and environmental point of view. When it comes to dust management, active measures are commonly taken, especially with the use of water for dust minimisation. However, water use must be balanced in the context of sustainability, not to mention that excess water can also cause handling issues. This leads to the need for finding the right balance, as well as applying “smart design” techniques, which aim at minimising dust without having to increase water use. It is recommended that material characterisation for dust start with particle size distribution, which reveals valuable information about the potential for dust generation. Furthermore, the risk to health is associated with the size and nature of the dust particles. Mechanical sieving is typically used to characterise particle sizes in the range of 100 mm to 45 µm, whereas laser diffraction can be used
Australian Bulk Handling Review: January/February 2022 І 49
PORTS
for powder-like materials, ranging from 0.1 to 1000 µm. The size of the particle has a direct relationship with its terminal velocity (vt), as per the following equation:
vt =
4g рs d
1 n
3рa CD
Where g is acceleration due to gravity, рs and рa are the solid and air density respectively, d is the particle diameter (assuming spheric), CD is the drag resistance factor and n is the drag index, typically considered 2. By plotting the equation above, the following relationship between terminal velocity (vt) and particle diameter (d) is obtained:
the effectiveness of different methods of dust suppression such as water or surfactants. The dust lift-off test can also determine threshold wind speeds and interaction between wind speeds and spraying regimes for instance. As a final point in Dr Bradney’s presentation, some principles of optimal chute design for dust control were presented, with a focus on passive dust control, such as minimising impact angles between the material and the chute walls, avoiding unconstrained or dispersed flow especially during free-fall, incorporating convergence and curvature of the material stream through deflectors and spoons wherever possible and maintaining streamlined flow with minimal impact losses to ensure dust particles are entrained in the stream. After looking at moisture from a dust point of view, another topic of great relevance to the ports industry was presented by Shaun Reid, focusing on the effects of excessive moisture. Shaun introduced the concept of cargo liquefaction and the Transportable
Figure 1 – Influence of Particle Size on Terminal Velocity.
The use of water or surfactants as dust suppression methods looks to increase the resistance of a particle to air, such that they bind smaller particles together, making them “heavier”. Further to this water also has surface tension which increases the resistive force. Given that water is a precious commodity that should be used with wisdom, the following question arises: how much water is enough? To answer this question, the Dust Extinction Moisture test can be performed, which aims to determine the dust/moisture relationship. Although the test was originally designed for Australian coal (AS 4156.6), it has been applied to other bulk commodities with adjustments in the material quantity used in the test. Also of great relevance to the ports industry is the assessment of dust liftoff propensity across material surfaces such as stockpiles and train wagons. Such assessment can be made using wind tunnels, and is useful to assess
Figure 2a
50 І Australian Bulk Handling Review: January/February 2022
Moisture Limit (TML), as well as an overview of the International Maritime Organisation’s IMSBC Code (International Maritime Solid Bulk Cargoes Code) and material classifications [7]. The Code sets out requirements for shipping bulk cargoes both from an operational point of view and a safe shipping perspective, and classifies materials into three categories: • G roup A cargoes are materials that may liquefy if shipped at a moisture content in excess of the Transportable Moisture Limit; • G roup B cargoes possess a chemical hazard which could give rise to a dangerous situation on a ship; and • G roup C cargoes are neither liable to liquefaction nor chemical hazards. It is worth noting that certain materials, such as bauxite, only present risk of liquefaction at specific particle sizes, such that characterising the material’s particle size distribution is often the first step in the testing process. Liquefaction is a phenomenon that
can happen to certain bulk materials after being loaded in granular form: in some cases, the induced stresses during shipping can cause the material to settle and compact, leading to liquefaction. This represents a hazard due to shifts in the centre of gravity of the liquefied cargo potentially leading to capsizing, with serious economic and environmental consequences, not to mention loss of lives. The Transportable Moisture Limit is then defined as the maximum moisture content at which a bulk cargo prone to liquefaction may be safely shipped, and, with several accidents occurring even in recent times, research on the topic is still ongoing. It is worth noting that the liquefaction phenomenon is not restricted to shipping, but it may also be observed in other systems. More generally referred to as “moisture migration”, it can happen in train wagons and even on conveyor belts, and although the safety risks are not as impactful as in vessels, it still poses significant operational challenges,
Figure 2b
such that moisture control is of utmost importance along the handling chain. Specifically at ports, a thorough understanding of the material’s behaviour in relation to moisture may be combined with other relevant variables to form a Moisture Management Plan. In these plans, the Dust Extinction Moisture is considered the lower bound, whereas
ups and blockages. The final part of Shaun Reid’s presentation involved an introduction to the different methods for TML testing, which are conducted by certified labs and in accordance with specific guidelines. The IMSBC Code contains 3 broad categories of testing with sub-categories for specific materials, summarised in Table 1:
Table 1 – Transportable Moisture Limit tests TML TESTING METHOD
Specifications / Comments
FLOW TABLE
Top Size < 7mm (though generally < 1mm)
PENETRATION TEST
Top Size < 25mm
PROCTOR FAGERBERG
Top Size < 5mm (for the Standard method) Modified methods developed for specific cargoes
the Transportable Moisture Limit is the upper bound which should never be exceeded. In addition to these, optimum moisture levels can be determined through flow properties testing, to ensure that the cargo is handled efficiently, minimising material hang-
Progressing on the topic of safe handling of cargoes, Dr Peter Robinson, Research Associate with the Centre for Bulk Solids & Particulate Technologies (University of Newcastle), was invited to present on self-heating. Self-heating materials generate
Figure 2c
Figure 2 – TML testing at TUNRA Bulk Solids. A) Flow Table Method, B) Penetration Test Method, C) Proctor Fagerberg Method.
Australian Bulk Handling Review: January/February 2022 І 51
XXX PORTS
heat through an exothermic reaction with atmospheric oxygen, consuming oxygen and typically producing carbon oxides. Some examples of self-heating materials include (not limited to): charcoal, linseed oil, biofuels, Direct Reduced Iron (DRI) and seed cake. The risk a self-heating material presents is primarily dependent on three factors: • M aterial properties such as activation energy, and the pre-exponential factor of the reaction, • V olume of material, larger volumes will self heat at lower temperatures due to ineffective heat dissipation, and • Storage temperature. Additional factors such as sample age, moisture, packing density and atmospheric oxygen content also affect self-heating rate. Dr Robinson provided an overview of the regulations used for selfheating cargoes, including the IMSBC Code and IMDG Code (International Maritime Dangerous Goods Code) for bulk maritime transport, both of which are fundamentally centred around the United Nations Manual for Tests and Criteria. The IMSBC Code classifies a selfheating material as a Group B cargo, that is one that presents a chemical hazard. These cargos may be classified as a Dangerous Good (DG), which are typically classified in accordance with the IMDG Code, Materials Hazardous only in Bulk (MHB) or neither, and these classifications result in different conditions for transport. Materials classified as Dangerous Goods may be further classified into several subcategories (packing groups), based on the proposed transport conditions for that material. Group B cargoes are initially characterised using the United Nations N.4 test, which subjects a 100mm sample cube to a test temperature of 140oC. When measured at the centre of the sample, if the temperature of the material exceeds the oven by 60oC or greater, the material is classified as Class 4.2 – Dangerous Goods, and further testing specified in the UN Manual is required to determine the Packing Group (PG). If the material
“Critical thought should be given to what problem is being analysed and whether DEM is the best tool available to replicate it, considering that DEM is a tool to build confidence regarding the design solutions being analysed.” is not deemed as a Dangerous Good, further testing is required as specified in the IMSBC Code to determine its MHB status (if any). The N.4 test is based on a kinetic scaling model developed by David Frank-Kamenetskii, and research into bulk carrier conditions by P. C. Bowes in the 1960s [8]. For bulk carriers transporting charcoal (on which the N4 test is based), Bowes observed sustainable mean ambient temperatures as high as 38°C, with the temperature in the cargo space up to 10°C higher, due to radiation from the steel hold. At that time, charcoal was typically shipped in a 10-tonne stow, equating approximately to a 3m-sided-cube (27 m3). This results in the need for charcoal to present no self-heating potential in a 27m3 volume at 50°C. Frank Kamenetskii theory, in short, depicts similarities in the self-heating behaviour of a material, for different temperatures and volumes. Applying this model to charcoal, the self-heating behaviour of a 27 cubic meter stow of charcoal at 50°C is equivalent to a 100mm cube at 140°C, resulting in the N4 test. Lastly, Dr Tim Donohue presented principles for adequate transfer chute design, and analysis tools such as the Continuum Mechanics approach and Discrete Element Modelling. Dr Donohue’s presentation included some applications of DEM, assumptions, and limitations. Critical thought should be given to what problem is being analysed and whether DEM is the best tool available to replicate it, considering that DEM is a tool to build confidence regarding the design solutions being analysed. Dr Donohue proposed the following considerations when defining the “problem”: • C an the correct mode of flow be captured, including internal shear and wall friction. • W hat is the scale of the problem, including particle scale and geometry
52 І Australian Bulk Handling Review: January/February 2022
scale? • W hat is the volumetric throughput? • U nder what circumstances does the specific behaviour occur? Considerations such as flow rates and wall friction are of relevance here. • A re the effects of the problem time-dependant? If so, how much simulation time would be needed to capture the behaviour? The presentation also included TUNRA’s 10 Commandments for Reliable Transfer Chute Design, and practical examples and design considerations. To conclude the workshop, the final session, led by Dr Bin Chen and Dr Jens Plinke, included a series case studies with special focus on wet and sticky material, dust and wear issues. The presentations have been recorded and are available on TUNRA Bulk Solids’ website, at https://www. bulksolids.com.au/category/technicalknowledge-base/
References: 1. 2020 Handbook of Statistics, United Nations, 2020. 2. Maritime Transport Infrastructure Discussion Paper, Transport Australia Society, 2020. 3. https://www.minerals.org.au/coal/ports-andtransport 4. Department of Industry, Science, Energy and Resources, Commonwealth of Australia Resources and Energy Quarterly September 2021. 5. Song, D. W., & Panayides, P. (Eds.). Maritime logistics: A guide to contemporary shipping and port management. Kogan Page Publishers, 2015. 6. https://www.portofrotterdam.com/en/news-andpress-releases/eu-awards-nearly-eu-25-millionfunding-green-port-project-rotterdam 7. [International Maritime Organisation, 2011. International Maritime Solid Bulk Cargoes Code. 8. Bowes, P. C., The Marine Observer, 1969.
2021
AUSTRALIAN MINING PROSPECT AWARDS
E L A S N O W O N S R G E T I M NIN E E R I K P M S ’ C E A I H I T T TRAL OR RY F LS ST S S U A ARD ERA NDU AW D MIN ING I au . S om N c S . A CE s d r O a w PR a ct pr Pre
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ENGINEERING
Bridge and culvert inspection requirements for mines and ports Bridges and culverts may be subject to more onerous conditions in the mining industry from heavy vehicle loadings, changes to road alignments and changes to landscape and stream catchments to suit production. BRIDGES AND CULVERTS ARE are important assets in road systems. Their primary purpose is to allow vehicles to safely travel over obstacles such as rivers and drains. Another purpose is to cater for water flow. Failure to maintain the structural integrity of these assets can lead to the collapse of the structure itself and the adjacent roadway, causing an increase in downtime for traffic and resultant costs. VicRoads defines a bridge as “a structure with a minimum span or
diameter equal to or greater than 1.8m or a waterway area equal to or greater than three square metres for the primary purpose of carrying a road or path over obstacles”. A culvert is defined as “a structure with the primary purpose of providing a passageway beneath a road or path, usually but not necessarily for stormwater”. This is particularly important in mines where the landscape can change at a frequent rate, causing local traffic access and the flow of
Figure 1 shows culvert components for inspection.
54 І Australian Bulk Handling Review: January/February 2022
waterways to be rediverted constantly. Asset integrity management and maintenance of bridges and culverts is crucial in allowing roads and waterways to operate effectively on mine sites and elsewhere.
Asset integrity management Asset management is divided into two types: proactive and reactive. Proactive asset management involves a preventative approach to minimise deterioration and preserve structural
Figure 2a: Concrete damage to the underside of a bridge deck, exposing corroded reinforcement.
integrity. This will consist of systematic servicing of a structure on a scheduled basis. Requirements for proactive asset management should be included in the asset owner’s specifications. The following documents are also applicable: • ISO 55000 – Asset Management Set • IPWEA – International Infrastructure Management Manual • Austroads – Guide to Asset Management • Austroads – Guide to Bridge technology Reactive asset management is a responsive approach involving the identification of major damage or defects observed in the structure. Reactive maintenance is performed when the need for maintenance intervention is necessary to prevent an unsafe situation occurring. Both asset management types rely on structural inspections.
There are three levels of inspections that are recognised in the management framework and are usually undertaken by a qualified inspector or engineer. These three levels are:
Level 1 – Routine Maintenance Usually undertaken between 6-12 months, a routine maintenance inspection visually checks the overall serviceability of the structure and identifies any immediate risks to the user. Level 1 inspections generally provide simplistic descriptions of the condition of the structure’s main components and are intended to prompt the asset owner if maintenance or a level 2 inspection is required.
Level 2 – Structure Condition The structure condition inspection places emphasis on the overall condition of
the structure based on the complexity and severity of the defects observed. Predominantly done as a visual check, the inspection is usually undertaken between 1-5 years and is done by providing a detailed assessment and defect rating of each component of a bridge or culvert as shown in Figure 1. This includes a baseline check that is performed within three months of commissioning, or as specified by the asset owner’s contract documents. Similarly, for any defects found, the asset owner may choose to undertake immediate repairs or escalate the situation to a level 3 inspection.
Level 3 – Engineering An engineering inspection is an investigative approach to address complex issues found from the previous inspection levels, particularly for areas
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ENGINEERING
Fast Fact A culvert is defined as “a structure with the primary purpose of providing a passageway beneath a road or path, usually but not necessarily for stormwater”. This is particularly important in mines where the landscape can change at a frequent rate, causing local traffic access and the flow of waterways to be rediverted constantly. Asset integrity management and maintenance of bridges and culverts is crucial in allowing roads and waterways to operate effectively on mine sites and elsewhere. that are out of the normal scope (e.g. underwater inspections). This is usually undertaken by a qualified structural engineer as a response to a change in loading or from a defect/incident that could affect the overall capacity of the structure. As determined by the level 2 inspection, requirements such as shutdowns or non-destructive testing, such as strain gauging, may be implemented to undertake further testing of the components.
Inspector requirements Visual inspections for bridges and culverts should be undertaken by a competent inspector that has undergone an approved level 1 and 2 bridge inspection training course with the following competencies: • RIICSG405D: Carry out inspections of civil structures • RIIIMG301D: Maintain site records • RIIRIS301D: Apply risk management processes In addition, it is also recommended that the inspector has the following (although not limited to): • Structural/civil/construction background • First aid training • Appropriate personal protective equipment (PPE) and equipment (e.g. camera, hammer, binoculars) • Completion of any site inductions/ permits/risk assessments documentations
•
Driver’s license and approval for driving on site • Work at heights training/awareness • Elevated Work Platform (EWP) • Confined space awareness/training Any engineering assessments or recommendations provided by the inspector should be supervised by a Registered Professional Engineer with relevant experience in the field.
•
Common defects
The Department of Transport and Main Roads (DTMR) offers standardised servicing requirements for both preventative (proactive) and reactive maintenance on various components of the structure. This can generally be used as a basis for recommending the appropriate action for each defect.
Bridges and culverts tend to share common defects as their materials and functionality are typically similar. The common defects found in bridges and culverts include: For concrete structures: • Concrete damage • Concrete cracking • Concrete spalling • Delamination For steel structures: • Steel corrosion (including exposed reinforcement) • Loss of protective coating • Steel cracking • Damage and deformation Miscellaneous: • Missing / loose bolts / fixings • Weld defects (e.g. cracks, corrosion, undercut, etc.) • Rotting and infestation (timber structures) • Displacements / Movements of components • Erosion / Scouring / Settlement of the ground • Drainage effectiveness and moisture ingress • Blockage from sediment / debris / vegetation buildup For a level 2 inspection, the condition of each defect must be rated based on a severity guideline specified by the client/site standards. The overall condition rating of the structure will depend on both the quantity and quality of defects observed. Depending on the severity of the damage, the recommended actions can vary as below. • Regular monitoring / maintenance for minor defects
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Full repair and/or replacement for components considered severe/ critical as shown in Figure 2.
Inventory In comparison to commercial sites, industrial sites such as mines tend to constantly change landscape and be prone to highly corrosive environments. Although this means that bridges and culverts tend to be at a younger age, the environment exposure can lead to higher severity of defects. A mine site can contain over 200 culverts at any given time which are scattered over large distances across the site. The travel time between culverts may take longer than the actual inspection of the culvert. Bridge inspections take a longer time due to scale. Hence, more planning is required to undertake bridge inspections effectively. As a result, proper inventory management is critical in undertaking the inspection to ensure that resources are allocated efficiently between time and personnel. Descriptions for inventory items should include the following information (which should be maintained or updated at every level 1 and 2 inspection): • Name or Tag ID for all assets • Function, age & environment details (e.g. river/tide levels for accessing the piers) • Map of all asset locations (including GPS coordinates) • Structural drawings for out-ofsite components (e.g. connections, drainage, bearings, etc). • Relevant measurement/dimensions • Relevant survey data Once the inspections have been undertaken, condition and risk levels can be assigned and determined efficiently for each asset.
Figure 2b: A collapse of a culvert headwall due to the loosening of the internal steel barrel from ineffective drainage.
General Requirements for Inspection In summary, the following requirements are recommended for conducting and managing bridge and culvert asset inspections on a mine or industrial site. Inspector requirements: • Undertake a level 1 and 2 bridge inspection training from an
approved training course Consider the requirements needed for accessing the site and structure (e.g. work at heights, PPE, etc.) • Recognise the type of defects that occur on bridges and culverts and familiarise with the rating systems specified by the site to assess the level of risk of the structure` Asset Owner requirements:
•
•
•
•
Provide an asset inventory of bridges and culverts on the site, and keep the information up to date Schedule inspections when environmental factors are most favourable Establish strategies for proactive maintenance on a scheduled basis, in conjunction with level 1 and 2 inspections.
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MEMBER PROFILE
I have been a member of ASBSH since… The end of November 2021.
MEMBER PROFILE:
Stephan Hötte In each issue, ABHR profiles a member of the Australian Society for Bulk Solids Handling (ASBSH). In this edition, we speak to Stephan Hӧtte. To join the ASBSH, visit bit.ly/3aibXNf
The Australian Society for Bulk Solids Handling (ASBSH) aims to enhance the discipline of bulk solids handling through research, education and sound engineering practice. It aims to do this by • Promoting cooperation between universities, research establishments, consultants, equipment manufacturers, suppliers and industrial users. • Encouraging research and development, technology transfer and training. • Promoting education at the undergraduate level and continuing education at the postgraduate level. • Holding national and international conferences at regular intervals.
I am a member of ASBSH because… I started my professional career at Continental in Germany and took the chance to support our business here in Western Australia. ASBSH provides the great opportunity to extend my network with other bulk material handling professionals and enthusiasts here in Australia. I’m looking forward to participate at ASBSH events to meet colleagues in the industry and develop or share technical knowledge.
I got into bulk handling because... I worked as a student at the Institute of Transport and Automation Technology (ITA) at the University of Hanover, Germany and did an internship at the Centre for Bulk Solids and Particulates Technologies (CBSPT) in Newcastle. Once I returned to Germany, I finished my Engineering degree before I did my PhD on pipe conveyor belts at ITA. I’ve always enjoyed bulk materials handling with conveyor belts in particular and therefore I started as application engineer at Continental.
I am currently researching … In various directions around belts, especially to improve sustainability topics around belt conveyors.
I love my current work because... It gives me the opportunity to find and provide the best suitable solution for the customer and specific technical requirements. Even though the mechanical principles of conveyor belts remain seemingly unchanged, solving technical challenges in the Australian and APAC region together with a great team is motivating me every day.
In my role it’s important to... Be open minded, have open eyes and collaborate in a team. Being close to the customers and develop a feeling for
58 І Australian Bulk Handling Review: January/February 2022
their specific technical requirements is essential every day. Staying connected with the customers as well as with our global team allows me to provide not only proven but also out of the box solutions.
The project I am most proud of is... I had the pleasure of managing an extensive project in Qatar where we delivered and replaced all installed conveyor belts for the customer. The project consisted of a variety of challenging conveyors including pipe conveyors. One of these conveyors was at point of installation the world’s most critical pipe conveyor in terms of ratio between curve radius and pipe diameter. We planned the complete project, designed the required booster and winding machines, had our own international team on site and were able to commission the systems within the given time frame.
My career highlight is... Leading the Technical Consulting Team in Segment APAC for ContiTech Conveying Solutions.
The most valuable lesson I have learned is … Never stop learning. Every challenge has an opportunity to develop the best possible solution with your team.
My plans for the future are … Enhancing and developing my technical knowledge on bulk solids handling. I want to continue building and strengthening my professional network.
When I am not working you will probably find me... Exploring Australia. I’ve travelled as much as possible across WA since I left Germany end of 2018. There’s still so much to do, see and discover. It’s an amazing country to which I always wanted to come back since I finished my internship at the CBSPT as a student.
REGISTRATION FORM
Bulk Solids Handling
AN INTENSIVE SHORT COURSE IN...
GENERAL INFORMATION FEES
Storage, Feeding, Transfer, Belt Conveying
Early Bird Delegate Registration: $2950+ GST (Before 15 February 2022) Delegate Registration: $3450 + GST 5 or more delegates receive a 10% discount. All fees must be paid prior to the event. Fees include program notes, lunches and refreshments. Please note, course presenters are subject to change. All fees must be paid prior to the
Title:
event.
First Name:
VENUE
Surname: Position: Organisation: Address:
The Mercure, Perth WA 10 Irwin St, Perth, WA 6000 +61 8 9326 7000 www.mercureperth.com.au
Bulk Solids Handling Storage, Feeding, Transfer, Belt Conveying
ACCOMMODATION Postcode: Telephone: Facsimile:
CANCELLATIONS
Email: Dietary Requirements:
PAYMENT OPTIONS: Credit Card
Visa
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For credit card payments Please call TUNRA to obtain a link to an online payment portal (please note we do not accept AMEX).
Please note, all face to face courses are subject to current COVID-19 government regulations. If you are unable to attend the event a substitute delegate is welcomed at no extra charge. If notification of withdrawal is received no less than 14 days prior to the event, 80% of the fee will be refunded. No refunds will be made if notification of cancellation is received less than 13 days prior to the date of the event. The organisers reserve the right to alter or cancel the program due to unforeseen circumstances. In the event of cancellation, a full refund of fees will be made.
3-Day Course 15 - 17 March 2022 Perth
Purchase Order
Cheque - Made payable to TUNRA (Please post with registration form)
This registration form should be forwarded together with payment to: TUNRA Bulk Solids Newcastle Institute for Energy and Resources, The University of Newcastle, Callaghan NSW 2308, Australia Tel: +61 2 4033 9055 Email: danielle.harris@newcastle.edu.au
TUNRA Course Brochure_March 2022.indd 1
Presented at
THE MERCURE PERTH W.A
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OVERVIEW BULK MATERIALS HANDLING
The storage, handling and transportation of bulk solid materials are major activities for a vast number and variety of industries throughout the world. These range from the gentle handling of very small quantities of material in the pharmaceutical and chemical industries to the vast quantities handled and processed by the mining and mineral companies. This diversity is particularly evident in Australia where the wide-ranging nature and scale of operations is somewhat unique. Considerable advances continue to be made in research, development, application and implementation of the technologies associated with various aspects of bulk solids handling. This course will be of particular interest to a wide range of industries including: • • • • • • • •
ABOUT TUNRA BULK SOLIDS
Mining and mineral production and processing Power generation Energy and environment Chemical and petrochemical process industries Agriculture processing and production Manufacturing Pharmaceuticals Food industry
TUNRA Bulk Solids are world leaders in applied and fundamental bulk solids handling research and have been in business for more than 40 years. TUNRA has built a strong reputation in industry for its professional services and world class research in materials handling and flow properties. TUNRA have completed more than 4,000 projects for over 1,000 companies across Australia and more than 40 countries internationally. Comprehensive laboratory test facilities are available at TUNRA to aid research and consulting activities at the University of Newcastle. TUNRA is committed to forming long term partnerships with business to help them overcome existing handling problems and assist with planning projects to ensure trouble-free plant operation
THE CENTRE FOR BULK SOLIDS
The Centre for Bulk Solids and Particulate Technologies (CBSPT) is actively involved in both fundamental and applied research on a range of problems associated with bulk solids and particulate technology. Research areas include storage, flow, processing and transportation of bulk solids. It was established in 1995 and supported by the Australian Research Council (ARC) as one of a prestigious handful of national Key Centres of Teaching and Research between the University of Newcastle and the University of Wollongong. The Centre’s Newcastle Node is strongly linked with TUNRA Bulk Solids and the Faculty of Engineering & Built Environment at the University of Newcastle.
3 DAY COURSE OUTLINE FLOW PROPERTIES TESTING
• Description of test equipment and procedures • Influence of storage time and environmental factors such as temperature and moisture • Evaluation of hopper and chute lining materials for friction and wear • Application specific testing (inc. Dust and TML) • Analysis and application
MASS FLOW & FUNNEL FLOW
• Mass-flow and funnel-flow design procedures • Basic and hopper geometry • Interpretation of flow property reports in relation to bin design • Case studies • Dynamic modelling of bulk solids systems
STOCKPILE DESIGN
• Influence of flow properties and geometry on draw-down and live capacity • Selection and positioning of hoppers and feeders for optimising gravity reclaim • Stockpile base pressures and loads on reclaim tunnels, hoppers and feeders
D.E.M ANALYSIS
• Introduction to the Discrete Element Method • Modelling approaches and limitations • Overview of critical model parameters including particle size and shape • Considerations and best practices for industrial application
WALL LOADS
Application of AS3774 for static and flow load cases Gate Loads Symmetric versus Eccentric Discharge Silo Quaking and Shock Loads Loads on Buried Structural Elements
WHY ATTEND THIS COURSE
• Diversify your expertise and further knowledge of materials handling concepts • Professional Development (CPD hours) • Increase awareness of material phenomena occurring on site • Learn methods for troubleshooting, optimisation and best practice design • Develop skills in fundamental and numerical analysis approaches • Learn how to apply flow properties test results to benefit your operation or designs • Stay up to date with the latest developments in industry and bulk solids research
COURSE PRESENTERS
Emeritus Professor Alan Roberts founded TUNRA Bulk Solids in 1975 to facilitate research and consulting services in bulk materials handling. Following Alan’s long standing commitment to the bulk handling industry, he developed, guided and led a team of experts at TUNRA Bulk Solid who continue to be at the forefront of the materials handling industry. Following in Alan’s footsteps, TUNRA continues to offer professional training courses to industry as a part of our commitment to continuous improvement of the materials handling field. These training courses are run by a minimum of 3 experts from our engineering group who are specialists in their fields.
FURTHER INFORMATION Should you require any further information regarding
FEEDERS
TRANSFER CHUTES
• Importance of hopper and feeder interfacing • Review of basic feeder types • Determination of optimum hopper and feeder interfacing for uniform draw-down • Determination of feeder loads, torque and power initial and running conditions • Controlling feeder loads and start-up torque
the course, please contact:
• • • •
Email: danielle.harris@newcastle.edu.au
• • • •
BELT CONVEYING
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• • • • •
3 DAY COURSE INFORMATION
Basic principles of chute design Application of flow properties in the design process Chute flow problems due to adhesion and wear Dynamic modelling of hood and spoon for optimum accelerated flow Optimising chute profiles for feeding and transfer Optimising chute geometry for controlled wear in the flow zone and at the belt feed point Dust control in transfer chutes Application of DEM and CFD in chute design and performance evaluation
TUNRA Bulk Solids The University of Newcastle Callaghan NSW 2308, Australia Tel: +61 2 4033 9055 www.bulksolids.com.au
• Overview of open and closed systems. Special belt conveyors and conveyor selection recommendations • Review of basic design procedures • Economic and technical considerations in optimising conveyor design • Analysis of main resistances – idler indentation, idler spacing, bearings and seals, stress states in bulk solids and contribution to drag. • Specialised testing
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