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VOLUME 26, ISSUE 4 | JULY/AUGUST 2021
In this issue: BULK2021 Showguide Belt cleaners and scrapers Automating bulk handling
DELIVERING ONE OF AUSTRALIA’S BIGGEST UNDERGROUND DOWNHILL CONVEYOR SYSTEMS
Reliable. Tested. Safe. Radar for exact levels in bulk solids applications From simple to challenging: With radar technology that is highly robust, flexible and economical all at the same time, VEGA is putting things on track to ensure more reliable and efficient production processes involving bulk solids – of any kind and any grain size. Due to our decades of experience we understand the requirements of the industry quite well. That’s why VEGAPULS level sensors are able to deliver exact measured values even when conditions get extreme because of dust, noise or buildup.
www.vega.com
CONTENTS JULY/AUGUST 2021
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6 Industry news 10 Event news 12 Product news 14 Fenner Dunlop builds one of Australia’s biggest underground downhill conveyor systems 16 The edge of tomorrow 18 Dust – do we need it? 20 The science and art of designing safer conveyors 22 Premier Tech backs BULK2021’s connection to MEGATRANS 24 MCS tackles dust control for its grab hoppers 26 Pushing forward with LINAK’s actuators 28 Just like the simulations 30 Brilliant belting is the backbone of Boton 32 vWork launches three-way communication 34 Customising silos for the discerning customer 36 Load it up, lock it in and blow it away 38 Bag to the future 40 Bringing over 100 years of industry experience together
42 Bongliglioli’s new orbit 44 Guardian angles 46 Planting the seeds of global agriculture 48 Keep it simple, sensor 50 Practical and effective dust control technologies 52 Keeping the neighbours happy 54 Kotzur leads feedlot design 56 Treotham’s energy chain keeps cables moving 58 Braking the storm 60 The Eagle has landed 62 OPS Group celebrates start of its national distribution 64 Hemp processor improves product 66 Finding efficiencies in conveyor systems 68 The modern challenges of industrial powder conveying 70 A history of wind loading changes 80 Dust in bulk handling operations: sources, testing and passive control through effective design
84 Applying simulation methods to improve dust control outcomes 88 Segregation and stratification in granular mixtures
Belt Scrapers 72 Dyna Engineering’s safer scraper solution 74 Hosch heads east 76 Designing clean bulk material operations
BULK2021 Showguide 94 Introduction 95 Quick reference guide 96 Floorplan 98 Bringing bulk experts together 100 Bulk Handling Award finalists 102 Showguide
Distance Plant Personnel while put and Preventing Contamination
nclosed bulk equipment and systems from Flexicon
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t
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VOLUME 26, ISSUE 4 | JULY/AUGUST 2021
Enclosed Bulk Bag Weigh Batch Systems feed a central weigh hopper mechanically, and remove weighed batches pneumatically, requiring labour only to attach/detach bulk bags.
Bulk Bag Discharging Systems can loosen solidified material and meter it into liquid streams (shown), screeners, size reduction equipment and continuous blenders—automatically.
Flexicon Bulk Bag Filling Lines automatically dispense pallets, fill bulk bags, and disconnect/accumulate filled bags, minimising operator involvement.
TIP-TITE® Drum/Box Tippers seal, tip and mate a discharge cone to a gasketted hopper lid, open a slide gate and feed downstream processes— automatically and dust-free.
In this issue: BULK2021 Showguide Belt cleaners and scrapers Automating bulk handling
FENNER DUNLOP BUILDS ONE OF AUSTRALIA’S BIGGEST UNDERGROUND DOWNHILL CONVEYOR SYSTEMS A coal mine in Queensland’s Central Bowen Basin had a challenge on its hands. The underground mine needed to upgrade its existing equipment to reverse the grade of its conveyors. Instead of running uphill from tail to head, all main gate conveyors would run downhill. Faced with a complex engineering challenge, Fenner Dunlop designed, supplied and commissioned a conveyor system that could generate its own energy.
d systems can move your with fewer personnel, rators from one another.
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DELIVERING ONE OF AUSTRALIA’S BIGGEST UNDERGROUND DOWNHILL CONVEYOR SYSTEMS
For the full story, see page 14.
Australian Bulk Handling Review: July/August 2021 І 3
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AUSTRALIA
EDITORIAL
AUSTRALIA
REVIEW
Published by:
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The race to face-to-face 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, Madeline McCarty Subscriptions T: 03 9690 8766 E: subscriptions@primecreative.com.au
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The COVID-19 pandemic flipped the world on its head in 2020, changing the daily lives of billions. Times of plague have the potential to change societies. In Medieval Europe, the bubonic plague helped to destabilise feudalism and serfdom, giving way to a better way of life for the ordinary people. It was during this period that the concept of quarantine was developed. Historian Susan Mosher Stuard says that in 1377, the Great Council of the busy Mediterranean seaport of Ragusa passed a law establishing Trentino – a 30-day isolation period. This was eventually extended to 40 days and renamed to quarantino, a fundamental concept that has survived to this day, albeit in different forms. Now, instead of waiting outside of castle walls, many find themselves sitting in front of computer screens in the comfort of their own home, using programs like Zoom or Microsoft Teams to stay connected with business partners and family. However, video calls cannot completely replace a face-to-face meeting. Separated through a screen, participants cannot fully experience one another’s body language and other non-verbal communication. That’s why the Australian Bulk Handling Review (ABHR) is proud to support the 2021 Australian Bulk Handling Expo (BULK2021). The event will bring together key decision makers from across the sector, whether they specialise in agricultural silos to overland mining conveyors, to share their knowledge and do business The event conference, hosted by the Australian Society for Bulk Solids Handling, will provide a platform for academia and the business world to learn from one another. Additionally, the event will host the 2021 Australian Bulk Handling Awards, the only awards program that shines a spotlight on the quiet achievers of the Australian economy. Congratulations to all the finalists. The event will be one of the first opportunities since the global lockdown to reconnect with the industry in person and develop relationships with other like-minded business on the show floor. The next edition of ABHR will be the launch of our new Conveyor Showcase, which will highlight companies involved in all things related to conveyors, including belts, scrapers, rollers and more. Coverage will also be included online through Prime Creative Media’s digital platforms and magazines. It will then be housed on the respective websites as a PDF, with an extensive marketing campaign planned to increase awareness.
William Arnott Editor - ABHR
4 І Australian Bulk Handling Review: July/August 2021
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NEWS
WA TAFE builds belt splicing training workshop
The specialist training facility will support the delivery of a Certificate III in Polymer Processing (Conveyor Belt Maintenance and Repair).
CONSTRUCTION IS UNDERWAY on a belt splicing workshop at North Metropolitan TAFE’s Midland campus in Perth, WA. The training facility aims to meet industry demand in Western Australia’s resources sector, address skill gaps and increase the supply of a locally skilled workforce. The shed-style workshop was designed with industry input and will be fitted out with specialist equipment including conveyor belt, splicing tables and reels, ensuring students receive hands-on training. The specialist training facility will support the delivery of a Certificate III in Polymer Processing (Conveyor Belt
6 І Australian Bulk Handling Review: July/August 2021
Maintenance and Repair) – a new course to North Metropolitan TAFE. Armstrong Parkin Architects designed the new facility, with construction undertaken by Perth-based LKS Constructions. WA Education and Training Minister Sue Ellery says the Midland workshop will be used to train apprentices in the operation and maintenance of large industrial conveyor belts – a critical skill in industries such as mining and logistics. “It is vital that we support training for Western Australia’s resources sector, an industry that delivers significant benefits to our local economy and has the potential to employ even more
locally skilled workers. “The $2 million project is in addition to the McGowan Government’s record $167.4 million commitment to upgrade TAFE colleges as part of the WA Recovery Plan.” Midland MLA Michelle Roberts says the facility is a brilliant investment in providing skills and opportunities for our local workforce. “It’ll equip local people to get the skills they need to gain employment in some of the most in demand industries in our State, setting them up for jobs and the future.” Construction is expected to be completed by October 2021, with training commencing in Semester 1, 2022.
EXPERIENCE THE DIFFERENCE
ACROSS 121 COUNTRIES OVER 10,000 SILOS 25 MILLION M/T CAPACITY Contact APAC@aggrowth.com
aggrowth.com Australian Bulk Handling Review: May/June 2021 І 7
NEWS
Inland Rail could save $170M annually in transport costs THE INLAND RAIL PROJECT could save Australian producers, manufacturers, and growers around $170 million in transport costs each year, according to a CSIRO supply chain analysis. CSIRO has developed the Transport Network Strategic Investment Tool to analyse existing freight supply chains and the potential cost reductions based on future infrastructure investments or operational changes. Freight travelling the full length of Inland Rail between Melbourne and Brisbane achieves a higher transport cost reduction of 44 per cent. Finance Minister Simon Birmingham welcomed the initial findings of the CSIRO report that highlighted the significant savings Australia’s supply chains could expect when switching to Inland Rail. “The report recognises businesses as far as Townsville, Perth and Launceston would have the potential to
Freight travelling the full length of Inland Rail achieved a transport cost reduction of 44 per cent.
8 І Australian Bulk Handling Review: July/August 2021
reap the benefits with suitable roadbased supply chains to expect a 44 per cent reduction in their transport costs when switching to Inland Rail,” Birmingham says. “Equally, existing rail-based supply chains are estimated to see an annual cost reduction of around $21 million when shifting at least part of their route to Inland Rail between Melbourne and Brisbane.” Regional Health, Regional Communications and Local Government Minister Mark Coulton says the largest freight rail infrastructure project in Australia would bring extensive opportunities to regional Australia. “This study is the green light signalling to the industry to start planning now because the potential cost savings for being connected to, or close by, Inland Rail are immense for farmers and regional businesses,” Coulton says. “Heavier, faster freight trains will
divert non-bulk products from roads and provide the competitive edge regional Australia has been calling for.” Concrete World is one of the businesses reconsidering options to move freight with rail. The company’s director, Troy Paton, says Inland Rail will be a welcome freight option, provided it can deliver the cost reductions outlined in CSIRO’s study. “Up to 39 per cent savings on the cost of moving freight is huge in this industry; we will definitely be looking at Inland Rail for our future freight needs,” Paton says. “Additionally, it will assist us with further expansion of the business. The time delays in moving freight over the Blue Mountains are a constant constraint.” Full results of the CSIRO Inland Rail Supply Chain Mapping Study will detail the potential cost savings for 140 commodities and is expected to be released in coming months.
NEWS
NT makes first shipment of iron ore from processed waste THE FIRST SHIPMENT OF IRON ore from processed waste materials at Frances Creek Mine in the Northern Territory has left Darwin Port. The NT Government approved the Mining Management Plan for the Frances Creek Mine in March 2020 enabling the processing of existing ore stockpiles at the mine. The Operator of the mine, NT Bullion, has used x-ray technology from German based Steinert to screen waste rock stockpiles at the site to produce export quality iron ore. NT Bullion aims to use this world-first technology to convert low grade ore to
export-quality iron ore at a low cost. NT Mining and Industry Minister Nicole Manison says jobs are critical to Territorians and companies like NT Bullion are well placed to take advantage of the fantastic investment opportunities in the Territory and the record high iron ore. “We know the Territory is resource rich and that a healthy mining sector will deliver more jobs, significantly boost the economy and keep us on track as the Comeback Capital,” Manison says. As part of its Economic Reconstruction, the Territory aims to become a globally significant hub for minerals production, processing, and manufacturing.
The NT Government approved the Mining Management Plan for the Frances Creek Mine in March 2020.
World leaders with over 45 years’ experience in Bulk Materials Handling Research and Consulting TUNRA Bulk Solids develops custom solutions to suit the individual needs of our clients. Services: Flow Properties and Materials Testing Dust (environmental) Testing Wear Testing (Impact, Abrasion and Erosion) Conveyor Belt and Idler Roll Testing Custom Numerical Simulation and Calibration Testing Materials Handling Consultancy and Contracted Research Bin and Stockpile Design Pneumatic and Hydraulic Conveying Technology and Knowledge Transfer Site Visits Professional Development Courses +61 2 4033 9055
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Storage, Feeding, Transfer and Conveying 2021 Course Dates: 18-20 May (Newcastle) 16-20 August (Online) 3-5 November (Perth) Transfer Chute Design: 5-7 July (online)
EVENTS - WOMEN IN INDUSTRY
Women in Industry finalists announced This year’s Women in Industry Award nominees have been selected, with winners to be announced at the Women In Industry Awards Gala evening on 19 August 2021. FINALISTS HAVE BEEN ANNOUNCED for the 2021 Women in Industry Awards, with the winners to be showcased online and through print. The awards aim to highlight the outstanding female leaders and their achievements across the mining, engineering, manufacturing, road transport, logistics, infrastructure, rail, bulk handling, and waste industries. Winners will be announced at a gala event in Melbourne on Thursday 19 August.
Business Development Success of the Year Louise Johnson – Scientific Specialist, BOC Puneeta Chellaramani – Director, KPMG Australia Katherine Walton – Cyclone Specialist, Weir Minerals Kylie Hollonds – Managing Director, GF Oats Australia Lacey Webb – Founder & Director, Resource Hub
Excellence in Engineering, sponsored by BAE Systems Narelle Dobson – Director Special Projects, Department of Transport and Main Roads, QLD Brownyn Evans – CEO, Engineers Australia Ashleigh Fulcher – Mechanical Engineer, Viva Energy Australia Rachel Barrett – Senior Verification and Validation Engineer, Bosch Australia Amelinda Ilardi – Project Manager, ANCA
Excellence in Manufacturing Heidi Bergman – Director of Manufacturing Sciences & Technology, Seqirus Noelle Parlier – Chief Engineer, PACCAR Australia
10 І Australian Bulk Handling Review: July/August 2021
Cori Stewart – CEO, ARM Hub Julie Jones – General Counsel and Company Secretary, Matrix Composites and Engineering Ltd Shay Chalmers – Director, Strategic Engineering Australia Pty Ltd
Christine Morris – Director Human Resources, Komatsu Mining Angela Wiggins – Chief Counsel, BAE Systems Australia Kylie Fraser – President of Consumer & Healthcare Group, Linfox
Excellence in Mining, sponsored by Weir Minerals
Rising Star of the Year, sponsored by Atlas Copco Compressors
Carrie Heaven – Superintendent Mine Services, Glencore Christine Morris – Director Human Resources, Komatsu Mining Carly O’Loughlan – Director, Ore Contracting WA Pty Ltd
Monique Yap – Graduate Engineer, Weir Minerals Louisa Jansen – Site Engineer, Fulton Hogan Kirstie Looke – Crude Scheduler, Viva Energy Australia Deanne Heier – Product Performance Specialist, Norske Skog Isabella Freeman – Project Manager, RoadTek / Department of Transport and Main Roads, QLD
Excellence in Transport Merry Manton – Board Member, Transport Women Australia Limited Penny Ford – Executive Director (Transport Planning Services), Department of Transport and Main Roads, QLD Kirstyn Glass – Rail Operations Consultant, Trapeze Group Asia Pacific Catherine Baxter – Chief Operating Officer, Metro Trains Heather Jones – Director, Pilbara Heavy Haulage Girls
Industry Advocacy Award Megan McCracken – Chair, NAWO Gina Rinehart – Executive Chairman, Hancock Prospecting Jo Sainsbury – Director, Kickass Women Hermione Parsons – Director, Centre for Supply Chain and Logistics, Deakin University Kylie Ward – Asia Pacific HR Director, Stantec
Mentor of the Year Larissa Rose – Director Consultant, Glowing Green Australia Lidia Trehane – Software Engineering Manager, Bosch Australia
Safety Advocacy Award, sponsored by BOC Grace Kube – Graduate Process Engineer, Norske Skog Merry Manton – Board Member, Transport Women Australia Limited Ainsley Fish – Project Systems Representative, RoadTek / Department of Transport and Main Roads, QLD Stephanie O’Dwyer – Manager Health, Wellbeing and Innovation, BlueScope Steel Sabrina Sequeria – Project Engineer, Lighting Protection International
Social Leader of the Year, sponsored by Komatsu Anne Williams – Plant Operations Manager – Rail, John Holland Penelope Twemlow – Director, KPMG Jane Tiller – Ethical, Legal & Social Advisor, Monash University Pranjal Pawar – Project Manager, Development Victoria Jo Withford – Senior Project Engineer, Transport for NSW
Introduces its Mobile Grab Unloader with dust control
Features: • Transportable as 3 loads • Movable on site in 2 readily connectible pieces • Under cover loading in dust shed • Truck cab outside the loading area • Loading controlled through the driver’s window • Driver controls weight loaded into tipper • Screen provides driver with live view of loading
• Hopper supported on skids for loading • Grizzly on top of hopper can support a grab • Certified belt weigher on discharge belt • Dust extraction on hopper and dust shed • Dust recovered and loaded onto belt (no waste) • Up to 2500 tph • Suit ship loading or large projects
For sale, wet hire or contract operation Mobile Conveying Services Pty Ltd PO Box 608, Narangba Qld 4504 1300 665 409 631 Uhlmann Road, Burpengary QLD 4505 enquiries@mobileconveyors.com.au www.mobileconveyors.com.au
CONSTRUCTION
SHIPPING
PRODUCT NEWS
New ESS conveyor belt secondary cleaner hits market ESS ENGINEERING HAS RELEASED the new ESS IPS Secondary, combining the design features of the 20Ten Inline cleaner with new features that improve serviceability and safety. Carryback from conveyor belts is an everyday occurrence, resulting in reduced operation efficiency, reduced safety, increased maintenance cost and increased environmental contamination. ESS IPS Cleaners deliver high-quality belt cleaning performance and highquality serviceability for a variety of applications. Like the ESS 20-Ten Inline Premium, the IPS Cleaner utilises a mainframe and cartridge manufactured from stainless steel, making them suitable for all environments, including sites that deal
with corrosive material. The narrow profile design of the IPS Cleaner allows installation in confined spaces like restrictive head chutes. The new IPS cartridge design fully encapsulates the mainframe, reducing the material that can build-up inside the cleaner, making it safer to service with less effort. The IPS Belt Cleaner is usually used in conjunction with a head pulley primary cleaner such as the ESS XHD, DT or TM DOCTOR BLADE Primary Cleaners. The IPS cleaner is normally mounted so the cleaning blades contact the belt as it leaves the head pulley or other
The IPS Belt Cleaner is usually used in conjunction with a head pulley primary cleaner.
accessible position on the return belt. The blades of the IPS, when tensioned, lay in the direction of belt travel, contacting at a negative angle and presenting no snag or danger to the belt or splices. The belt cleaner’s other features and benefits are narrow profile design, new tensioning bracket design, ESS tensioning devices for blade adjustment while the conveyor belt is running and modular blades that allow for the optimal blade to belt contact.
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Aerobelt starts supplying US rice industry AEROBELT AUSTRALIA IS NOW exporting its conveyors to the Unites States for the rice industry. The company has made extensive investments into the market across the past four years, attending two rice conferences plus additional visits to the US to promote the Aerobelt system. Aerobelt’s agent in the US is Premier Tech Prairie, part of the Premier Tech Systems and Automation Group based in Johnstone, Iowa. The company has supplied six conveyors to Kennedy Rice in Louisiana, which include a 400 millimetre-wide belt and five 500 millimetre-wide belts for 50 tonnes per hour and 100 tonnes per hour of food grade rice. Lengths vary
Aerobelt has supplied six conveyors to Kennedy Rice in Louisiana, in the US.
from 16 metres to 48 metres long. The 400 millimetre conveyor was shipped in mid-2020, followed by the 500 millimetre conveyors later in the year. The first conveyor performed
as per the design and faced no operational issues. Aerobelt is also shipping another two 400-millimetre conveyors for food grade rice to Farmers’ Rice Cooperative based in Sacramento, California.
Distributing Irish ingenuity IRISH MANUFACTURING SERVICES (IMS) was formed in 2010 by a team of specialists in the mining, quarrying, recycling, and materials handling industries. Its range of pugmill, mixers, blenders and conveyors can add powders and liquids to neutralise contaminates in the material being handled, reducing the environmental impact, and eliminating the need for the removal and importing of replacement materials, truck movements and dumping fees along with mixing cement and lime for the construction industry. The IMS pugmills and blenders are available on tracks and offer modular electric visions. They can be manual or fully automated with a PLC control and recording system to ensure the correct mix percentages of powders and liquids are added. The company’s track and wheel conveyor range include radial conveyors, high production 1200-millimetre-wide
Crusher Screen Sales & Hire is the Australian distributor for IMS.
belts, and the option for electric or dual diesel electric drives. This allows them to connect to mains power without sacrificing the mobility to move on tracks. The IMS MC1200 – 20T heavy duty track conveyor can move materials at up to 700 tonnes per hour and can use be operated with a jaw crusher at the quarry face. The track conveyor can then transfer material to secondary crushers and screens working on the quarry floor, reducing the need to move the whole crushing train along the blast face and remain operating on a flat area. Automation can be built into
the conveyors, allowing the radial conveyors to automatically radial return and lift as the stockpile increases in height, reducing the separation of the material. The pugmill, blenders, feed hopers and conveyors can be automated to operate as one plant to ensure constant flow and reducing bottlenecks and overflow. Crusher Screen Sales & Hire is the Australian distributor for IMS and offer the company’s range of plant, including track pugmills, blenders, track and wheel conveyors, feed hoppers and screening plants for sale and hire.
Australian Bulk Handling Review: July/August 2021 І 13
COVER STORY
All the equipment has also undergone full load testing in the workshop before being sent to site.
Fenner Dunlop builds one of Australia’s biggest underground downhill conveyor systems Faced with a complex engineering challenge, Fenner Dunlop has designed, supplied and commissioned a downhill conveyor system that generates its own energy. A COAL MINE IN QUEENSLAND’S Central Bowen Basin had a challenge on its hands. The underground mine needed to upgrade its existing equipment to reverse the grade of its conveyors. Instead of running uphill from tail to head, all main gate conveyors would run downhill. One of the engineering obstacles was finding a way to ensure operators could have complete control over the descending material. The four-kilometrelong conveyor is capable of handling 3500 tonnes an hour and the mine wanted to ensure it could operate under all load conditions safely and effectively. Mark Wilcock, Branch Manager and Mechanical Engineer at Fenner Dunlop’s ACE Queensland division, led the upgrade project and has been involved in the twoyear upgrade from the very beginning. He says that in the initial study stage, it was clear that the downhill angle of the
14 І Australian Bulk Handling Review: July/August 2021
conveyor was so aggressive that it would be capable of generating its own power. “Normally, most downhill conveyors aren’t on such an aggressive slope and are therefore incapable of generating their own power. This introduced a range of additional factors to be considered, which made it a unique and challenging project for us,” he says. “We proposed to upgrade the customer’s existing conveyor technology from the previously installed Controlled Start Transmission (CST) system to an electrically-controlled variable speed drive (VSD) system. “The big advantage to using VSD technology in a system like this is it provides significantly more control over the conveyor during starting and stopping scenarios.” Wilcock says the CST system is essentially a large clutch which is slowly
engaged against a motor running at 100 per cent to bring the conveyor up to speed. “While this is fine for uphill conveyors, when going downhill and especially when starting under a regenerative load, the CST drive can’t control any of the negative power until the motor reaches full speed,” he says. This means a complex process is required to drive through mechanical brakes until the conveyor is up to speed and any failure of these components could create a period where the conveyor belt is out of control, which can lead to serious safety issues. By comparison, the VSD system incorporates a simple direct drive gearbox coupled to an electric motor which is speed and torque controlled through the substation and PLC control system. This control system is continually
monitoring for a regenerative power condition and will automatically provide the negative power required to achieve the desired speed control during all controlled starting, running and stopping conditions. This regenerative power is fed straight back into the grid without generating any additional heat. Safety was at the forefront of everything involved with the project, starting with an overarching risk assessment. Wilcock says ACE lead the risk assessment process and pushed to have as many people from the site involved as possible, with around 20 people providing their input. “We really want to be at the forefront of conveyor planning, so we engage with the people on site who will be responsible for the ongoing conveyor operations and maintenance as early as possible in the design process,” he says. “All of the conveyor engineers from the site, along with several operators, fitters and electricians spent a week in total helping assess potential risks associated with the new system. We really value this involvement from the customer and strongly believe this up-front approach to risk management results in a much safer and more productive system in the long run.
Redundancy is baked into the system to ensure the failure of any one component cannot result in a hazardous situation for the mine. If the mine ever loses power, fail-safe mechanical braking stations along the conveyor activate to bring the belt to a controlled stop in a safe timeframe. All the equipment has also undergone full load testing in the workshop before being sent to site. This involved a full 11-kilovolt power-up of the substation, regenerative load tests and dynamic brake tests. This provided the customer another level of confidence that the equipment would function as designed once in operation. Updating to the VSD system had the added benefit of reducing the number of moving parts, helping to create a much more reliable system. Eventually, when the conveyor moves to the next area of the mine, the system can easily be reverted to an uphill conveyor system. Fenner’s team have now completed commissioning of the first conveyor and are busily preparing for testing and commissioning of the second conveyor. The customer has contracted Fenner to maintain a key role in the ongoing operation of these conveyors, providing ongoing commissioning services at key stages of the mining sequence.
In addition, Fenner will provide remote monitoring support to detect any issues that may arise and deploy a team to site to resolve them as needed. Wilcock says with the new system, Fenner can log in remotely and check on the operating parameters of the conveyor. This is particularly important in the event of a breakdown, as it allows engineers quick access to help diagnose the problem. “A major benefit during the project was the ability for the mechanical, electrical and belting engineers to work so closely together. Being a one-stop shop for the complete conveyor system allows an in depth understanding of how all components interact, resulting in the most efficient conveyor system possible,” he says. “Fenner takes pride in the conveyors we deliver, and we want to provide confidence to the customer that our service continues well beyond the delivery of the equipment to site. We offer a complete solution encompassing design, supply, commissioning, installation and maintenance services.” “When we supply a complete solution, we know how all the parts interact, creating a cost effective, efficient, and inherently safe system. For our customers, we are one point of contact – we do it all.” VSD technology provides significantly more control over the conveyor during starting and stopping scenarios.
Australian Bulk Handling Review: July/August 2021 І 15
AUTOMATION
The edge of tomorrow thyssenkrupp Industrial Solutions has developed a new device that can automate existing bulk handling machinery. loading, unloading, stacking, reclaiming, or anything the machine could do normally,” he says. “We have installed systems on ship loaders that have been able to handle a full load without a single person on site. Semi-automated functions are also popular, such as anti-collision or finer detail control.” Depending on what systems are installed, the Edge can perform full machine diagnostics, assist with
Laser and LIDAR sensors can help determine the position of a bucket excavator from a wall better than a human operator ever could from a cabin.
AUSTRALIANS ARE COMING TO terms with the Internet Of Things (IoT), with more than 61 per cent of households adopting at least one smart home product, according to the Telsyte Australian IoT@ Home Market Study 2020. Digitalisation of devices is creating smarter machines, whether it’s a smart speaker or smart stacker/reclaimer. Scott Clenaghan, Regional Sales Manager at thyssenkrupp Industrial Solutions (Australia), says the technology is now at the point where equipment is stepping into the next level of smart machine. “Automating machinery adds an extra level of safety, throughput and utilisation,” he says. “You no longer have restrictions between the timing of shifts or interchange between machines. Anti-collision devices talk to each other and allow the machinery to operate more efficiently.” “Laser and LIDAR sensors can determine the position of a bucket
16 І Australian Bulk Handling Review: July/August 2021
excavator from a wall much better than a human operator ever could from a cabin, allowing it to get much closer safely.” This is why thyssenkrupp developed the Edge – a specialised computer that helps automate bulk handling machinery. The Edge has been installed on more than 100 sites and can be used to retrofit machinery into a smart network. It connects to a Programmable Logic Controller (PLC) and acts as a translator between the two systems. From there, it can mimic the full operations of the machine through sensors installed in the machinery. A data logger examines the information gathered through operation and finds ways to optimise the user’s processes. Clenaghan says the Edge allows users to automate their machines to the level required, it’s all dependent on how far they want to go. “The Edge device sits on each machine and can then be programmed to handle
predictive maintenance, remind customers of upcoming maintenance dates and shutdowns, and even perform predictive wear analysis for parts. Uwe Zulehner, thyssenkrupp Industrial Solutions, Director of Sales and Service, and Head of QM and Business Excellence, says a lot of minds are currently being changed as the implementation of smart devices increase. “Customer organisations and demographics are changing,” he says. “A few years ago, it was hard to identify who was best to talk to in a clients’ organisation when it comes to digitalisation.” “We’ve seen big changed over the past 12 to 18 months as more mining organisations begin to implement specific teams to implement these technological changes. We intend to build a business cases and work as partners alongside our partners, not just install a couple of sensors on site. “Safety has been main factor behind the need to upgrade. It is unacceptable for anyone on a mine site to be hurt or injured. The second driving force is to increase machine uptimes, productivity and performance, which is especially relevant as commodity prices continue to fluctuate.” Modularity is built into the system, with customers able to decide just how much they would like to automate. thyssenkrupp aims to work with customers to find exactly what they need, instead of designing solutions
around what the technology is capable of. The Edge can also be installed in any machinery that can connect to a PLC, from small crushers to massive stackers. Safety and security were major factors in the design of the device, which is why no software can be modified while the machine is operational. Data can be stored on the cloud or on local servers to maximise security if required. Zulehner says nowadays, nobody can afford to be ignorant when it comes improving operations through digitalisation. “It’s an essential part of doing business, which is why thyssenkrupp aims to be at the forefront of this development,” he says. “We will continue to support our customers to make the move over to smart machinery and continue to grow as a technology-focused business.” As part of this focus, all new thyssenkrupp machinery will come equipped with Edge devices. The
The Edge can perform full machine diagnostics, assist with predictive maintenance, and remind customers of upcoming maintenance dates and shutdowns.
Australian branch has also hired an electrical automation engineer to support the growing sector locally. Clenaghan says the next step for this technology is artificial intelligence. “Once this technology is fully embraced, we are likely to see fully automated systems in mines providing
better quality throughput than a human ever could,” he says. “We’re already beginning to see it happen today. Rio Tinto and BHP have begun to fully automate their trucks, taking humans out of dangerous environments. The possibilities are endless.”
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DUST CONTROL
Dust – do we need it? Sean Kinder, the Field Applications Engineer at Kinder Australia, explains how engineering controls can drastically reduce dust emissions. DUST IS THE UNCONTROLLABLE fugitive emission from a process which escapes into the environment. It can occur in almost all bulk material processing industries. Construction industries require fine aggregates and sands from quarries for road base and concrete. To extract gold, copper, lead, zinc, and nickel from their parent ores in a mine, the processing plant must grind the material to an ultrafine particulate where it can be separated. Crushing and refining of bauxite into alumina powders is the manufacturing technique of smelting aluminium. Unfortunately, given its physical properties, dust can cause respiratory and cardiovascular disorders. According to Safe Work Australia to reduce the risks of silicosis an agreed respirable exposure of crystalline silica will be reduced to a time weighted average of 0.05 milligrams per cubic metre. Coal mines also must contend with the hazardous dust particles where prolonged exposure can lead to coal workers pneumoconiosis or chronic obstructive pulmonary disease. To manage risks, organisations and individuals should perform a risk assessment which may involve utilising the hierarchy of control (elimination, substitution, engineering controls, administrative controls, and personal protective equipment). Elimination and substitution are borderline impossible given that most bulk material handling process facilities require the dust to obtain their final product. Therefore, engineering and administration controls must be utilised with personal protective equipment technologies. Dust has been observed to occur mostly when presented with an unnatural excitation of its surrounding environment due to turbulence. In a processing plant for example, dust forms in crushing and screening chambers and poorly designed
18 І Australian Bulk Handling Review: July/August 2021
Air pressure can expel dust from system at a higher volume than the design capacity of the system.
conveyor transfer chutes. It’s observed that if the output air pressure is not equal to the introduced air pressure, and lighter than the processed asset, material in the form of dust will fill all voids in the system and escape via any means possible (holes, gaps). Being a lighter material, fines when excited, take longer to settle than the bulk handled. When designs don’t take into consideration the settling time of the finer particles, they remain in the atmosphere resulting in emission. In some cases, the air pressure can be so great that it will expel from system at a higher volume than the design capacity of the system. Engineering controls are the first line of defence against dust. To minimise dust emissions from conveyor transfer points, a skirting system is installed in the loading zones to seal accordingly. Skirting systems are generally made up of a hard-internal primary skirt (which holds the larger asset), protecting it from damaging the secondary skirting. Secondary skirting (made of rubber or polyurethane) seals the transfer point from emitting dust into the environment. Unfortunately, the skirting systems are often a rushed component of the overall conveyor design, often being inserted almost during the commissioning phase of projects which prove a lack understanding. Generally, an area of cost cutting and poorly designed, transfer points and skirting systems are one of the first locations to be reviewed during the first months of a new operation.
On a conveyor system, they would be considered one of the most frequently complained about locations due to their confined working conditions and dusty environments (which require continuous cleaning by plant operators). There is a variety of different types of skirtings that can be installed. Selection should always be considered early on during the design stages of the project plan as a number of factors need to be taken into consideration, to ensure that an engineered control is being provided. Some skirts apply a vertical seal, whereas other lay-in and offer self-adjustment. Mounting and clamping systems also vary depend on the allowable heights provided by the surrounding steelwork. Skirting should never be fouled by ‘bolting or screwing through’. By doing this, once the skirting wears away gaps will form and the skirting will not be able to be adjusted leaving a permanent dust emission point, until the skirting is fully replaced. Depending on production requirements, this might be left in this position for several weeks. An important subject which is often misplaced is that of freeboard, the distance between the outer edge of the chute and the edge of the conveyor belt. This is the space where the secondary dust skirting is installed. Often, in the event of higher loading on to the conveyor belt and increasing throughput, freeboard is sacrificed. This is very problematic for a secondary skirting system. If the conveyor belt mistracks,
which is common in transfer points too due to many factors, it will creep under the skirting, popping the skirting material and create gaps. This allows dust to escape and results in emission. An added dilemma is when the conveyor belt tracks back to a central position (or even the other side if conditions are worse), the conveyor belt is known to cut through and prematurely fail the popped skirt. Freeboard should always be considered in conveyor transfer point design. Conveyor belt sag between idlers in transfer points is another common observed dust emission point on conveyor systems. Sagging is the result of material loading on to the flexible conveyor belt. The weight of the bulk material enables conveyor belt to dip in unsupported areas. Although sag is generally only few millimetres, it is enough for a gap to form between the secondary skirting and the conveyor belt resulting in emission. Sag can be eliminated by utilising a conveyor belt support system or impact bed (if
the application includes large primary or secondary lump bulk materials). Compromising the skirting system and conveyor belt performance itself, some conveyors are designed and fabricated without the understanding of a designated transition and transfer point. The transition point is defined as the area in which the conveyor belt changes its profile from zero degrees (horizontal when it wraps around a pulley) to the desired troughing angle. In confined locations, some conveyors have seen to have ultra-short, borderline non-existent transition points. This results in the bulk material impacting and loading on to the conveyor belt, while the conveyor belt is forming from a zero to 35-degree (or steeper) trough profile. Attempting to apply a secondary skirting system to an application that is changing its profile seldom functions as intended and generally always result indust emissions. Another common way of controlling
dust is with the addition of water. By adhering to the dust particles, clumping them together and increasing the weight, water quickly supresses the dust slowing is projection velocity and causing it to lose momentum allowing it to fall into the material flow. This technique when implemented well by professionals can dramatically reduce the dust emissions in many applications by carefully and methodically. Attempting to add water via a hose without taking into consideration many other parameters can lead to costly issues including oversaturation of product (material loses specification) or plant blockage due to screens blinding or chutes hanging up. Important in production of materials, dust will be impossible to eliminate within the bulk materials handling industry. It does need management though. Utilising engineering controls and taking progressive and innovative steps, dust emissions and safety standards can be improved.
SAFETY
The science and art of designing safer conveyors Engineers from Martin Engineering explain how combining a mixture of hierarchies can lead to safer, more efficient conveyors. NEW CONVEYOR SYSTEMS WILL inevitably succumb to the punishing bulk handling environment and begin the slow process of degradation. The system will eventually require more time and labour for maintenance, shorter spans of time will pass between outages, downtime periods will become longer, and the cost of operation will continue to grow. The chance of injury or fatality increases as well, as workers are further exposed to the equipment to perform cleaning, maintenance and to fabricate short-term fixes to long-term problems. When examining the safety of a system, improving efficiency and reducing risk can be achieved through a hierarchy of control methods for alleviating hazards. One of the most effective ways to mitigate risks is to design the hazard out of the component or system. This usually requires a greater initial capital investment than short-term fixes, but can yield more cost-effective and durable results.
The science: hierarchy of control methods Designs should be forward-thinking, exceeding compliance standards and enhancing operators’ ability to incorporate future upgrades cost-effectively and easily by taking a modular approach.
Safety improves as the type of hazard control moves higher up the hierarchy of methods.
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Incorporating effective hazard control techniques is easier and less costly in the early stages of a project.
In many cases, it will be necessary to use more than one control method, by incorporating lower ranked controls. However, these lower-ranking approaches are best considered as support measures, rather than solutions in and of themselves. PPE includes respirators, safety goggles, blast shields, hard hats, hearing protectors, gloves, face shields and footwear, providing a barrier between the wearer and the hazard. They can be worn improperly, may be uncomfortable to use through an entire shift, can be difficult to monitor and offer a false sense of security. But the bottom line is that they do not address the source of the problem. Administrative controls (changes to the way people work) create policy that articulates a commitment to safety, but written guidelines can be easily shelved and forgotten. Establishing ‘active’ procedures can take these controls a step further. For example, supervisors can schedule shifts that limit exposure and require more training for personnel, but
these positive steps still do not remove the exposure and causes of hazards. Warning signage is generally required by law, so this is less of a method than a compliance issue. Installing systems such as engineering controls that allow remote monitoring and control of equipment – or guards such as gates and inspection doors that obstruct access – greatly reduce exposure, but do not remove the hazard. Using the substitute method replaces something that produces a hazard. For example, manual clearing of a clogged hopper could be replaced by installing remotely triggered air cannons. Examples of eliminate by design are longer, taller and tightly sealed loading chutes to control dust and spillage or heavy-duty primary and secondary cleaners to minimise carry back. Engineers can use hazard identification and risk-assessment methods early in the design process to create the safest, most efficient system for the space, budget and application.
Risk assessment applied to design helps create a safer conveyor system.
Low-bid process and life cycle cost Although the policy is generally not explicitly stated by companies, the Low-Bid Process is usually an implied rule that is baked into a company’s culture. It encourages bidders to follow a belt conveyor design methodology that is based on getting the maximum load on the conveyor belt and the
minimum compliance with regulations using the lowest price materials, components and manufacturing processes available. But when companies buy on price, the benefits are often short-lived, and costs increase over time, eventually resulting in losses. In contrast, when purchases are made based on lowest long-term cost (life-cycle cost), benefits usually continue to accrue and costs are lower, resulting in a net savings over time.
The art: design hierarchy
safety demands. Built competitively with a few modifications in critical areas, an evolved basic conveyor is a standard bulk material handling conveyor designed to allow easy retrofitting of new components that improve operation and safety, solving or preventing common maintenance problems. Installing maintenance solutions in the loading zone can greatly improve safety and reduce man-hours and downtime. These components include slide-in/slide-out idlers, impact cradles and support cradles. On larger conveyors, maintenance aids such as overhead monorails or jib cranes assist in the movement and replacement of components. Designers should ensure adequate access to utilities – typically electricity or compressed air – to facilitate maintenance and performance. Dust, spillage and belt tracking are top concerns for many safety professionals. Field tests have shown that enlarged skirtboards and engineered settling zones promote dust settling and reduce fugitive material. Curved loading and discharge chutes control the cargo transfer for centred placement and reduced turbulence. As the load is centred on the belt, guides ensure even travel through the take up to promote consistent belt tracking. Any transfer point is prone to build-up and clogging under the right conditions. Flow aids such as vibrators or air cannons on chutes can sustain material movement, improve equipment life and reduced the safety hazards associated with manually clearing clogs. Although design absorbs less than 10 percent of the total budget of a project, additional upfront engineering and applying a life cycle-cost methodology to the selection and purchase of conveyor components proves beneficial.
Life cycle costing should play into all component decisions. Buying on Life Cycle Cost and anticipating the future use of problem-solving components in the basic configuration of the conveyor provides improved safety and access, without increasing the structural steel requirements or significantly increasing the overall price. It also raises the possibility for easier system upgrades in the future. Using the hierarchy of controls along with the design hierarchy, engineers will be able to construct an ‘evolved basic conveyor’ that meets the needs of modern production and
The return on better design and quality is realised over the extended life and safety of the system.
Rather than meeting minimum compliance standards, conveyor systems should exceed code, safety and regulatory requirements.
Australian Bulk Handling Review: July/August 2021 І 21
BULK2021
Premier Tech backs BULK2021’s connection to MEGATRANS Following the success of MEGATRANS2018, ABHR sits down with Premier Tech Managing Director Francois Steyn to ask what value the company sees in BULK2021. AUSTRALIA’S TRANSPORT AND logistics industry earns an estimated revenue of $96.65 billion each year, employs nearly half-a-million people and is being rapidly affected by a surge of new technologies, according to Australian Industry Standards’ 2018 Transport and Logistics discussion paper. It also says that by 2020, there will be more than 50 billion Internet of Things (IoT) devices around the world, with spending on connected logistics solutions expected to more than double between 2018 and 2020. The global pandemic that swept the world in 2020 and the shift to online work has helped to highlight the importance of this digital technology. Francois Steyn, the Managing Director of Premier Tech, says the logistics industry
Premier Tech, formerly known as Kockums Bulk Systems, manufactures technology to handle and package bulk powders.
22 І Australian Bulk Handling Review: July/August 2021
and in particular manual handling, is facing rapid transformation. “We’ve observed that much of Victoria’s manufacturing industry is now being replaced by warehouses and logistics operations,” he says. Premier Tech, formerly known as Kockums Bulk Systems, takes pride in being a leader in the field of handling and packaging difficult to convey bulk powders. Traditionally, the company targeted the manufacturing industry, as many processes involve some sort of powder. However, as the market developed, the business began to diversify its offering to cover the needs of the growing logistics industry. The company’s first major foray into logistics was at MEGATRANS2018, one of Australia’s biggest intermodal logistics trade events, where it was able to display its manual handling solutions. “MEGATRANS was such a valuable event, as we connected with a new demographic of customers and listened to some of the issues they were facing in their day-to-day operations,” Steyn says. “So, when we heard that BULK2021 would be connected to MEGATRANS2021, we knew we had to jump on board to showcase our materials handling capabilities as well as our manual handling solutions. We will truly have a foot in both camps of the show.” The Australian Bulk Handling Expo 2021 (BULK2021) is Australia’s only exhibition dedicated solely to the bulk solids handling industry. The event, which will take place from 8 to 10 September 2021, is designed for businesses that are bulk commodities producers, which require the use of equipment for the movement of bulk goods, domestically or internationally. Held in conjunction with MEGATRANS2021 at the Melbourne Convention and Exhibition Centre, BULK2021 will showcase some of the latest
technology, equipment and services the bulk handling industry has to offer for manufacturers and producers. Some examples of the equipment that will be on display include conveyors and their components, motors and drives, belt scrapers, container tipplers, weighing and level measurement devices. Steyn says he is keen to see how the connection between the two shows will provide additional value. “MEGATRANS2018 was big, so with the addition of the bulk handling side of things, we expect there will be even more networking opportunities available,” he says. “It also helps get all the suppliers together in the one room, letting people see what’s going on in the industry, who is doing what, and plans for moving forward.” As part of this industry collaboration, the Australian Society for Bulk Solids Handling (ASBSH) will host an industry conference at the inaugural event. “It has been many years since we had an exhibition dedicated to bulk handling in Australia, and this will be an excellent opportunity to connect bulk handling engineers with suppliers across multiple industries,” Mark Jones, President of the ASBSH, says. “We will be advising organisers Prime Creative Media on the conference program and look forward to seeing you all there.” Simon Coburn, the BULK2021 Show Director, says that since announcing the event, there has been plenty of local and international interest from potential exhibitors and visitors. “It’s exciting to have all these exhibitors together, in not only a great place for business opportunities, but also a fantastic occasion to network within this fast-paced and essential industry,” he says.
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DUST CONTROL
MCS tackles dust control for its grab hoppers Mobile Conveying Services has developed a variant of its mobile grab hopper that has significant potential to capture volume sales. DUST CONTROL IS A SIGNIFICANT issue that affects many industries, including bulk handling. While conveyors generate less dust than equipment alternatives, there are still issues at transfer and discharge points that require addressing. Mobile Conveying Services (MCS) began work on its dust control solution soon after its mobile grab hoppers were released to the market. Graeme Cooney, MCS Director, says a client using the company’s standard grab hopper for ship unloading suggested that a dust control system would be a great addition for cargoes prone to creating dust at transfer points. “We were happy to pursue this as we had already been researching dust control for other equipment. While conveyors generally create less dust than mobile equipment because the bulk material does not move relative to the belt, we are conscious that transfer points can create dust and have been looking at technologies to suit this application,” he says. “Our dust control system uses a portable dust shed to load trucks from the grab hopper transfer conveyor. A telescopic chute controls dust at the discharge point while a dust extraction system collects dust from the grab hopper and dust shed, filters out the material and returns it to the belt so that no material is wasted and there is no dust disposal problem.” Doors below the grizzly bars that only open downwards prevent dust from moving upwards out of the hopper and rubber curtains at the top of the grab hopper control dust movement around the discharging grab. There is also an air curtain at the exit of the dust shed. The standard mobile grab hopper
24 І Australian Bulk Handling Review: July/August 2021
Dust control pipework for the grab hopper and dust shed.
can be towed on the highway as a single load. However, the dust control system involves substantial additional equipment that increases the highway transport requirements, including a step deck for the dust shed and a semi-trailer for the
removable dust extraction equipment. When moving on site, the dust extraction equipment remains attached to the grab hopper while the dust shed is on wheels and can be towed around the site. Once in position, the grab unloader
Truck being loaded in the portable dust shed with dust extraction, telescopic discharge chute (not shown), and air curtains.
and dust shed are quickly connected via flexible ducts. Usability is another key feature. The truck cab is outside the shed during loading and the driver can reach a control pad through the window to enter the payload that they can carry. A large screen connected to a camera in the loading area allows the driver to see the loading and drive forward as required to distribute the load evenly. In the past, MCS has modified equipment that it has bought ‘off the shelf’ to better meet its requirements. It is the knowledge built up over years of modifying standard equipment from traditional suppliers that has gone into the development of “ground up” MCS equipment such as the mobile grab hopper. While MCS has modified equipment to better suit its purposes and built oneoff equipment for specific projects, the mobile grab hopper and its companion dust control system are the first pieces of
equipment that MCS has developed from the ground up with a view to commercial sales both in Australia and overseas. Cooney says this is the start of the MCS journey to produce a broad range of niche bulk handling equipment and systems with core values of productivity, ease of movement, set-up, operation and maintenance, safety, and environmental responsibility. “MCS will continue to operate equipment selectively as it provides valuable on-the-ground input to guide and refine product development,” he says.
“As we move forward in developing other equipment, OHS will be a cornerstone of design.”
While the skeleton of the mobile grab hopper with dust control has been built for some time, it has been undergoing rigorous testing in the yard of the MCS factory at Burpengary East in Queensland, with subtle modifications being made to refine it and improve
Cooney believes that the extraction system has application beyond the MCS grab hoppers. “Dust is recognised as a significant occupational health and safety (OHS) risk, and we want to provide a safe working environment not only for our people but also for others who work with or around our equipment,” he says. “As we move forward in developing other equipment, OHS will be a cornerstone of design. Already, our mobile conveyors with remote control provide a safe working environment because people don’t need to work close to the equipment, but we want
its dust capture.
to reinforce those benefits.”
Rigorous proving before going to market
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ACTUATORS
Pushing forward with LINAK’s actuators Electric linear actuator specialist, LINAK, has developed new products and solutions for industrial operations. ELECTRIC ACTUATORS COMMONLY provide the force and movement required for many bulk handling applications, especially in the grain handling industry. An electric linear actuator essentially consists of a housing with a DC motor, gearing and a spindle inside with a moving piston rod, to simply provide the force to move heavy loads effectively, efficiently and reliably. Andrew Cooper, Australia Industry Business Unit Manager for LINAK Australia says they are typically designed to last for thousands of cycles which results in many years of maintenance free operation for most applications, but a few applications require a very high number of cycles and for these applications one of the lifetime limiting factors can be found in the motor itself. “The brushes in a brushed DC motor wear. For most applications this is not an issue, and an actuator lifetime of many years is common. But for applications with a very high number of cycles this can be limiting, which is why we have designed an actuator with a brushless DC motor, typically increasing its lifespan by a factor of 20.” LINAK specialises in the design and manufacture of electric linear actuators. It works closely with its customers to develop new products that will help solve their problems. One trend Cooper says is becoming increasingly popular is the integration of electric actuators into the fieldbus communications network of automation systems. “LINAK actuators can be easily integrated into a site’s automation system’s communication network
26 І Australian Bulk Handling Review: July/August 2021
C
LINAK’s TECHLINE range of actuators have been designed for industrial equipment.
enabling simple control and monitoring of the actuator and providing access to a wealth of valuable data points that can provide actionable insight for operators,” he says. “The more insight plant operators have on the operating status and condition of equipment installed on their plant, the better. Access to this data allows plants to roll out things like predictive and pre-emptive maintenance and to keep the plant operating as efficiently as possible.” To accommodate this, LINAK’s actuators can be integrated into automation systems using many different protocols including CANopen and I-O Link. This allows the devices to seamlessly work alongside other machinery in the plant. Cooper says as soon as the actuator is connected to an automation system’s network, the information gathered becomes much more sophisticated. In many cases, all that is required of the actuator is to extend or retract. However, more complex applications may change the speed of the actuator or gather information on operating data such as current, temperature and the number of strokes.
M
Y
LINAK’s TECHLINE range of actuators have been designed for industrial equipment, which is why their robust design includes a heavy-duty aluminium housing and a high IP66 rating, even when operating. Each actuator goes through an extensive testing programme including salt spray, chemical resistance, climatic and vibration tests to ensure they can handle the intense environments. The company will be exhibiting at BULK2021 from 8 to 10 September at the Melbourne Convention and Exhibition Centre. On display will be several of the company’s actuators for attendees to get up close and personal with, alongside miniature grain silos showing common actuator applications. Cooper says the event will provide an excellent opportunity to engage face-to-face with customers, both new and existing. “Despite the capabilities of remote meetings, the industry needs that faceto-face interaction,” he says. “BULK2021 will allow us to show our range of robust, reliable actuators and how they can help derive additional value on site.”
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SIMULATION
Just like the simulations Discrete Element Method (DEM) modelling software gives engineers all the information they need to design bulk handling systems. ABHR speaks with Peter Rizkalla, Rocky DEM Product Manager at LEAP Australia, to learn more. TO OPTIMISE THE DESIGN OF A bulk material handling system, it is important to have as much information as possible. Without having a good understanding of how your material flows through the system, it can be difficult to achieve the throughput targets required. In some cases, it is almost impossible to get this information simply due to how a system is built or operates. In other cases, building a prototype is prohibitively expensive and not worth it in the long run. This is where simulation software can add value, and according to Peter Rizkalla, the industrial use of DEM software such as Rocky DEM is becoming more and more popular. “A lot of engineers are confronted with problems which involve the design and troubleshooting of machinery but can’t always access the data they need, no matter how many sensors or cameras are onboard,” he says. “This can be particularly important for equipment operating close to capacity or in extreme conditions, such as transferring wet, sticky ore. In addition, there can be a safety aspect to this, as not all equipment is safe to access while it is operational. “Such problems are addressed by
LEAP Australia is a sponsor of the BULK2021 industry conference.
28 І Australian Bulk Handling Review: July/August 2021
DEM software provides engineers with the data they need to tackle complex problems.
simulation software which provides all the data you need to make an informed decision.” LEAP Australia is supporting the BULK2021 industry conference and will be showcasing several software offerings, such as ANSYS and Rocky DEM. It will also be co-presenting a transfer chute case study at the conference proceedings with its local client Onyx Projects Pty Ltd. Rocky DEM is a high-fidelity particle simulation tool which models the movement of granular material and the way it interacts with a bulk handling system. It allows engineers to
visualise the general flow trajectory to understand forces, velocities and how they affect critical points in a system. This can help diagnose problems such as spillage, breakage or wear early on in the design phase or to improve and optimise processes so that costly shutdowns or frequent maintenance intervals can be avoided. LEAP Australia’s booth will be staffed with DEM simulation experts to answer questions regarding the virtual prototyping process and the ability to run simulations on a desktop or workstation. It will also be a chance for the company to demonstrate the capability to couple DEM simulations with ANSYS for structural and fluid flow applications. “Our main objective at the show is to educate Australian engineers on how DEM simulation can be integrated into their workflow including the many benefits of using Rocky for DEM,” Rizkalla says. “The uptake of Rocky over the past decade has been quite staggering. BULK2021 Show Director, Simon Coburn, says LEAP Australia’s support of BULK2021 means that event can offer delegates an up-to-date knowledge for software applications that could assist their business. “We’re committed to providing conference attendees with the best spread of content,” Coburn says.
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Brilliant belting is the backbone of Boton Brilliant Boton Conveyor Services supplies the flowing black belts that are responsible for carrying bulk materials in critical operations across the world. BRILLIANT BOTON CONVEYOR Services wants to help its customers move mountains. To do so, it provides conveyor belts that can handle non-stop use in the heavy-duty mining industry. Its belts can be found across the globe, from Western Australia’s scorching Pilbara region to frigid Quebec in Canada. David Gilmore, Brilliant Boton Conveyor Services Vice General Manager – Australia, says in each application, Boton aims to find the sweet spot between structural build and compound formula to provide the best outcome. “We don’t want to just meet targets,” he says. “We want to exceed them.” “Whether it’s in an open cut or underground mine, a power station, smelter, cement plant, quarry or port, our belts are the go-to choice for several substantial clients,” Incorporated in the 1950s, the Boton group entered the Australian market in 2015, approaching key customers in the mining sector. As of 2020, the business has now supplied conveyor belts to more than 30 mines and ports. Over the past three years, it has sold a total of 800 kilometres of belt, enough to drive from the Gold Coast to Sydney. To keep up with growing demand, Boton established two subsidiaries in Australia and assembled a team of 80 national specialists. Gilmore says the company offers much more than just belts, providing conveying system maintenance, smart monitoring platforms, and engineering, procurement, and construction solutions. “Boton provides expert conveyor knowledge to site operators. We have a suite of tools to review conveyor designs and optimise performance, along with root cause analysis to understand
30 І Australian Bulk Handling Review: July/August 2021
The Boton group has supplied conveyor belts to more than 30 mines and ports since entering the Australian market.
why equipment failures may be occurring,” he says, “We also provide end to end design solutions suitable for a variety of project sizes and scopes. Our team can also retrofit existing systems.” Boton can also provide construction, operation, maintenance, and improvement services, with teams able to mobilise to sites to help clients avoid downtime. Safety is a constant concern for the company, which is why it is an active advocate for knifeless splicing solutions, which it believes it beneficial to the safety standards of the mining industry. To help its customers remain safe during the COVID-19 pandemic, Boton has developed an Industry 4.0 solution to condition monitoring, made up of 13 modules. The modular design means the modules can function collectively or respectively, allowing the system to be tuned to the need of specific clients. Gilmore says the company is also ready to roll out its plan to build rubber recycling facilities in Western Australia. “Following construction, Boton will be able to transform used conveyor belts and end-of-life tyres into reusable building
materials and alternative fuels,” he says. “We expect this to help create a circular economy, reduce carbon emissions and be a positive environmental impact.”
Boton’s smart conveying modules 1. Digital conveyor belt system 2. Conveyor belt tearing monitoring system 3. Online abrasion monitoring system 4. Online temperature monitoring system 5. Online vibration monitoring system 6. Intelligent roller system 7. Splice monitoring system 8. Conveyor belt skeleton monitoring system 9. Monitoring system for lining board loosening 10. Blockage monitoring system 11. Material temperature monitoring system 12. Intelligent cleaning robot 13. Data acquisition gateway
INDUSTRY 4.0
vWork launches three-way communication A software-as-a-service company has designed a new messaging system that connects customers, dispatch teams and delivery staff in real time. AUSTRALIANS HAVE EMBRACED services like Netflix, Uber and Amazon thanks in part to high levels of communication and personalisation. vWork, the developers of online dispatch and job scheduling software for medium to large businesses, recognised that customers in the bulk transport sector now expect this same level of care. The company identified a gap in the market after receiving feedback from customers on the challenges of trying to successfully manage re-delivery when using SMS messages. To solve this, it has launched a three-way messaging system between a customer, driver and dispatcher that can provide immediate updates on status, ETAs or delays.
Making the most of the moments that matter
Three way conversation in vWork’s mobile app from the perspective of the truck driver.
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Roy Moody, CEO at vWork says there are a huge number of opportunities for transport brands and companies to reach customers with the right message, at the right time. “It just takes a bit of work to move from the “she’ll be right” mentality to a customer-first orientation that will provide those Amazon like delivery experiences,” Moody says. An important step to create that kind of experience is to get clear on exactly what moments in the journey matter and the messages that customers can expect at these points. “You can work this out by mapping out all the phases of the customer journey - right from the time an order is placed, all the way through to proof of delivery and invoicing - and decide what sort of updates or communication your customers will expect at these points,” Moody says.
“Then take that even one step further and determine how those deliveries that are at risk of being delayed will be managed. “By then identifying these moments in your job scheduling software, you’ll know that you’ll be present for the ones that matter most to your customers and have better business outcomes and stronger relationships because of it.”
Right message at the right moment Implementing several pre-set workflows or time or action-based triggers on vWork’s platform allows users to act before anything becomes a problem through. Triggers can be context rich signals – such as traffic delays, or intent driven signals like risk of churn. Adding a custom field around the trigger, means that when the event occurs, an automatic email or text will be triggered and sent to the customer explaining what the problem is, why it’s happened,
“By then identifying these moments in your job scheduling software, you’ll know that you’ll be present for the ones that matter most to your customers and have better business outcomes and stronger relationships because of it.” and attempting to reschedule the delivery time. This is also where vWork’s threeway messaging is useful as it allows users to immediately engage with the customer in real time and get on top of any concerns. For transporters who potentially face demurrage penalties, the opportunity to interact directly with a delivery site when deliveries are not on schedule, could prove valuable. “The benefits of these real-time updates to your business are that you can keep your customers in the loop at any time during the delivery cycle,” Moody says. “They can also be sent updates on how far off the delivery is, a map
tracker to track the driver’s progress, and even a heads-up reminder sent via text or email the day before delivery.”
Measuring your moments of success vWork’s platform offers a range of options to confirm the progress of a scheduled job that includes electronic proof of delivery with time-stamps, and photos. It can also automatically measure for when a delivery is made in full, on time – an important measurement for the transportation industry. The platform also integrates with AskNicely, meaning that customer surveys can be automatically triggered once a job is marked complete.
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SILOS
Customising silos for the discerning customer Every bulk operation is different, which means HE Silos can design and manufacturer tailor-made solutions. ABHR speaks with Stevie-Leigh Morrison, Business Manager at HE Silos to learn how. WHEN DESIGNING A SILO, THE TEAM at NSW-based HE Silos always starts with the parameters of the product to be stored. The business was originally founded as a general engineering company that specialised in agricultural products. Over 50 years ago, it has shifted its focus primarily to silos, but remains connected to its engineering roots. Stevie-Leigh Morrison, Business Manager at HE Silos says the business saw a trend in the marketplace towards custom designed silos around two decades ago. “No two operations are the same – everyone has their own specific requirements – whether it’s the type of grain they produce, when they harvest it, to how they in load and out load their product, we’re able to provide it all” she says. “It was a no brainer to invest into our project management and engineering teams.” “If a customer needs something HE Silos staff are trained to discuss detailed specifications with customers and use their experience to help find the right solution.
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The company has more than 50 years of experience in silo design.
specific, like an offset cone 90°x75°, live bottom silo for powders or sticky stock foods, or drive under silos for trucks, we can use our in-house engineering expertise to design it to their exact specifications and then have them structural certified interdependently”. The company can design a silo for almost any kind of operation, from a small four-tonne storage silo to
a massive 10,000 tonne flat bottom industrial silo. Its standard cone elevated silos can be built with cone angles 30°, 45° or 60°, having built equipment for use in the food and beverage, chemical, plastics, stock feed, agriculture and even the bean bag industries. All the company’s silos are designed and manufactured to the Australian Standards and are installed by its
highly factory trained installation team, Australia wide. Customers can also decide if the wall stays are put on the inside of the silo for a cleaner finish, or outside to keep highpriced commodities such as nuts or poppy seeds in the cleanest possible conditions. The HE Silos team are trained to discuss detailed specifications with customers and use their experience to help find the right solution. Morrison says the company has more than 50 years of experience and are wellplaced to provide continual support and deliver the latest industry trends. She adds that many silos are last more than 30 years in commercial operations. “Like our customers,” she says. “We’ve been through fires, floods and multiple droughts. The good seasons and the bad. Through that experience alone, we can use our understanding of the Australian climate and what is expected of us to build the right product for the conditions.”
“Our sales and logistics team check up on our customers to ensure the silo is operating as per their expectations and can provide them with all the resources they need to succeed,” Morrison says. The company operates two factories, one in Forbes and another in Gunnedah, with custom designed manufacturing equipment, developed in-house. Morrison says this gives HE Silos a fundamental understanding of the manufacturing process and quality control across its operations. In addition, the factories make use of best-practice technologies and engineering processes to ensure maximum efficiency and safety. Over the past 12 months, the business has undergone an expansion, growing its manufacturing capabilities by another 1860 square metres, with further room to grow. Morrison says the upgrade has increased HE Silo’s capacity and reduced lead times significantly. “With the new equipment, we can now
All the company’s silos are designed and manufactured to the Australian Standards.
manufacture more silos in less time,” she says. “We’ve also seen an increase in the demand for large capacity bulk silos, so the new factory will help us manufacture these larger items more efficiently and more competitively priced.”
BLASTING SYSTEMS
An ATD Cardox blasting tube is filled with liquid carbon dioxide that when energised, instantly converts the liquid carbon dioxide to a gas.
Load it up, lock it in and blow it away Specialist industrial safety equipment manufacturer Absafe has been granted a licence to begin Australian manufacturing ATD Cardox C02 pressurised blasting systems. FOLLOWING A GLOBAL PANDEMIC and the blocking of the Suez Canal, local manufacturers are avoiding instabilities in overseas imports. In addition to helping with local supply, it also creates create Australian jobs as well as increasing availability and lowering the price for these systems across Australia. Absafe, the Australian distributor of ATD Cardox C02 Pressurised gas blasting systems, saw the benefits of local manufacturing and has been granted approval to begin.
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Andy Caddy, Absafe’s Director, says the company has experience in custom design and fabrication of specialist equipment and plant for remedial works within the power and water industries. “We have our own in-house engineering team as well as steel fabrication trades and have always supported local industry. That’s why we see manufacturing Cardox products ourselves as a great move forward,” Caddy says. “We realised early on that freight and logistics were going to be high
for Cardox parts. We also had the frustration of being dependent on overseas production and turnaround especially when it came to specialised items.” The company has formalised an agreement with ATD-Abbausysteme GmbH – based in Dortmund, Germany – to manufacture Cardox ATD C02 tube filling stations and other componentry at its Hallam and Morwell locations in Victoria. Absafe is also commissioning prototypes of steel base ports and grip
cases for the Cardox tubes from Latrobe Valley Machining, with production to commence immediately once the company has approved the components. Cardox is a non-explosive blasting system for build-up and blockage issues in storage vessels, pre-heaters, coolers, inlet chambers, silos, raw feed mills, riser ducts, rotary kilns, and other high-heat process equipment. An ATD Cardox blasting tube is filled with liquid carbon dioxide (the same as a fire extinguisher). When energised by the application of a small electrical charge, the chemical heater instantly converts the liquid carbon dioxide to a gas. This conversion expands the carbon dioxide volume and builds up pressure inside the tube until it causes the rupture disc at the end of the tube to burst. This releases the carbon dioxide – now 660 times the original volume – through a special discharge nozzle to create a powerful heaving
force, at pressures up to 40,000 pounds per square inch. This all takes place in milliseconds. These tubes can be placed into problem areas by specially engineered locking ports to clear away build up and increase flow of bulk materials. Tubes can also be placed in areas of build up by hand to help clear emergency blockages and can then be refilled. Caddy says Absafe is unique because, in addition to designing and installing permanent systems, it can also place Cardox in areas such as internal silos to facilitate emergency clearance operations of most dry bulk materials. “Utilising our rope access and confined space expertise we can safely access most areas to drill and plant the Cardox units with optimum results,” he says. “Absafe can supply the Cardox system itself, set up a permanent system for ongoing use, and provide
Absafe can place Cardox in areas such as internal silos to facilitate emergency clearance operations of most dry bulk materials.
your staff with full training, regular support and annual maintenance.” The company will be attending the Australian Bulk Handling Expo (BULK2021), at the Melbourne Convention and Exhibition Centre from 8 to 10 September 2021.
BAGGING
Bag to the future Aurora Process Solutions is using augmented reality to help bulk baggers bring their operations into the 21st Century.
The PanPac automated bagging system is a high-speed filling and closing system.
MANUALLY BAGGING BULK materials exposes workers to risks. With bags weighing up to one tonne, if something goes wrong it isn’t easy to stop or control. In addition, dust created through the bagging process can be harmful, especially if it is materials used in the construction industry. Rock, sand, gravel, and clay can create silica dust, which if inhaled, can cause the potentially deadly disease silicosis. Manually closing bags is also often a slow process, can lack uniformity and means workers are spending more time around heavy, moving machinery. Braden Goddin, Sales and Marketing Manager at Aurora Process Solutions says an increase in compliance requirements for safety and dust control has created more demand for innovations in bagging and decanting bulk products. “One key innovation is the PanPac fully automated bagging system – it’s a high-speed filling and closing system designed for automatically processing one, two, and four loop bulk bags in industrial applications,” he says. The PanPac system handles bag presenting, filling, and closing. It can handle a wide range of bulk bag types and can be retrofitted into existing process lines or supplied as part of a turnkey solution.
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Bulk bags are placed on a reel and are then automatically presented to the filling unit.
“The bulk bags are placed on a reel instead of in a magazine format and are then automatically presented to the filling unit with a robotic arm,” he says. “There has also been a lot of advances in the sealing of closed bulk bags using heat, ultrasonic or an automatic cable tying system. They create a strong and uniform seal with good integrity. “Manual bagging systems are often closed by the tuck-in valve, or manually knotted using a drawstring closure. This takes a reasonable amount of time, during which the bag is stationary, creating a bottleneck.” Uniform bags can also help when it comes to shipping, as it is easier and safer to stack and fill containers with bags that have a consistent envelope. The system can also be fitted with a dust extraction device on the filling head, and when combined with an ultrasonic, heat or automatic cable tie closing
system, can effectively eliminate dust emissions in the process. Aurora’s automation advancement Aurora works with small-to-medium enterprises to provide end-to-end services for manufacturers of bulk products, including grain, seed, flour, cement, and stockfeed. Its products include semi- and fully automated machinery to automate the packaging, conveying, conditioning, and palletising of commodities. One such company is Biomar, a Tasmanian-based aquaculture feed manufacturer. The company needed a bagging system for its new facility and after weighing up the pros and cons, decided it needed an automated bulk bagging system to meet its production requirements. Aurora worked with its Denmarkbased partners at PanPac to provide a solution that would fit Biomar’s needs. When the bagging system was installed, Aurora supplied the company with a set of HoloLens glasses for maintenance, optimisation, and training. Goddin says the Biomar uses augmented reality to link staff members on site with technicians in New Zealand or Denmark. “This removes the tyranny of distance, which is vital for high volume businesses that can’t afford to wait for time zones or flights. When you put the HoloLens on, the program recognises the equipment and makes available assets like operations manuals to provide text and video-based instructions as well as a live feed to technicians,” he says. Aurora will be exhibiting at BULK2021, and Goddin says the company will have an augmented reality experience on display at the event. “You’ll be able to walk around and use the augmented and mixed reality to see how it works and how it could help your operation. It’s bringing military technology to the bulk materials industry.”
INDUSTRY PARTNERSHIPS
Bringing over 100 years of industry experience together Transmin and Martin Engineering have launched a new partnership to enhance their bulk handling offerings. ABHR learns what this will entail. BULK MATERIALS HANDLING equipment manufacturer Transmin launched its ConveyorPro brand around five years ago to consolidate its conveyor offering under one brand. It acts as a one-stop-shop for any business operating conveyors or feeders across all industry sectors. Its range includes everything from belt and chain, to idlers, pulleys, tools, cleaners and scrapers, calibration systems and tramp detection/removal systems. Adam Dodson, Head of Aftermarket at Transmin says the ConveyorPro team is always on the lookout for ways to further complement its offering, which has led to a new partnership forming. “Martin Engineering is a very well established and recognised company. They’ve been around for 75 years and
offer a unique product range of cleaners, scrapers, air cannons and impact beds which will allow us to provide a more effective solution to some of the problems faced by our customers.” One product that Transmin was impressed by was Martin Engineering’s CleanScrape Primary Cleaners. The cleaners are installed diagonally across the discharge pulley, forming a three-dimensional curve beneath the discharge area, allowing minimal space for installation. Its unique design offers a range of advantages over traditional belt cleaners including, low belt wear, extended service life, reduced maintenance, and improved safety, ultimately delivering lower cost of ownership. It has been proving itself in a wide range of applications,
Transmin launched its ConveyorPro brand around five years ago to consolidate its conveyor offering under one brand.
40 І Australian Bulk Handling Review: July/August 2021
such as mining, coal handling, quarrying, cement, and other material bulk handling operations. Alvaro Chacon, Martin Engineering’s Australian Managing Director, says the professional presence Transmin has developed in the Australian mining sector brings it with better options for the bulk handling industry. “Finding out what our customers want is an important part of the process for us,” Chacon says. “Martin Engineering is a world-leader when it comes to conveyor solutions and the key features of the technology, we provide is the result of constant development.” “Innovation takes us to the next step, which is why we have a centre for innovation to generate solutions for specific applications, instead of just providing an anu of options and products. “Partnering with Transmin means we will be bringing together the resources of people, products and processes. People with the knowledge of the processes to solve problems with the right products.” The two companies aim to improve their tendering opportunities through an enhanced knowledgebase and customer base. The businesses will also share information with one another to enhance development and help to create unique market offerings. The two businesses will be attending the 2021 Australian Bulk Handling Expo (BULK2021), as part of their partnerhsip launch. Dodson says it will be a great way of finding out what is happening in the industry. “There’s no other opportunity to so something at this magnitude,” he says.
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GEARBOXES
Bongliglioli’s new orbit Bonfiglioli Australia’s Managing Director, Martin Broglia, explains how the company’s new customer service model has transformed the business. MARTIN BROGLIA, MANAGING Director for Bonfiglioli ANZ, joined the company in July 2019 and has helped its transformation. Bonfiglioli has a history that spans 60 years and 80 countries, and according to Broglia, has become known for its industry solutions for its planetary gear systems. However, he says that the company has taken a renewed, customercentric focus. “Bonfiglioli in Australia and New Zealand has a reputation for excellence, innovation and sustainability, but there is still room to improve when it comes to customer service. “Early in the pandemic, we anticipated worldwide shortages of products, especially in the mining industry. Projects in this space are planned for the longterm, and delays can cause serious issues. “We increased our stock significantly
Bonfiglioli has expanded the number of staff on hand so that there are more people available to assist customers.
42 І Australian Bulk Handling Review: July/August 2021
Martin Broglia, Managing Director for Bonfiglioli ANZ.
during this time to ensure projects were delivered on time.” During the past year, the business has also worked closely with customers to find solutions to common problems
within the industry. The result is the 3/H series of combination gearboxes, which offer the high performance and efficiency of planetary gearboxes with the robust reliability of bevel helical gearboxes. Suitable for any heavy-duty applications that requires slow, controlled movements, the combination unit can provide the best of both worlds while having a significantly reduced weight, lead time and cost. Broglia says the unit came directly from discussions with the mining industry and is the result of extensive research and development. “Our customer applications engineering (CAE) team learned what the industry needed and worked with our development team to find a solution,” he says. Engineering support is key to Bonfiglioli’s new customer-centric approach, with a dedicated team to work
alongside customers and design custom solutions. When the scope of a project is outside of what a sales engineer can provide, the CAE team begins drafting potential designs using specialised software to determine bearing life, thermal analysis, and more. As part of its standard offering, Bonfiglioli also provides a standard commissioning option for all projects, with on-site commissioning and installation assistance if required. Engineers are also divided geographically and by sector specialist to make it easier for customers to get in touch with the right person. Broglia says Bonfiglioli has expanded the number of staff on hand so that there are more people available to assist customers when needed. “Everyone’s going through the same pandemic, and all need quick access to stock. That’s why we’ve increased our local holding and staffing,” he says. “We have also reworked our factory
Engineering support is key to Bonfiglioli’s new customer-centric approach.
layout for improved workflows and enhanced service delivery, with a new spray paint booth for quicker drying. “In the future, we are looking to expand our localised assembly capabilities to cover more types of gearboxes and increased sizes, and we are looking to grow our staff and facilities to account for this.” After a few years of not exhibiting, Bonfiglioli will be attending BULK2021 at the Melbourne Convention and
Exhibition Centre from 8 to 10 September 2021. Broglia says the business wants to support the industry and showcase some of the success stories that have come from its new business approach. “We will have our combination unit and our planetary range of gearboxes and potentially some brand new technological innovations on display if subsequent freight times from Italy can support it,” he says.
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BELT COVERS
Guardian angles Gough Plastics has developed a conveyor belt cover that not only reduces dust emissions, but also cuts down on waste and maintenance. AN ACTIVE CONVEYOR BELT handling bulk materials will almost always create dust and noise, two things that can harm the nearby environment and population. One method of containing these emissions is through a belt cover, which encloses the belt and traps any dust that could have escaped. As an added benefit, the material is also protected from the weather and less noise is created. Typically, these covers are made from fibreglass or steel. Gough Plastics on the other hand, uses low-cost, low-weight polyethylene plastic. The business began manufacturing the belt covers after a client approached it looking for an alternative to the steel covers that were on the market at the time. James Gough, Engineering and Mining Sales Consultant at Gough Plastics says the team came up with a design that would be easy to manufacture and fit the client’s needs. “The properties of polyethylene have been harnessed in the design to help the covers suit the application,” he says.” “It’s impossible for plastic to rust
Beltcover has been designed to handle some of the harshest environments and conditions.
44 І Australian Bulk Handling Review: July/August 2021
A belt cover encloses the belt and traps any dust that could have escaped.
and it doesn’t dent like steel does if something strikes it. It also doesn’t crack like fibreglass can. You could drop them from heights, and it would simply absorb the impact.” Called Beltcover, Gough Plastic’s solution uses a modular design to offer as much flexibility for fitting and maintenance. The modular sections have varying lengths of effective cover with two metre, 1.5 metre and one metre options, consisting of multiple models to suit the required belt width. The light-weight sections are easily manoeuvrable for convenient installation and individual sections can be cut to shorter lengths. Beltcover has been designed to handle some of the harshest environments and conditions, engineered to withstand wind load forces in accordance with AS1170.2 Severe Tropical Cyclones in Regions C and D, Terrain Category 1 up to a height of 30 metres above ground. The plastic is UV and corrosion resistant, and Gough says they are extremely long lasting. “We have quite a few Beltcover installations that have been in operation
for 15 to 20 years. Our polyethylene material is designed to stand the test of time.” he says. “It is also recyclable, which has become an advantage as more customers look towards reducing waste and improving their sustainability.” The Darwin Port Authority is one organisation that uses Beltcover as part of its operations. The Authority has installed around 4123 metres of medium, all-weather Beltcover at wharf loading facilities in the Darwin Harbour to help provide protection to the surrounding environment and to protect the products being conveyed from the extreme external elements in this part of Australia. The system carries several products such as lead, zinc, and copper concentrate. All covers were fitted in situ to the existing system. Gough Plastics will be exhibiting at BULK2021 on 8 to 10 September 2021 at the Melbourne Convention and Exhibition Centre. Gough says the Beltcover will be on display at the show, giving attendees the chance to see and feel them in person.
SILOS
Planting the seeds of global agriculture AGI was founded in 1996 and is made up of brands with decades of experience in agriculture. Peter Forster, AGI’s Australian Business Manager, explains where it all began and where it is set to grow. ONE OF AGI’S EARLIEST AND fundamental piece of equipment was invented in the early 1950’s by Abraham Plett, owner of Pletts Industries, the yellow and red grain auger, well known around the world as Westfield Augers. It all started when Pletts decided to build a better auger after learning of the failed undercarriage design on the auger he resold to a customer. He improved upon the original model, and the first two yellow and red augers were sold in 1951. Over the years the company and brand name “Westfield’ has become one of the most recognisable for portable grain augers in the world. Just like Plett, the AGI Westfield team continues to advance and improve their augers from the Canadian prairies at their manufacturing facility in Rosenhort, Manitoba with the
Abraham Plett sold the first yellow and red grain Westfield Auger in 1951.
46 І Australian Bulk Handling Review: July/August 2021
goal to deliver world class handling for farmers around the world. From 1996 to 2004, AGI’s founders Rob Stenson, Art Stenson, and Gary Anderson grew their business through the acquisitions of complementary companies. Starting with portable handling equipment, AGI acquired Batco, Wheatheart and Westfield in 1997, 1998 and 2000 respectively. This expanded AGI’s manufacturing capabilities and help it gain access to an extensive dealer network. In 2006 AGI strategically grew their product portfolio to include commercial machinery when they acquired globally recognised, Hi Roller enclosed belt conveyors. Founded in the 1970s by inventor, engineer and CEO Phil Clark there are now more than 10,000 Hi Roller
enclosed belt conveyors installed all over the world. AGI’s founders understood that conventional belt conveyors can be dirty and unsafe for the agricultural industry. Grain dust can lead to explosions in facilities and pose severe risks to grain operators. It also presents environmental issues and can have high clean-up costs. These are just some of the reasons why grain terminals and operators are choosing Hi Roller’s enclosed belt conveyors for their facilities around the world. The Hi Roller is completely enclosed, self-cleaning and reloading. Their unique safety-first design has no internal brackets or ledges where excess build-up can occur. The bearings are isolated from the internal atmosphere of the conveyor, removed from potentially explosive grain dust. A primary feature of the enclosed belt is the reloading tail section. All dust, debris or in some cases spilled product, is returned to the tail section by the returning belt and then diverted by a V-Plow installed within. Peter Forster, AGI’s Australian Business Manager, says these brands are among the many that have helped AGI become the global business it is today. “The first thing that strikes you as you travel through the halls of AGI head office in Winnipeg is the real sense of history as you view the founder’s wall,” he says. “AGI celebrates the men and women who have contributed to the business. The founders have all had a genuine belief in the importance of their mission to serve agriculture and help feed the world. “From humble origins in Rosenort, Canada, AGI now operates across six continents, through iconic brands such as Westeel Silos, Westfield augers and Vis Industries, a feed mill business which the two founders George, (Executive Vice-
President of North America) and Jim, (Executive Vice President, Global Product Management) still work in AGI today.” The largest acquisition in AGI’s history occurred between 2015 and 2017. In these two years AGI grew to include Westeel Silos, PTM Technology, FRAME, MFS, and AGI Brasil (previously Entringer). The move solidified AGI’s presence in many international markets including Europe and Brazil and brought over 110 years of silo manufacturing expertise. Since its beginnings, the business has acquired more than 35 companies and now employs more than 2500 staff worldwide. Their manufacturing capabilities spans across 6 countries, with 34 facilities – delivering world class equipment to customers in over 90 countries. Through it all, AGI’s vision is to provide the infrastructure required to feed the world. To achieve this, in 2019, it launched the 5-6-7 strategy. As part of this, the business targeted five platforms: ai157197452440_Capability - Half - ABHR grain, fertiliser, food, feed, andPage seed.
Its systems and solutions would then be taken to the six continents it operates across and delivered through seven components: storage, handling, structural, processing and controls, engineering, and project management. Forster says AGI designs its products to the strictest safety codes and to the highest quality. “We make products used daily in every continent and in every climate under the most extreme of conditions,” he says. “Our dealers are all Australian farmers and engineers; they use what they sell, and they have delivered storage and handling solutions in every state in the country. “It is exciting working with our customers to see them succeed is the reason we started this business.”
Into the future AGI is currently investing heavily into its SureTrack platform, which enables November 2019.pdf 2:35 pm farmers to make 1the 25/10/19 most of the resources
they have and assists producers to manage inventories effectively. The technology has been installed in farms and storage facilities to enable precise conditioning of crops using aeration, fumigation, drying and rehydration techniques. Four of the company’s brands – CMC, Intellifarms, Compass and Farmobile – combined make up AGI’s technology divisions and digital tools. The insight and market intelligence delivers the solutions farmers and producers are looking for. Forster says AGI offers the technology through its local dealer network in Australia. “The Australian market is going through a period of reinvestment. As a result, consumer confidence and food security are becoming an important trend to focus on, especially within periods of drought,” he says. “AGI expects the Australian market to continue to be a growth opportunity in the future, and we aim to continue expanding our portfolio of turnkey solutions.”
SENSORS
VEGA has worked to improve its Bluetooth technology, with programming to bring sensors towards broader Industrial Internet of Things compatibility.
Keep it simple, sensor As technology develops and becomes more complex, VEGA Australia is striving to remain as simple as possible. FOR A LONG PERIOD OF TIME, measuring what was in a bulk silo was complex, inaccurate, and often unsafe. Level switches could tell operators when the material had reached a certain point, but when material starts to be removed, it was difficult to get an exact idea of how much was left. Some methods involved manually inspecting the silo, which often meant physically climbing the tall structure – putting someone in a risky position. Material can also flow and fill the silo unevenly, making it even harder to get a grasp of how much material is being stored. John Leadbetter, Managing Director at VEGA Australia, says simplicity is the driving force behind the company’s measurement technology. “Realistically, around 95 per cent of our customers are just looking for six simple parameters,” he says. “What is the distance from the transmitter to zero, what is the distance to 100 and the difference between these two
48 І Australian Bulk Handling Review: July/August 2021
create the operating range. This is then displayed as a percentage. The product type, for example granular, is selected and a failsafe to let the client know if there is a problem with the system.” New technology can wildly transform how bulk operations operate, making things safer and more productive. However, as technology advances it runs the risk of becoming overwhelming and confusing. VEGA Australia has worked to avoid this, making sure its products are as familiar as possible. Its products use Bluetooth connectivity to connect with smartphones and tablets that most people own or have used before. The company has also worked to improve the Bluetooth communications technology, with programming to bring the sensors towards broader Industrial Internet of Things compatibility. In particular, the business is focusing on allowing for uploads to the cloud. Leadbetter says the technology is always being updated and refined, to the
point where what was used 10 years ago is well out of date. “We’re always working on new tech formats to keep ourselves ahead of the market,” he says. “That means listening to our customers and finding out what their needs and plans are. No system is the same, and each industry has different requirements.” “Automation is something we’re hoping to integrate into our offering. Historically, the bulk handling industry has relied on a lot of manpower to measure tanks and silos, which has driven a need for a more refined system of inventory management. “Remote industry management is set to become a bigger part of the industry, with stronger integrations into logistics system. We’re seeing companies with systems that look at a network of silos to find out how much material a customer has and then automatically send a truck to refill it if needed.” VEGA is developing its own softwarebased system that can communicate
with a client’s operation to provide real time updates on the facility and their customer’s facilities. Currently, most of VEGA’s customers are looking for a simpler solution. To find the right tool for the job, VEGA determines what material will be measured, whether it is explosive, how often the vessel will be filled or emptied, if there’s a power supply and what restrictions there are. VEGA also talks about the installation and which contractors will be handling to process. Leadbetter says the most important thing to determine is what the customer is looking to achieve – whether its basic measurement with a level switch or they are looking for contiguous information. “VEGA is a customer focused company, our staff treat each application as an individual case – there’s no one size fits all,” he says. “All of our equipment is German manufactured – we don’t buy other products or substitute them. Everything we do is 100 per cent VEGA and we’re very
proud of that.” One of the most important parts of VEGA’s offering is its after sales support. The company ensure the sensors are properly calibrated to ensure all readings are reliable and accurate. It also offers training courses to help make the site more self-sufficient. If needed, there is a 24/7 technical support line that can help if any problems arise. VEGA’s Sydney office also doubles as a repair facility, meaning it can repair or replace stock that requires it. Leadbetter says providing this support is the most important thing the company can do. “Anyone can sell a piece of equipment, it’s whether or not you can support that equipment into the future,” he says. “Customers invested their trust into us to provide reliable, accurate performance and we need to stand by that promise.” VEGA will be exhibiting several of its products, including its Bluetooth technologies and working examples
VEGA Australia makes sure its products are as familiar and simple as possible.
at the Australian Bulk Handling Expo (BULK2021), from 8 – 10 September 2021 at the Melbourne Convention and Exhibition Centre, where it is a platinum sponsor. Leadbetter says the company is proud to support BULK2021, as the event supports the Australian industry.
DUST CONTROL
Practical and effective dust control technologies Not all dust control solutions are the same. Dave McMillan, Air Division Manager at Marc Technologies explains how different technologies can provide effective solutions, as a holistic approach to mine site dust control. Dust is generated wherever the product is disturbed, such as at truck dumps and hoppers.
RESPIRABLE DUST UNDER 10 micron in size poses a health hazard to workers exposed to it and is the main contributor to lung disease in the industry Legislation is being implemented around occupational exposure limits for crystalline silica, which can be found in many ore bodies, following Safe Work Australia’s extensive review into safe exposure levels. Dust is generated wherever the product is disturbed, such as at truck dumps and hoppers, crushers, screens, conveyor transfers, stackers and reclaimers, train loaders and unloaders, and shiploaders, as well as in stockpiles where wind has the potential to lift dust off the piles. Where material is being handled, it is important to limit fugitive dust and tackle the dust problem at the source. Engineering controls such as covers, well-sealed conveyor skirts and extraction
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systems can assist, but additional controls need to compliment these controls and provide effective prevention of emissions where they occur. Dave McMillan, Air Division Manager at Marc Technologies, says the droplet size from traditional low pressure water sprays will dwarf the dust particles the sprays are trying to control, and as a
result the dust will migrate round the water droplets, and escape the area. “Most water sprays are designed to wet the material surface, but unless these are applied in the right way, they will also cause problems with overwet product such as carryback, avalanching and blockages,” McMillan says. “Once the material is disturbed again, either at conveyor transfers or into secondary or tertiary crushers for example, more exposed dry surfaces appear and are likely to cause fugitive dust. Add to that, the increasing cost of the precious water resource, and it becomes an expensive way of not dealing with a common problem. “Engineered solutions incorporating a few different technologies in a holistic approach can make a huge difference to controlling the fugitive dust in various parts of the mining process.” In operations such as crushing and stockpiling, careful water addition in a controlled fashion, with targeted moisture addition using properly selected spray types and positions, can ensure minimal dust emissions further down the process at the stackers and transfer points, as well as controlling the dust at source.
Dry Fog produces water droplets that bind with the dust particles in the air, preventing it from leaving the area.
A windfence is a permanent structure that uses a hard wearing, ultraviolet light stable kitted polyester material.
Material being stockpiled can become susceptible to dust lift-off, where wind causes dust particles to escape the pile. Using a windfence positioned upwind of the pile helps to minimise this issue. Where there is no opportunity to condition the material as it enters the handling process, such as at a load hopper or a dump truck, fugitive dust can be controlled with microscopic Dry Fog, that produces water droplets that bind with the dust particles in the air, preventing it from leaving the area. Dust Solutions Inc has developed systems that can be used in combination to offer a complete dust control solution. The Dry Fog system uses an ultra-sonic nozzle with low pressure air and water to produce water particles less than 10 microns. These scrub out fugitive dust by agglomeration of like-sized particles, effectively binding with the dust particles and drop it them out of suspension. McMillan says Dry Fog uses less than one fifth of the water used in a traditional water spray, producing a fog that is dry to touch and helps avoid associated issues with carry back and belt wear. “This also reduces decreases thermal penalty in coal power applications,” he says. “Blockages are rare as the venturi design within the nozzle means that the water and air orifices are relatively large, though these systems also have dual
filtration as standard to factor out poor water supply.” “Dry Fog is not a new technology, and it is widely used in the US and many other countries, with a proven track record of well over 500 installations with the major miners. “The US Environmental Protection Agency lists it as a best demonstrated technology for suppression of subbituminous and lignite coal dust and is listed as a control technology for new CCR Rules in the USA in relation to fly ash and coal residuals handling.” DustTamer Windfences are also an
effective dust control method for larger areas such as stockpiles and tailings piles. Controlling the top surface of the pile with water cannons offers limited protection but must be constantly applied and excess water can cause detrimental and unwanted effects. DustTamer Windfence Systems are designed to drastically reduce wind velocity and particle movement for a potentially large area such as a stockpile, minimising fugitive dust emissions with consistent reliable results. The windfence is a permanent structure, and uses a hard wearing, ultraviolet light stable kitted polyester material that is strong enough to be used in cyclonic regions. This material exerts a drag force on oncoming wind velocities and allows a portion of the wind volume to penetrate through the screen as well as deflect the remainder of the wind to the surrounding sheltered area. McMillan says MARC technologies has been delivering dust control solutions to the mining and industrial sectors since 1995. “MARC Technologies is a wholly owned subsidiary of the Brisbane based ALS, providing a global presence,” he says. “MARC is also a licensed electrical contractor in Western Australia. This means our products are shipped out to our clients with safe electrical systems and we we can offer the supply and installation of distribution boards and control systems with our products.”
Dry Fog uses less than one fifth of the water compared with a traditional water spray.
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PORTS
Keeping the neighbours happy New Zealand-based Page Macrae Engineering is hearing a common theme in the challenges port operators are facing with the overlapping of boundary interests impacting on their operations. IT’S A SITUATION COMMON FOR many industrial ports. When they were initially developed decades ago, the sites were greenfield areas. However, as development sprawls outwards, the sites soon find themselves with new neighbours. Often, this brings with it, environmental concerns, with environmental protection agencies around the world looking to reduce the amount of dust emissions released. Peter Swan, the General Manager for Sales and Marketing at Page Macrae Engineering, says a pain point for ports is the need to maintain, if not improve, their productivity whilst operating within those parameters. “There’s a clear need for efficiency gains in the industry, especially following the COVID-19 pandemic and all of the disruptions it has caused,” he says. “Whether it’s bulk materials or twenty-foot equivalent unit containers, there are unprecedented quantities of ships waiting to get into the ports all over the world. These delays can come at a significant financial cost to multiple stakeholders. On the bulk material side, to ensure efficient port discharge operations and avoid loss of product from wind carry off and spillage during the ship to shore transfer, effective solutions are required. Based around their client’s challenges, Page Macrae has developed a new product range that aims to address these pain points – a great example of this is the new EDG hydraulic grab. The grab range has been designed to provide as much flexibility as possible, as customers can configure 52 І Australian Bulk Handling Review: July/August 2021
Page Macrae designs highly efficient and versatile equipment.
the capacity of the grabs to suit the type of material being handled. If a change in product or capacity is advantageous in the future, these changes are as simple as purchasing the new buckets and fitting to the existing grab head. The buckets have also been designed with a focus on dust and material containment. Dust control covers minimise dust emissions into the air and bucket seal system prevents spillage onto the wharf, enabling the port to keep its operation clean without impacting productivity. Bruce Ennis, Port Products Solutions BDM at Page Macrae Engineering, says we are evaluating the
“Providing quality is what drives us. Our target market appreciates robust equipment with a long life. Case in point is our range of log lifters. The first one we ever made is still in the field operating as productively as when it was used for the first time 20 years ago.” global focus on reducing carbon dioxide emissions and how our future products can meet this challenge. “To improve the system’s energy efficiency, we’ve optimised our new grabs digging geometry which has seen an increase in
“To take our client support to the next level, we are now launching a full-time presence in Australia. This in county presence will take the form of a Port Operations manager who will facilitate our product and operating spares in a timely, efficient manner, support our product commissioning efforts along with new product sales and development.” performance and a reduction in energy requirements,” he says. “A lot of work has gone into the geometry of the grab operation to ensure the most efficient and economical outcomes are achieved.” “Providing quality is what drives us. Our target market appreciates robust equipment with a long life. Case in point is our range of log lifters. The first one we ever made is still in the field operating as productively as when it was used for
our product commissioning efforts along with new product sales and development he says. It will also be exhibiting at the Australian Bulk Handling Expo (BULK2021) from 8 – 10 September 2021 at the Melbourne Convention and Exhibition Centre. Ennis says the company will be presenting its new product range and offerings to attendees and is inviting many of its clients to the show. “There hasn’t been an opportunity to meet our valued clients in a while to
talk about what their challenges are,” he says. “We’re looking for new ideas in the market and to share our story and what we’re planning to do with our Australian presence.” “We also want to speak with potential new clients and listen to their plans for the future. Incorporating these ideas into future innovations is how we provide our customers with products tailored to their industry and challenges ensuring not only compliant efficient operations but innovative reliability and versatility.”
Page Macrae’s electric log loader is designed for safe and efficient log loading.
the first time 20 years ago” While Page Macrae Engineering’s head office is based in New Zealand, it has equipment in most major ports around Australia. With such a large international customer base, its staff are constantly on the move, visiting sites and customers. Prior to COVID-19, the company’s staff spent as much time as possible in Australia, having one on one conversations with operators about the problems they were struggling with. Swan says these conversations were incredibly valuable to Page Macrae Engineering, as they helped shape the future development of itsproducts. “To take our client support to the next level, we are now launching a full-time presence in Australia. This in county presence will take the form of a Port Operations manager who will facilitate our product and operating spares in a timely, efficient manner, support
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SILOS
Kotzur leads feedlot design Family-owned Kotzur Australia has designed and fabricated a major feedlot facility in rural Australia. ABHR speaks with Ross Murray, the project manager, to learn more. WHEN AN AGRICULTURAL COMPANY wanted to build a new facility, it contracted Kotzur for help. Based in Walla Walla, Kotzur specialises in designing, manufacturing, and installing bulk solids storage handling facilities for the agricultural, mining and manufacturing sectors. Ross Murray, one of the project managers involved in the project, says the client wanted a minimum of seven days of grain storage available on site with the ability to expand as required. “Currently, the project is designed for 20,000 head of cattle at the feedlot,” he says. “As opportunities in the market arise, the customer wants to be ready to meet them.” “We drew on experience from similar projects and kept the design of the plant modular so an extension can take place with minimal interruption. “Understanding what the customer’s needs are and then working with them to find a solution both parties are happy with is what Kotzur does best. In our initial design we found the end stage that could feed 40,000 cattle and then scaled it back from there.” The overall facility consists of 4500 tonnes of grain storage in elevated silos,
Kotzur designed much of the system, including all the mechanical equipment.
with a 250 tonnes per hour intake through a drive over pit. Conveyors feed the grain storage system and a reclaim system with 60 tonnes per hour of capacity is included. Two 60 tonne day bins were also installed along with advanced grain laying and a controlled wetting system for four stainless steel tempering silos. Kotzur designed and manufactured much of the system, fabricated between Toowoomba and Walla Walla and transported across the country to the site. This included all the mechanical equipment, such as the bucket elevators, screw conveyors, rotary scalpers, and aspirators. The typical Kotzur project is made of more than 80 per cent Australian made products. Murray says a lot of work went into Kotzur is a family-owned business based in Walla Walla, NSW.
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making sure the feedlot could handle both wet and dry grain during the tempering process. “The tempering process is essentially the grain absorbing the water so it’s able to be milled and produce a high-quality flake to optimise cattle performance.” he says. “The more water the grain absorbs, the more it swells and the higher the loads the equipment needs to handle. We took that into account and used 304 tempered stainless steel to avoid corrosion. “We also make sure all of our work is done to the Australian Standards, from windloading to seismic loads to handrails and access codes.” Kotzur is no stranger to this kind of project and has developed a process for handling them. After it had received a tender from the client, the business worked closely with the customer to make a proposal that met the right requirements. The company’s in-house engineering team includes structural, civil, and mechanical engineers, helping it handle complex design requirements. After a design is set, the business can then fabricate and deliver the rest of the project. The feedlot is now in the final stages of completion, entering the commissioning phase. Murray says following the installation, Kotzur’s dedicated maintenance division will provide after sales support as required.
GLOBAL LEADING EXPERTS IN CUSTOMISED BRAKING SOLUTIONS
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CABLES
Treotham’s energy chain keeps cables moving
Igus energy chains are used on container cranes, on stackers, reclaimers, and other heavy machinery.
Component supplier, Treotham Automation, is helping bulk handling machines protect and carry vital cables with its igus energy chain technology. CABLES HELP POWER AND CONTROL the heavy machinery responsible for handling bulk materials. If they are damaged, it can cause serious headaches for everyone involved. Traditionally, reelers and festoons are used to carry several cables to these large pieces of equipment. However, John Sharp, Bulk Materials Handing Specialist at Treotham Automation says these systems often have limitations with reliability or speed and cause damage to the cables over time. “For festoon systems, when the machine moves it can create violent motions between the trolleys these collisions lead to failure and damage. Cables are also exposed to the elements, which can degrade them over time,” he says. “Cable reelers can be helpful, but if you need to add an additional cable, for water or data, you will need another reeler which can get expensive quickly.” To simplify cable management, Treotham provides a solution called an Energy Chain. Also known as a power
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chain, drag chain or cable chain, Energy Chains supply, guide and protect moving cables and hoses for heavy machinery. The cable chains use high durability plastic, and as a result, suffers from significantly less wear when compared with metal components. They can also be run in environments with sand or near corrosive salt water. Sharp explains it is possible to run a maintenance free system for 10 to 15 years with extremely high duty cycles because of its construction, which he adds is also significantly cheaper than stainless steel or steel versions. “The engineered plastic offers a lower cost solution with a significantly higher lifespan. Energy chains are moulded on the inside so that any cables within don’t suffer any wear and can handle high-use in harsh environments like ports and wharves,” he says. “If a component begins to wear, it’s easy to inspect and replace. It’s also customisable and made from a catalogue of standard parts, that can be tailored to a specific application.
“They’ve been used on container cranes, on stacker/reclaimers and all sorts of other heavy machinery.” Energy Chain can also be used in areas where a long travel length is required. Treotham offers specific solutions for longer travel lengths, as potential challenges can arise when the length of chain goes over 400 metres at cable loads of 50 kilograms per metre. Treotham’s system engineers can tailor the chain to a company’s specific operation, providing travel lengths of up to 800 metres long and high additional loads of up to 30 kilograms per metre. A new design of Energy Chain is used in these scenarios, suitable for the mining, warehousing, and crane industries. Treotham has installed Energy Chains at the Port of Esperance for a ship loader handling iron ore. Sharp says the company’s cable festoon option was only providing power, but with the installation of an Energy Chain system it could also provide water for the dust suppression system and fibreoptic cable for cameras, data and control.
“Bluescope Steel has also used the technology to upgrade its ship unloading operations. Previously the machine’s power came from a trolley crane with a busbar, which was limited in speed and required a lot of maintenance,” Sharp says. “After the upgrade, the crane had the connectivity for autonomous use and vision systems, allowing the grab to unload the ship. This also mean the company no longer required an operator, letting them use the employee in a higher value task.” The company will be attending the Australian Bulk Handling Expo, which will take place at the Melbourne Convention and Exhibition Centre from 8 – 10 September 2021. There, the company will be exhibiting its offering with samples of the product on display. Sharp says speaking to the industry is important, as it helps Treotham explain how its energy chains can be used.
The cable chains use high durability plastic, allowing them to be used in environments with sand or near corrosive salt water.
“One of the biggest problems we have faced historically was people asking for a steel chain – they don’t fully trust plastic,” he says. “BULK2021 offers us the opportunity not only to meet with decision makers from the east and west coasts
of Australia, but also lets us show examples of how well our system works. “Massive port operators like Dubai Ports use an igus chain system. We can show people who doubt our claims the product in action, which tends to change a lot of minds.”
Air-cushion BELT CONVEYOR Both belt and product are carried on a cushion of air
MONEY SAVING FEATURES: • • • • • • •
Low power consumption • Reliability Low wear and tear • Low maintenance High capacity • Light weight belt Steep angles of inclination • High belt speeds Dust tight • True belt tracking Complete settling of materials on belt Simple conversion from open to closed conveyor
CONTACT US FOR MORE INFORMATION
Aerobelt Australia Pty Ltd Ph: 02 4631 2919 | Mob: 0419 279 566 | Fax: 02 4631 2915 info@aerobelt.com.au | aerobelt.com.au
BRAKES
Braking the storm Investing in quality brakes can be crucial to avoid unplanned movement, which is why Svendborg has developed a new range of rail-mounted Storm Brakes. ALTRA INDUSTRIAL MOTION’S
A retractable rail clamp.
brand Svendborg Brakes has a history in braking solutions dating back to the 1800s and has developed solutions for the mining industry for more than 30 years. They have just released the latest in rail-mounted braking systems, called Storm Brakes. Svendborg Brakes application engineer Mads Willum is an essential member of the Altra Motion - Svendborg Brakes team and explains the importance of Storm Brakes. “Storm brakes are devices which provide braking forces on the crane rails or crane wheels for rail-mounted material handling cranes, onshore or inland,” Willum says. “They prevent a crane from
uncontrolled moving along the rails in a case of sudden gusts of wind. “Storm Brakes, also known as ‘parking brakes’, are specially designed for stackers, reclaimers, ship loaders, outdoor cranes, and any rail-mounted material handling equipment at risk of an unplanned movement incident.” Altra Industrial Motion national sales manager Rex Sinclair says the acquisition of an industry leader like Svendborg Brakes in 2013 significantly expanded the company’s global presence. Sinclair adds that rail-mounted brakes
An electric wheel brake EWB-90.
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have faced issues in the past, which Storm Brakes mitigate. “There have been situations with these kinds of brakes on ship loaders where a storm has come along and blown them down the rails,” Sinclair says. The additional safety benefits of Svendborg’s Storm Brakes include there is no need for lubrication, easier maintenance and fewer hands on the equipment at risk of injury. To cater to its customers’ specific needs, Svendborg offers a range of models that can be applied to various rail conditions. Whether a rail is new, mushroomed, worn, has splice or angle bars, is buried in asphalt or is surrounded by bulk materials like iron ore, Svendborg has a Storm Brake to suit. The rail clamp is a type of Storm Brake which applies pressure to both sides of the rail, which Willum says will ensure the equipment is incapable of getting away from an operator. “The rail clamp ensures 100 per cent fixation of the equipment, so it doesn’t move, and rail clamps are designed to release and retract completely from the railhead,” Willum says. Rail brakes, alternatively, apply pressure to the top of the rail using the machine’s weight. Svendborg also offers a third wheel brake system as part of the Storm Brake range, which provides a combination option between the brake and clamp – applying force to the idler wheel flange of the machine. Willum explains how the Storm Brakes avoid the need for lubrication, using a clever design to protect the product. “Rail clamps are the devices which apply on both sides of the railhead with a
mechanism designed to have provision for vertical and horizontal float to accommodate potential rail deviations,” Willum says. “Our design allows for very easy floating with minimal side loads, and there is no possibility of mechanism jamming. Protecting the rail clamp, so they do not rub on the rail and get easily worn out. “Poorly designed floating mechanism with float blocks must be lubricated to function, especially in the dusty environments.” Storm Brakes also come in a hydraulic or electric option, removing the need for hydraulic oils. “If hydraulics are deemed a risk for whatever reason, environmental or hydraulics are not wanted, the electric option is a viable solution,” Willum says. While producing fewer emissions through the lack of hydraulic oil, the electric option also involves less maintenance. “An electric Storm Brake generally has a non-pollution advantage compared to hydraulic controlled – in an electric unit, there are no circulating hydraulic oils,” Willum says. With an electric/hydraulic option, retractable clamp for easy installation and removal, and integration with Svendborg’s Industrial Internet of Things software platform for condition monitoring, the competitive advantages of Storm Brakes cover all bases. Svendborg’s Storm Brakes are the latest solution to avoid failures in rail-mounted operations.
Comprehensive Processing & Handling Solutions
A dynamic rail brake.
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CONDITION MONITORING
The Eagle has landed Acoem has designed a wireless sensor system that can accurately predict machine faults before they escalate.
The fully integrated Nest i4.0 software platform is powered by Acoem’s Accurex Artificial Intelligence - giving customers the data they need to make informed maintenance decisions.
THERE ARE SEVERAL REASONS why a piece of bulk material handling equipment could vibrate while operating. It could be due to thrum of the gears, a reaction to the material or any number of normal behaviours. The issue is when equipment vibration deviates from the norm. A bearing hidden within the machinery could become damaged, a shaft might become misaligned, or a fan could become imbalanced. These small changes can cascade into massive problems, creating unplanned emergency downtime, hampering productivity, and potentially causing additional safety risks for operators. Michael Roinich, Reliability Solutions Manager at Acoem Australasia, says the company has developed technology that monitors machine vibration to quickly find the root cause. “Acoem has developed specialised sensors that are mounted onto bulk handling machinery to collect vibration data, which is then uploaded and run through an algorithm,” he says. “The algorithm then determines what the cause of the problem might be, in conjunction with a vibration analysis specialist.” The device, called the Eagle, is a wireless sensor that is permanently attached to a piece of machinery and programmed to periodically activate based on individual requirements. The operating conditions, such as speed, power and
60 І Australian Bulk Handling Review: July/August 2021
pressure are considered and translated into trends to be compared. Reliability and ease of maintenance are core parts of the Eagle’s design. It can withstand harsh mining and industrial environments, and is certified for use in explosive areas. The stainlesssteel body with low thermal expansion allows it to operate in temperatures of up to 120 degrees and within corrosive environments. The Eagle’s battery life has been optimised to provide up to five years of availability under rated operating conditions and with no external source of power supply or maintenance. The battery is inexpensive, interchangeable and easy to change out on site. What brings all this data together is the Nest i4.0 monitoring software that uses Artificial Intelligence (AI) to provide automatic diagnosis of a range of faults found within bulk handling machinery. Roinich says Acoem’s Accurex AI is as an automated diagnostic tool and can be used to put proactive condition monitoring into anyone’s hands. The Accurex system can also be a time saving filtering tool for expert level analysts. “Vibration analysis experts are few and far between. We saw this shortage of analysts and developed the platform in response,” he says. “Nest i4.0 uses easy to understand language, icons and interfaces to present data in an intuitive manner on any enabled device, so that anyone can use it.”
The software outlines what the problem could be, which machine is affected and what the actual fault is in real time, on a single screen. This lets operators make informed decisions for maintenance priorities as soon as possible, helping to avoid costly unplanned downtime. Roinich says the AI is a useful tool that can help someone with no skills in vibration analysis understand the condition of their machinery with a high level of certainty. Headquartered in France with offices around the world, Acoem has grown to be a major player in the Australian, European, Asian and American markets. Acoem Australasia will be participating in the Australian Bulk Handling Expo (BULK2021) at stand 4340 to showcase its products such as the Eagle and Nest i4.0. “The Acoem reliability technology is powerful but at the same time incredibly intuitive when compared to current technologies in the market. This now gives plant operators an easy decision-making tool at all levels,” Roinich says. With the demand for wireless technologies in the condition monitoring market globally, the Eagle wireless system is a true standout when it comes to useability and technology. The Acoem Eagle sensor mounts easily onto any bulk handling machinery for real-time vibration monitoring.
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EQUIPMENT
OPS Group celebrates start of its national distribution The OPS Group has officially started distribution of Telestack Bulk Material Handling Equipment across the entirety of Australia, including the new Tele-Mix Pugmill. MINERAL PROCESSING SOLUTIONS (MPS), an OPS Group (OPS) company, has started 2021 with a bang following the rollout of its exclusive distribution of Telestack bulk material handling equipment across Australia and Indonesia. OPS represents several global brands and manufacturers within its target market and segments. Its customers range from multinational mining companies and contractors, right through to owner/ operators. The Australian owned business has been exclusive the exclusive distributor for Telestack bulk material handling equipment in WA, NT and SA for many years. As part of the new agreements reached with Astec Industries, Telestack’s parent company, MPS will now extend this distribution of Telestack products and services to Eastern Australia. The Telestack range extensively covers all facets of moving material from one point to another and includes machinery with up to 3000 tonnes per hour capacities. Shane Czerkasow, OPS Group
The Telestack range extensively covers all facets of moving material from one point to another.
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Telestack’s TS 1542 Radial Telescopic Stockpiling Conveyor allows for maximum flexibility.
Managing Director says the business has grown on the core values of delivering world class products with industry leading service and support. “Astec and Telestack are an obvious fit and perfect partnership for our business, as these are commonly shared values,” he says. “Telestack has a long tradition of quality and robust equipment. With the somewhat recent acquisition of Telestack by Astec Industries, we have seen significant advances in the product line, particularly in capacity and quality stemming from the significant investment in their Northern Ireland
manufacturing facilities. “We at OPS are delighted to formally announce the extension to our long-standing partnership with Telestack, which is already in effect with OPS and MPS stocking and servicing Telestack nationally.” MPS will deliver its expanded Astec product offering through its existing and new Australian support infrastructure. The company has existing facilities in Perth, Darwin, Adelaide and Central Coast NSW, with new and used equipment stocks, hire fleets, local applications and sales teams, spare parts warehouses and local service and support. To strengthen its Eastern Australia presence, MPS has established new branches with stocks of equipment and parts, along with local teams in Brisbane and Melbourne. Significant investment is underway on two new facilities in these capital cities, targeted to be completed in 2021. Czerkasow says the market is embracing solutions which can reduce reliance on manual labour, fuel usage, manpower and ultimately
improve efficiencies. “We believe the timing is perfect for OPS to expand our Telestack offering right across Australia. Great equipment requires great back up and support and we believe this is a well-matched partnership that will deliver quality outcomes for customers of these industries,” he says. OPS’ investment in its facilities is aimed at continuing to improve its service and support capabilities for its current and future customers. Andrew Lock, OPS Group Regional Manager – Eastern Australia & Pacific says it is critical that the company constantly develops and improves its overall customer support. “Our facilities will enable our businesses to stock unprecedented levels of capital equipment, readily available for sales, hire and demonstration, as well as ensure we stock industry leading levels of spare parts,” Lock said. “OPS have always strived to deliver class leading service and support. These new facilities will allow us to take this to a whole new level in Eastern Australia. We now have tremendous capabilities in large scale plant refurbishment, fixed plant services, fabrication and component manufacturing and refurbishment, including screen media and conveyor products.”
The arrival of Telestack’s Tele-Mix Pugmill Telestack has widened its product offering to include the Tele-Mix, a track mounted, fully mobile, high-volume continuous
The Tele-Mix P2000T has a throughput of up to 300 tonnes per hour and a sevenmetre hopper capacity as standard.
mix pugmill. It was developed in response to an increased demand for a reliable and mobile continuous mixing system that was easy to set-up, operationally efficient, transported easily without the need for special permits. The Tele-Mix is fitted with a twinshaft mixing chamber and incorporates a direct hydraulic drive, mesh gears for rotors and removable paddles. The P2000T model boasts a high throughput of up to 300 tonnes per hour and has a sevenmetre hopper capacity as standard. Easily integrated into an existing system, or with the ability to stand alone, the Tele-Mix is designed for a range of applications including optimising the moisture content in road-base, blending, lime addition, cold-mix asphalt, cementtreated base and in stabilisation. The Tele-Mix pugmill offers a large capacity with optional 500-millimetre and 700-millimetre hopper extensions, optional bolt-in feed boot liners, optional fall-break system, and optional hydraulic tipping grid. The optional split feed boot
also provides a vertically split hopper plate that allows two separate products to be fed into the hopper. A cement in feed chute can also be used to blend into the main product. A key pre-requisite of the Tele-Mix pugmill was the ability to transport and set-up easily. The unit is designed with an on-board diesel engine and hydraulic power pack and is available in a range of power or engine options. Philip Waddell International Sales Manager at Telestack says the Tele-Mix tracked P2000T Pugmill is a consolidation of the world-renowned Telestack tracked Hopper Feeder range with the proven design of the Astec Pugmill box. “We already have had significant interest and uptake from our dealer network, and we are confident that the Tele-Mix will enhance the comprehensive range of products from Telestack,” Waddell says. “We are proud of the breadth of our range, and we are committed to putting the voice of our customer at the core of our product development and continuing to bring innovative, reliable and costeffective solutions to the marketplace.”
Telestack’s range includes: • Track mounted stackers • Wheeled stackers and link conveyors • Radial telescopic stackers • Ship loaders and unloaders • Tracked and wheeled hopper feeders • Reclaim hoppers • Tracked and wheeled truck unloaders • Bulk reception feeders • Static and project conveyors
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SCREW CONVEYORS
Hemp processor improves product A Canadian hemp processor was losing almost nine kilograms of seeds every eight-hour shift before Flexicon stepped in to help. MANITOBA HARVEST IS A MAJOR producer of hemp hearts, hemp powder, hemp granola, hemp bars, hemp extract and other hempbased products. It prides itself on its seed-to-shelf quality control, advanced packaging processes and sustainability practices. With growing demand for its products, the company looked to improve the efficiency of its raw hemp seed processing operations, and the packaging of finished products for shipment to retailers. Hulled hemp seeds tend to clump and require gentle handling to avoid product degradation. Existing equipment was proving unsatisfactory. Plant space was limited, and dust needed to be contained to maintain plant hygiene. “We were experiencing issues with operations,” Eric Pilor, Manitoba Harvest Process Engineer says. “We had been using a bucket conveyor to move hulled Castor-mounted hoppers and flexible screw conveyors transport work-in-process and bulk shipment material into each bulk bag.
hemp seeds into the milling process, but it was not designed for handling seeds. As a result, we were losing nearly nine kilograms of seeds every eight-hour shift.” To improve productivity, product quality, dust control, and overcome space constraints, the company installed Flexicon flexible screw conveyors, BFC Bulk-Out bulk bag dischargers and a Twin Centerpost bulk bag filler.
Processing hemp seeds Manitoba Harvest acquires hemp seeds from more than 125 growers across Canada. The raw seeds arrive at the facility by truck and are stored in silos until ready for processing. The seeds are conveyed to the processing area and into hulling machines which crack the outer shell. The company previously employed a vacuum conveyor to move the cracked seeds to two screeners that separate the hemp hearts from their outer shells but replaced it with two flexible screw conveyor systems. Each nine-metre system consists of
Twin sets of conveyors, each with a 3.6 metres long flexible screw conveyor interconnect with a threemetre-long screw conveyor.
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a three-metre-long screw conveyor that connects to the charging adapter of a sixmetre-long screw conveyor. Designed to gently move difficult-tohandle materials, each Bev-Con conveyor consists of a rugged, flat steel spiral with a bevelled outer edge rotating within a rigid, food-grade polyethylene outer tube. The rotating screw self-centres within the tube, providing clearance between the screw edge and the tube wall, allowing the material to move forward without crushing or grinding. “The conveyors are gentle on our product,” says Samuel Leung, Process Engineer. “No crushing occurs or turning the product into butter. We get a consistent product and, compared with previous methods, we get consistent feed rates. Previously we had issues with clumping and material slippage. All of that stopped when we installed our conveyors.” The conveyors, as well as bulk bag dischargers and bulk bag filler, are enclosed to protect the plant environment from dust contamination.
Mobile flexible screw conveyors boost productivity The screened hemp hearts proceed to packaging or to be further processed into hemp oil and hemp protein powder. Coldpressing hemp hearts yields not only the oil, but protein-rich hemp meal that is milled and refined into protein powder. To better manage the transition to downstream processing, Manitoba Harvest invested in two mobile flexible screw conveyor units with hoppers. Mounted on castors, these units move around the plant as needed to convey finished and semi-finished materials into bulk bags for the next processing step. “The portable conveyors have made a big difference in our productivity and eliminated almost all of the waste,” Pilor says. Finished hemp hearts enter the packaging area in bulk bags which are loaded into BFC bulk bag dischargers. Each discharger is configured with an electric hoist and trolley that ride on a cantilevered I-beam to lift bulk bags from the floor into the frame. Pilor says the plant’s constrained space does not allow room for manoeuvring a forklift. He adds that the BFC discharger’s hoist allows rapid and safe loading of bulk bags into the discharger without the use of a forklift.
Overcoming difficult-tohandle powders In addition to hemp hearts, oil and protein powders, Manitoba Harvest manufactures a variety of hemp-based snacks and nutritional supplements. In support of these products, another BFC discharger and flexible screw conveyor combination feeds a blender that mixes protein powder and other ingredients. This discharger hoists bulk bags from the level below onto a mezzanine where the contents empty into a hopper from which a flexible screw conveyor feeds them into the blender. Since hemp protein powders are difficult to handle, the dischargers are equipped with FlowFlexer bag activators that raise and lower the bottom edges of the bag into a steep ‘V’ shape to totally empty the bag. The bag spout connects to a SpoutLock clamp ring that allows a highintegrity, dust-free sealed connection
Each pair of interconnected flexible screw conveyors discharges processed material into a separator for further processing.
between the clean side of the bag spout and the clean side of a Tele-Tube telescoping tube, which lowers, applying continual downward tension to aid flow from the bag. “The dischargers have eliminated issues we had previously with material bridging and rat-holing,” Pilor says. The blender gravity discharges into a Twin Centrepost bulk bag filler on the level below through a sealed chute. The filler is equipped with an inflatable connector to seal the bag inlet spout to prevent escape of dust, and a feed chute outlet port maintains dustfree air displacement during filling. The bulk bag filler is totally sealed, eliminating contamination and dusting throughout the process.
greatly reduced our manual processing efforts and we are virtually worry-free over dusting or the introduction of foreign objects into our material flow.” “We’re a pioneer in the hemp processing business,” Pilor says, “and our updated bulk handling system has helped maintain our leadership position.”
Quality control and testing Manitoba Harvest conducts more than 30 safety and quality control processes in its operations, so before purchasing new equipment, the process engineers tested the flow of various hemp materials on full-size equipment at the supplier’s test lab. All material contact surfaces of the new systems are constructed of 304 stainless steel and suitable for foodgrade operations. Fully contained, the conveyors maintain ambient moisture and prevent against contamination. “Obviously, quality is very important in the packaging process,” Leung says. “These systems have
A flexible screw conveyor transports material from the bulk bag discharger to the packaging line.
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CONVEYORS
Finding efficiencies in conveyor systems End-to-end solutions on offer from conveyor companies are improving the material processing industry through quality, innovation, and reliability resulting in reduced maintenance costs and increased productivity for their worldwide customer base. ONE THING REMA TIP TOP’S customers want is “longer service life for increased plant availability and production” Joss Lynch, National Product Manager for Conveyor Components at the company says this has become even more important following the economic shocks of the COVID-19 pandemic. “Our customers want their conveyor assets to last longer, produce more and cost less to maintain,” he says. Earlier this year a client wanted to move to a 16-week shutdown cycle to increase productivity and save on downtime costs. However, the polyurethane belt cleaning blades they had available were not durable enough to handle that kind of extensive use. The business contacted Rema Tip Top, which worked to provide a solution from its extensive belt cleaner product line. After confirmation from its main research and development centre in Germany, Rema Tip Top determined that based off belt speeds of 5.5 metres per second, tonnage of 14,000 per hour, material grade, hours of operation, and tension, a high-grade long life REMACLEAN polyurethane blend was recommended for the site’s belt cleaners. Results showed the REMACLEAN blades still had 35 per cent blade life remaining after a full 16-week production period with no down time for belt cleaner maintenance. The previous blades had a blade life of nine weeks and generally resulted in an hour of downtime maintenance over a 12-week period. This cost the business upward of $500,000 in production loss, product, and maintenance costs. Rema Tip Top are now applying this model to various other conveyors across the site with similar savings expected. Wade Richardson, National Product
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Rema Tip Top Belt Technicians performing a belt splice and roller change in New South Wales.
Manager for Conveyor Belting at Rema Tip Top, says taking an end-to-end approach and listening to our extensive maintenance team on site means the company can provide reliable components and conveyor belting exceeding customer expectation. “Rema Tip Top Materials Processing is focussed on manufacturing high quality conveyor belting and conveyor components, to drive performance and deliver longevity which enables savings to the benefit of our customers,” he says. “At Rema Tip Top we have developed our processes by taking advantage of our onsite representation and expertise in the field including problem solving for our customers, filtering back information to our national product team allowing for enhancement of our manufactured product.” Rema Tip Top’s people are the backbone of the company. The business offers one of the largest experienced service divisions in the country. Specialists can provide anything from problem identification, product recommendations, scoping, quotes, shutdown execution, project tendering plus act as site based in-field experts for belt cleaning, tracking, belting and rollers. To support this service presence, Rema Tip Top invests heavily into training. It has established a facility
to provide Certificate 3 qualifications for new employees and all site-based crews who undergo additional education while on the job. Lynch says, “Without qualified people in the field, it makes delivering what we say we are going to do for our customer much harder. Our people really complement our product range and showcase we are a one brand, one source, one system solution provider for our customers.” “Customers appreciate how up close and personal our team likes to get when it comes to solving problems. We’re not afraid to get our hands dirty to find out what has to be done.” Rema Tip Top plans to continue innovating both its products and its people. The company is targeting industries it has not traditionally been involved with and providing new ideas and products, such as its Idler rollers and chevron belt for the quarry and recycling industries. It will also add alternative hightensile-strength rubber belting and other compounds to its local range, developed though engineering centres around the world. “We have end to end solutions that can go the distance,” Richardson says. “We want to innovate with our customers to help them improve availability, reduce downtime and save them money.”
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POWDER HANDLING
The modern challenges of industrial powder conveying Hazardous material reclassifications can create headaches for bulk powder handlers. That’s why Floveyor has designed a solution to futureproof plant operations in the face of changing regulations. reclassifications have become an unwelcome challenge in industrial manufacturing. “When regulations change, or when there’s industrial action over worker’s safety when handling powders, your entire plant can be impacted. The recent Australian Council of Trade Unions (ACTU) complaint about the danger of silicosis from engineered stones and the dusts they create is a good example,”
Rhys Walker, Managing Director of Floveyor.
THE LOGISTICAL CHALLENGES OF handling hazardous, abrasive, and explosive powders have long been the focus of conveying manufacturer Floveyor. Loading and decanting road tankers from disposable bulk bags brings with it several limitations, especially when transferring dry powders and granules for construction, chemical and manufacturing applications. Rhys Walker, Managing Director of Floveyor says hazardous material Floveyor uses a fully enclosed system to transfer powders and granules.
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he says. The ACTU called on the Federal Government to urgently act on silicosis on 7 June 2021, saying that one in five of those who work with engineered stone are diagnosed with the incurable disease. ACTU Assistant Secretary Liam O’Brien said these diseases are entirely preventable and the Federal Government must ban high silica content engineered stone products and promote the use of safer alternatives. Walker says another example is the European Commission’s (EC) reclassification of titanium dioxide. The EC updated its regulations and standards and reclassified titanium dioxide as a “carcinogen category 2 by inhalation”. It
said precautionary measures need to be taken to minimise the hazard for human health. Employers have no choice but to implement better safety measures in their plant. One way to mitigate these kinds of regulatory problems is to manage dust from the onset. Walker says using a fully enclosed system to transfer powders and granules is the best way to circumvent the impact of future health and safety regulations. “We rely on our FloDisc technology in our conveyors, to create the safe environment for powder handling,” he says. “It uses centrifugal force to suspend raw materials in an air pocket and propel them to a collection point in an enclosed tube, with a minimal amount of dust. “This provides a rapid but gentle way to convey a wide range of materials in food, construction, chemical, manufacturing, and resources industry and logistics applications.” Floveyor will be showcasing its equipment to the Australian Bulk Handling Expo (BULK2021) at the Melbourne Convention and Exhibition Centre from 8 to 10 September. Attendees will be able to see the conveyors for themselves, along with a new Endura product line of aero-mechanical conveyors designed to accommodate sophisticated chemical and industrial applications in an unlimited number of process and plant configurations. “We’re looking forward to showing people our mobile unit which lets you decant powders and granules with a mobile, relocatable plant,” Walker says. “It’s ideal for remote locations or sites with limited space or difficult access.” The Endura series handles decanting and bulk loading of intermediate bulk
bags, flexible intermediate bulk containers (FIBCs) and sea containers into pneumatic and road tanker trucks. A range of complementary equipment provides integration to brownfield sites while meeting rigorous global compliance and safety standards. “Because so many of our customers are working in industrial settings, safety is always front of mind in our engineering department,” Walker says, “Every Floveyor conveyor in the Endura series is designed to make vast improvements in how FIBCs are handled when discharging into and from road tankers. “We’re committed to creating a rapid, safe, and low-maintenance conveying environment. Only gravity silos can transfer raw materials into pneumatic road tankers at a high transfer rate.” Using an original Floveyor machinery for manufacturing, resources and chemical industries means the transfer of powders and granules is faster, cleaner
Loading and decanting road tankers from disposable bulk bags brings has several limitations.
and at a reduced cost. Every engineering design and production detail in the Endura series reflects Floveyor’s commitment to creating a rapid, safe, and lowmaintenance conveying environment. “We’re looking forward to meeting our current customers and new prospects at BULK2021,” Walker said. “We’ve been manufacturing in Perth, Western Australia, since 1958 and
we’re always amazed to hear stories about how long people have been using the same machine. “It’s also a great chance for us to provide customer service, in person, and hear about new trends in the market. More than anything, it’s a chance to catch up with the industry after a long break. We’re bringing a whole team, and everyone is feeling positive about going.”
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ENGINEERING
Historical changes to the wind loading standards are important to understand when assessing existing structures.
A history of wind loading changes Aspec Engineering investigates the historical changes to Australian wind loading standards, and the rationale behind them. THE WIND LOADING OF STRUCTURES is a complex phenomenon and a major consideration when ensuring the safety and design of industrial assets. However, standards have changed over the years to incorporate the latest research findings, and the knowledge obtained from recent severe weather events. The first modern wind loading code published in Australia in 1971, was the CA 34.2, which replaced an earlier interim document, the SAA Int 350. Although it was printed in Imperial units, all subsequent standards have descended from it, with notable changes being made in each new edition. In 1973, the CA34.2 was converted to metric units in the AS 1170.2:
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1973 edition. Cyclone Tracy, which hit Darwin in 1974, created many modifications relating to the findings following the severe weather event. The AS 1170.2: 1989 was a major revision of previous standards, with the conversion to limit state design which is still implemented in the following 2002 and 2011 editions. To recognise the modifications made to Australian standards over the years, it is necessary to understand the underlying concepts of wind interaction with structures, and how this is accounted for in the design process. Using the current limit state design method, Australian Standards design for an ultimate wind speed, on a probability basis where the wind speed has a small chance of being exceeded in
the life of the structure. Wind speed data is collected from anemometer stations around Australia and was defined as a gust of two to three seconds duration, recorded at the meteorological height of 10 metres in flat open terrain. However, it has been since found that the averaging time of the peak gust was considerably less than two to three seconds, with the recent 2011 version redefining the peak gust as having a moving average time of approximately 0.2 seconds. CA 34.2-1971 contained a contour map of ‘regional basic wind speeds’ with a 50-year return period, and a table of wind velocities for 48 locations where data had been obtained. However, many of these values are
identified as ‘short record’, as less than 15 years of records were available from the anemometer station, making 50 and 100-year return period estimates fairly tentative. This edition of the standard included a cyclone factor of 1.15, to be applied to the wind speed of locations within a ‘Tropical cyclone area’. The need for cyclone factors was eliminated in the 1989 edition of AS 1170.2, with the specification of high return-period design wind speeds. Additionally, the need for importance multipliers in the 1989 edition was eliminated as variable annual probability of exceedance was adopted for wind speeds in the 2002 version. Once regional wind speed has been decided, other factors must be considered such as the increase in wind speed which occurs with height. Taller structures have higher wind loads than low level structures, which is considered by applying height multipliers. It must be realised that standards prior to 1971 did not account
for this effect and assume a single value over two central and coastal regions. When strong winds interact with a structure, pressure and forces are generated, with the characteristics of these pressures being defined by the characteristics of the approaching wind, geometry and permeability of the structure. Due to the turbulent and gusty nature of wind, these pressures are not constant but highly fluctuating, and the interaction with the shape of structure itself, such as local eddies at the edges, causes the pressure distribution to vary over the surface of the structure. The distribution of pressures is determined by aerodynamic shape factors, which have been developed and modified over the years reflecting new research findings. Additionally, for tall structures the dynamic response of the building must be considered. Information regarding the dynamic response has been expanded over the years, from an informative annex in 1971, to inclusion of a dynamic response
factor in design pressure calculations in the current standard. Considering all the above factors, in the table below it can be seen that the wind design pressure for a structure located in Central Queensland, varies with each standard. There is a particularly large increase in design pressure between a structure built in 1971, compared to a structure built in 1989, highlighting the changes in regional wind speeds post Cyclone Tracy. It can also be noted that the elimination of importance multipliers and instead the use of variable return periods in the 2002 edition, allows for a slightly decreased basic wind velocity. Clearly, historical changes to the wind loading standards are important to understand when assessing existing structures as it can have a direct effect on the design specifications. Therefore, it is useful to know what standard for which the structure has been designed, to evaluate its susceptibility to wind based on the current wind standard.
Recent severe weather events have led to changes in wind loading standards.
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BELT SCRAPERS
Dyna Engineering’s safer scraper solution The usually tricky task of removing a primary or secondary scraper from a conveyor belt for maintenance or replacement has been made a whole lot easier and safer. ACCESS TO CONVEYOR BELT cleaning equipment can often be awkward and usually requires maintenance personnel to work in confined spaces. In many cases the work is also elevated, further adding to safety issues. The pressure to perform maintenance efficiently and effectively can be difficult and dangerous. An Australian-designed solution allows for scrapers to be removed quickly and safely, reducing these safety risks. The DYNAFastFit has no need for fitters or maintenance people to get inside the chute, eliminating confined space permits and scaffolding. This allows
maintenance to be performed in a more secure location such as on walkways or platforms, even on the back of a ute or in a nearby workshop. The design also allows for the removal of the scraper shaft and blades without losing any of the settings as it is completely self-aligning, self-lubricating and self-locating. Thomas Greaves, General Manager at DYNA Engineering, says the focus of the complete scraper assembly redesign was to ensure maintenance work on scrapers is safer and easier. “It makes the job of the plant fitter a breeze by allowing fast removal of the scraper from the
chute. It’s a simple matter of removing two bolts so the scraper shaft and blades can be pulled out of the chute in one easy motion” he said. “Performing maintenance work outside planned shutdown hours can be a real cost-saver when you consider reduced reliance on overtime during shutdowns and increased equipment life because of more thorough maintenance. Personnel working conditions also improve because performing out of chute maintenance encourages correct working positions, avoiding poor ergonomics and reducing high risk work.” DYNAFastFit scrapers can be detached and removed from the chute more quickly and far more safely than with conventional scrapers.
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The polyurethane blades can wear into the shape of the belt, helping to maintain effective cleaning through varying conditions.
Adaptable design The DYNA FastFit scraper can be adapted to almost any location and style of scraper. The company says it currently has ready-to-go designs for all primary, secondary, tertiary and reversing scrapers. They are constructed completely out of stainless-steel and will not rust, corrode, or sustain paint damage. Its range of primary and secondary versions is available with either polyurethane or carbide (tungsten) blades for belt widths from 350 millimetres to 3500 millimetres wide. Polyurethane is a softer material when compared to carbide and can be used on new, older, or worn belts. It is particularly effective when the surface has become worn or uneven. They are generally not tough enough to damage the conveyor belt itself and thus are more forgiving when something goes wrong. As conveyor
belts wear, deformities, cracks, and dents are common occurrences. The polyurethane blades can wear into the shape of the belt in a reasonable time frame, thus maintaining effective cleaning through varying conditions. The disadvantage of polyurethane is that the softer material has a faster wear rate. Polyurethane wears at a faster rate than carbide due to the differences in hardness, therefore polyurethane blades are made with greater wear allowance to obtain an acceptable wear life. Carbide refers to tungsten carbide which is valued for its physical hardness, strength, and resistance to chemical attack even at high temperatures. Due to its high-resistance properties, carbide blades are chosen for heavy duty applications as the wear rate of the blades is low. However, the same
properties can cause issues with worn or damaged belts. Carbide blades are generally the best for new conveyor systems when the belt is undamaged or unworn. As the belt becomes worn, carbide blades can be switched over to polyurethane when required. When comparing polyurethane and carbide the main consideration is wear life and risk of wear, versus the application needs and the condition of the conveyor belt.
Modular range benefits DYNA FastFit belt scraper’s modular design is a useful feature as parts are interchangeable between different models and types, and many of the spare parts are common across the range. One example is the mounting bracket for the blades. The blades are mounted on a standard track mounting system. This allows any blade type to be installed without the need for replacing the scraper, which is the normal situation when compared to conventional alternatives. Different adjusters are available for each scraper and are fitted without modification. The choice of adjusters includes twist lock, pin lock, compression spring, tension spring, air, water, oil and gravity. Most adjusters can be fitted on either end of the shaft.
Handy tip from Thomas:
The FastFit belt scraper’s modular design is a useful feature as parts are interchangeable.
If you need to begin running the conveyor as soon as possible, consider installing a spare scraper. By doing so, maintenance can be performed on the removed scraper back at the workshop with less time pressure and greater safety. Then, at the next shutdown, you can simply reinstall the repaired scraper and begin the process again.
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BELT SCRAPERS
Hosch heads east Specialise belt scraper manufacturer Hosch plans to expand across Australia. Marisa Akamatis and Sonja Volhejn explain how the company’s scrapers are designed for success.
A positive cleaning angle uses less contact force to remove the smallest of particles from the belt’s surface. Hosch belt scrapers incorporate several torsion systems.
INNOVATE OR DIE – THAT’S THE philosophy industrial belt scraper manufacturer Hosch is built around. The company, which has had this mindset for more than 40 years, is a specialist. It focuses its attention and energy entirely into designing new and improved versions of its scrapers. Marisa Akamatis, the company’s Client Liaison Manager, says there are five design principles that set the Hosch’s scrapers apart – high efficiency, ease of maintenance, safety of the belt, flexible installation options and wearresistant blades. “Belt cleaners are one of the smallest components on a conveyor when it comes to price and they are often overlooked,” she says. “If you don’t have a good cleaner, product will remain on the belt, leading to a loss of production and higher chance of damage. Investing into quality scrapers is a small price to pay for something that can give you a big return on investment.”
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HOSCH belt scrapers use a positive cleaning angle inclined against the direction of belt travel to remove the finest residual material from the belt surface. A positive cleaning angle uses less contact force to remove the smallest of particles from the belt’s surface. It also reduces any forces required for belt cleaning, and greatly reduces belt contact wear. Belt scrapers rely on consent pressure to enable the blades to remove these sub-micron particles, also known as carry back. Hosch belt scrapers incorporate several torsion systems to keep its belt scrapers at optimum tension. These rubber torsion systems also allow the scraper to defect from any obstacles presented. Sonja Volhejn, Hosch Managing Director, says the company has been using scrapers on Australian materials handling sites for more than 30 years at this point. “We have a deep understanding of the physics involved with keeping conveyors clean, which is why our scrapers
have proved themselves in the field,” Volhejn says. “Because we are an original equipment manufacturer, we have the capacity to customise our products to fit the application. “We want to give our clients peace of mind – it’s hard enough to handle all the aspects of production. We’re the experts in our field and can find a way to install belt scrapers that will optimise the performance of the conveyor.” Hosch will be exhibiting at BULK2021 from 8 to 10 September at the Melbourne Convention and Exhibition Centre. The company will be showcasing some of its newest scraper systems, along with several videos and case studies. The company is well established on the west coast and is aiming to widen its footprint in the eastern states. It plans to open a warehouse and hire a local representative, service technicians and crew on the other side of the country to help build relationships and demonstrate its expertise. Volhejn says some of Hosch’s clients see the company’s scrapers as a secret tool to maximise their business. “We are proud of our success and want to let people know more about the brand and what we can offer,” she says. “Hosch began developing scrapers for the coal market in Germany in the 1970s, so we’re excited to return to our roots in Australia’s coal mines.”
Hosch can customise its products to fit the application.
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talk
Designing clean bulk material operations Most operators want to have a clean plant, but what does that mean? Steve Davis explains how to design systems to reduce dust emissions and spillage from the very beginning. 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.
IN A MINING ENVIRONMENT we start to release fine particles that become dust at the primary crusher, and from there on along a conveyor system through stockpiles, other crushing operations, screening and into storage for loading to transport systems. Most of these stages will be dry materials handling. In many operations there will be a processing stage that further reduces particle size and produces product and waste streams. Processes include dry and wet materials handling. Larger particles that don’t become airborne or flush away are easier to manage. However, design of systems should consider management and containment and avoidance of spills. Chutes
Poor design and maintenance results in spillage and dust.
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should be designed to load the receiving belt correctly, sized to contain carry over on a shut down and have blockage detectors that are sensibly located. Storage level control to manage fill, methods to prevent fly rock. Don’t overfill belts and do consider the large rocks that could migrate to the edges. Provide methods and access to clean up after the inevitable spill. Our focus should be on eliminating and controlling levels of fine particles in the materials handling streams. Fine particles are released and generated in material streams from any action that has potential to fragment larger particles into smaller. These actions can be deliberate forms of size reduction using
impact, attrition or compression in the design, or they can be incidental from material handling designs that cause high impacts and other forces from materials interaction with wear liners. When fine particles are generated, they will be released from the main material stream anywhere that circumstances permit. This is typically separation through gravity, air or water flow. Unintended separation causes many problems in materials handling apart from environmental and health issues. Airborne and waterborne fine particles accumulate on structures and mechanical equipment. This accumulation can overload structures, accelerate corrosion, create dust explosions, prevent visual condition monitoring, penetrate bearing and other seals, bury idler rolls, cause belt tracking issues, build up on pulleys and damage belts. The cost of damage and cleanup is high and ongoing and reduces plant availability and productivity. For many bulk materials there will be a cumulative loss of material that could be lost profit. Even if the product can be reclaimed there is additional cost to do so. Assuming we want minimum fines release in our plants, there are control methods available. First establish some data. Start with how dangerous are the dust particles that will be
Corrosion from wet bauxite spillage.
released during material transport. This will set the basis for control, noting that current advice is that all ultrafine particles have potential to cause lung and or skin irritation or worse. Smaller particles, particularly the -10µm and -2.5µm are noted as being worse, especially if silica or organic (coal etc.) Are they toxic (arsenic or lead concentrates for example)? Are they corrosive when wet or dry, soluble, (salt or potash)? What is the dust explosion level, will a static charge accumulate, (sulphur dust)? What is the dust extinction moisture level, noting that this varies with the overall particle size distribution of the material being handled? Is the Transportable Moisture Limit (TML) applicable? Is the dust hydrophobic? What is the dust lift off velocity? If any of these or other specifics apply, they should determine what dust control methods can and can’t be used. The type of material could affect the selection of processing equipment, e.g. which size reduction process releases the least amount
fewer problems. It is unlikely that any bulk materials installation will be free of fines and dust. Material handling system design impacts the amount of dust generated. Limiting dust generation and release is achieved by avoiding direct impact of material on any surface, minimising material free fall and minimizing any turbulence in the material flow stream. Design conveyor systems to keep the material on or in the belt. Look at enclosed systems such as pipe conveyors. Use a real surcharge angle –
many systems designed using textbook angles are near flooded when the actual angle turns out to be much lower. Belt edge clearance considers many aspects of conveying and should not be reduced. Design and install flow-controlled chutes and spouts that offer smooth flow and keep the flow stream together to keep impact and turbulence low. We can select liner materials and methods such as modular rotable parts to ensure that liner integrity is easily maintained. Keep drop heights as low as practical to avoid stream separation and dust release. Balance the discharge from chutes with the velocity of the receiving conveyor to avoid turbulence, reducing belt cover wear at the same time. Design chutes and bins to control the airflow and manage dust that is released and into dust collection systems. Select skirt and impact components to match the material and the flow vectors to contain bulk materials and dust and avoid run back. Install them correctly at the supplier recommended spacing on the belt. Wide spaced skirts can cause many problems. Provide good access so that these components can be adjusted and maintained safely. Select belt cleaning systems that match the bulk materials and the belt cover, remove as much as possible to avoid carry back and discharge into the chute without disrupting flow. Install them using supplier guidance, if not they may not function. Provide good access so that these components can be
The result of poor dust management.
of fines? We have many options for control of generation and management of fines. It seems reasonable to assume that we would focus on methods that generate less fines as this results in
Australian Bulk Handling Review: July/August 2021 77
BELT CLEANERS
only partially effective if incorrectly designed. Water droplets are generally much larger than dust particles and they tend to ‘push’ dust particles out of the way rather than coalescing and knocking them down. This leads to the use of fog or mist sprays, which are effective in suppressing airborne dust in dump hoppers and chutes. Systems are proven and readily available in Australia.
Effect of drop size on collision with fine particles Carry back under and adjacent to conveyor.
adjusted and maintained safely. Look for self-adjusting units, and units designed for maintainability. In Australia we have a wide selection of specialist suppliers who have global experience in many bulk materials that are happy to discuss and guide selection. Maintaining the condition of materials handling systems will be easier if the design provides safe and considered methods. A well designed and maintained system will generate less spillage and dust and be more reliable. We can minimise dust generation and release, but there will almost certainly be some dust and spills. There are several methods to containemissions. Water is the most common method used. It is also a method that is abused badly in my experience. Water is an expensive commodity, but even more expensive if an excess of water displaces saleable product in transport. In many operations water is added before and after transfer chutes through a simple spray bar with little thought of control or quantity. Large volumes of water are also added in dump hoppers and other locations. The intent seems to be that drenching the bulk material will keep the dust down. I rarely see any black belt shut off or assessment of water quantity required, often just a bar with a manual valve. Often this causes more problems than solved. Cleaners are overwhelmed by wet slurry causing carry back, there can be run back and spillage from inclined belts, surcharge angles reduce from design, stockpiles have water issues. Water does suppress dust emission but could be
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applied more effectively. The use of overbelt and in chute foam sprays, water plus surfactant plus air, has been proved effective for some applications. Selection of surfactant will be specific to requirements. Sodium lauryl sulphate (SLS) ‘soap’ is common. The bubbles consist of a thin film supported by air, when they contact a surface and break the thin film spreads over the local material adhering to small particles. Water consumption will be lower, potentially only 10 per cent of water only, and the effect lasts longer due to foam binding dust to larger particles. Capital investment is higher but effectiveness and operating costs are much better. Spray systems are also intended to knock airborne dust down. They are Water droplets are generally much larger than dust particles.
If wet suppression is not suitable for the materials handling system, we have fan driven dust collection systems. There are three aspects to consider; what will be done with the collected dust, the collector itself and the system used to carry dust laden air from the source to the collector. There is one aspect of dust collection that has always puzzled me. The concept of having integrated bag filter and fan systems in a chute. These collect dust relatively well, but then reverse pulse the bags to discharge the dust back into the chute from which it was collected. The dust is likely part collected over and over and otherwise dumped back into the system to be released or collected elsewhere. My feeling is that if dust is collected, there should be a disposal plan. The minimum I can see would be to wet the dust into a paste and
Focus should be placed on controlling the levels of fine particles in the materials handling stream.
return to the flow. As a paste it may be able to pass through the balance of the system without emitting too much dust. Alternates fordry collection are to bag and dispose or recycle. Wet collectors only have thedispose or recycle
option in most cases. There are several types of dust collector available. There could be a pre-collector or cyclone for coarse separation with most types. The most common is the dry bag house system. Dust laden air is pulled into a fabric or paper filter where it is held and either discharged through shaking or reverse pulse air flow. When dust is released, it falls into a discharge hopper for recycle or disposal. Wet scrubbers are used where bag filters are unsuitable, e.g. for explosive or flammable dust. The dust laden air is drawn through a liquid system and the dust separates from the air into the liquid. The liquid is circulated through settling or classification equipment to remove the dust as a slurry for disposalor recycle. The fundamental basis for a dust collector to collect dust is for the dust to get from the source to the collector. On many sites I have visited, this is one aspect that stands out as being
poorly implemented. There must be sufficient airflow velocity in the system from the extract point to and through the collector to entrain and keep dust particles entrained. If not, the dust will not get to the collector. This means sensibly located extract plenums, not just a convenient spigot, and a carefully designed low friction loss ducting system. If there are several plenums on the same collector, balancing facilities are necessary. Systems with multiple long and convoluted duct runs have too much resistance and are difficult to balance. When the cumulative flows and friction losses are added, then size a suitable collector and fan to provide flow and collect dust. The ducting must be accessible for cleaning. Many systems appear to select the collector and fan first and then randomly run ducts to convenient locations along structure that provides little access. This is one area where I have found it difficult to obtain a complete system design from any single supplier.
DUST CONTROL
Dust in bulk handling operations: sources, testing and passive control through effective design TUNRA Bulk Solids shares some of the testing and design strategies it has learned through research and collaboration to prevent dust emissions. THERE IS NO DOUBT THAT THE creation and management of dust is an ongoing challenge. In recent times, there has been an increased focus on environmental and health concerns related to dust emissions in mining and mineral processing activities. Understanding the behaviour of dry bulk materials in different handling operations is of utmost importance for the design of ‘dust-free’ facilities. Dust remains a key challenge in designing and operating specific links in the materials handling chain, such as transfer chutes, as well as in the holistic management of operations such as ports.
Dust testing: One of the methods used for characterising bulk materials is the Australian Standard AS 4156.6-2000 Coal Preparation - Determination of dust moisture relationship for coal, typically known as the ‘Dustiness’ or ‘Dust Extinction Moisture’ test, whose main aim is to determine the relationship between moisture content and dustiness levels. The test has been used as a tool in dust management strategies to reduce or control dust emissions in a variety of materials handling systems such as belt conveying, transfer chutes and stacking operations [1]. According to the standard, the “dust number” can be calculated as per Equation 1, and the Dust Extinction Moisture is the moisture at which a dust number of 10 is obtained. This means 0.1 gram of material collected in the bag per 1 kilogram of sample.
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Dust Number=(Mb-Ma) ×100,000 Ms Equation 1 Where: M_b = mass of filter bag and dust [g] M_a = mass of empty filter bag [g] M_s = mass of sample in drum [g] The test is performed with material samples prepared at several moisture contents and the results are plotted in a semi-log graph similar to the one shown in Figure 1. Originally developed for coal, the test has been used for other commodities as well with changes in the quantity of sample placed in the rig. TUNRA Bulk Solids has seen a significant increase in demand for dust extinction moisture testing over the recent years, which has led to the commissioning of its third dust
Figure 1: Example of Dust Extinction Moisture test result.
extinction moisture machine to meet this demand. The new machine has been in operation for almost a year, with a significant portion of the projects involving the testing of iron ore. It is important to highlight that AS 4156.6-2000 defines dustiness in terms of moisture content, while other standards, such as the European Standard EN15051-2, are mostly focused on concentrations of particulate matter fractions based on the particle sizes. Health-significant particulate matters include particles identified as PM 1, PM 2.5 and PM 10, with exposure limits expressed in milligram/ kilogram[1].
Dust Lift-off (wind tunnel testing): One of the most popular dust characterisation techniques is the use
the latter focuses on both the bulk solid particles and the air around them. As with every technique, each has its advantages and disadvantages, and different applications might require different techniques. Using a multiphase CFD modelling approach, for example, is advantageous in that it allows a clear representation of both particles and fluid, but this comes at a higher computational cost. Conversely, a single-phase CFD approach or using DEM might be sufficient to achieve certain objectives like comparing different designs or quickly assessing propensity to dust generation.
Using image analysis techniques to understand dustiness Figure 2: TUNRA’s third Dust Extinction Moisture machine commissioned in 2020.
of wind tunnels to simulate air flow across a variety of surfaces. These can include belt conveyors, stockpiles and train wagons. Typical tests can last from one to eight hours depending on the application, and the bulk sample moisture is measured before and after the test to control drying. The test parameters are adjusted to match, as close as possible, the actual operating conditions, including: material moisture content, wind speed and angle of repose, and, with the assistance of a dust track monitor, it is possible to control and record PM 1, PM 2.5 and PM 10 particles for the duration of the test. The dust lift-off test can also be used to assess performance of different types of veneering treatments, as shown in Figure 4.
simulating dust as it would require too large a number of small particles, which is currently not feasible. Furthermore, it takes place in a ‘vacuum’, and no air flow is present. However, the technique can be useful for a first evaluation of dust emission to analyse material flow in general: dust is often generated when there is an abrupt change in particle velocity or direction, which are factors that can be analysed with DEM. On the other hand, as the name suggests, Computational fluid dynamics (CFD) is specifically concerned with the flow of fluids. Current CFD software can simulate solid particles as well, but the focus is on the fluid medium. Single phase or multiphase simulations are possible, the first being used to investigate the air flow alone, whereas
Advanced image analysis techniques can also be used in conjunction with computational simulations to add valuable information about granular flow with respect to dust and other phenomena. One of such techniques is particle image velocity (PIV), which is used to obtain instantaneous velocity measurements and related properties in fluids, but it has also been applied as a flow visualisation tool for granularflow [3]. When applied to granular flow, PIV can be used to measure particle displacements and velocity fields, but, similarly to other analysis techniques,PIV also has limitations. PIV applied to granular flows is limited to quasi bi-dimensional flows where flow can be observed at a free surface through a clear wall [4]. As PIV is an indirect measurement technique,the small tracer particles are critical for reliable results [3].
Numerical modelling: The use of numerical modelling has grown in the field of bulk solids handling, with techniques such as Discrete Element Modelling and Computational Fluid Dynamics being used extensively to simulate the flow of particulates. These techniques are sometimes used by themselves or in combination. Discrete element modelling (DEM), with the current computational capacity available, is somewhat limited in
Figure 3: TUNRA’s wind tunnel.
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Application Example: Transfer Chute
Figure 4: Dust lift-off test for performance analysis of veneering treatments.
Passive dust control through improved design: Dust control is typically conducted actively, such as with water sprays or extraction fans. These methods, although effective and necessary in some cases, have limitations and disadvantages. In some countries (Australia included), water is a scarce resource, and minimising its use is a required sustainability measure. Furthermore, the use of water as a dust suppression in some coal handling plants may affect the calorific value of the coal per tonne due to the increased moisture [2]. Another drawback of dust control systems is the higher energy usage, thus incurring higher costs. Therefore, a combination of active and passive control measures is advantageous. In several applications, it is possible to prevent dust emissions through improved design. Such is the case with transfer chutes for example, where a deep understanding of material trajectories and impact points can aid in designing transfers with controlled flow. The following basic design principles are of relevance: • M atching the in-line component of the material exit velocity to the receiving belt as much as possible helps minimising dust and abrasive wear • M inimising the normal component
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of the stream velocity at discharge reduces impact damage to the belt and helps minimise dust generation and spillage due to material re-bounding • M aintaining impact angles within the transfer at a maximum of 20° and minimising free-fall heights help reduce impact and abrasive wear, as well as dust generation The overall objective is to obtain a design that results in smooth, controlled streams that aid in keeping finer particles within the stream.
Figure 5: Air vectors from the CFD analyses.
Passive dust control through improved design was the object of a project involving the analysis and redesign of a transfer chute handling iron ore. The project involved the use of a scale model chute, shown in Figure 4, the application of PIV in the analysis of velocities and CFD analysis. The PIV system used consisted of an Oxford Firefly diode laser and a hxighperformance camera, whose set-up is also shown in Figure 5. This work was conducted by Dr Xiaoling Chen as part of her PhD with the University of Newcastle. See reference [3] for more detail on this study. The images obtained with PIV were used to compare the experimental results (scale model) with the CFD model results, with a total of seven combinations of parameters (coefficient of restitution and specularity coefficient) used in the CFD model. Figure 6 shows an example of the air vectors obtained with the PIV analysis and with the CFD analysis. The CFD model was underestimating velocities in comparison with the scale model, which can be used as a means to calibrate the CFD parameters. Overall, multiphase CFD simulation showed good potential to predict the air flow in transfer chutes, and based on
the calculated air velocity at the chute outlet the likely performance of the chute with regards to dust emission can be predicted and used a design aid for transfer chutes handling dusty bulk materials [3].
Conclusion The use of combined analysis techniques in the field of bulk solids handling can be very powerful in understanding dust emission propensity of different materials in various handling systems. When applied correctly, such information can be used in more effective designs to minimise dust problems or avoid the need for active dust suppression systems. Figure 5: Air vectors from the PIV analyses. References 1 Ilic, D; Lavrinec, A; Williams, K - Revised Coal Dustiness Test Method AS4156.6 - Part 2: Preparation, 2019 2 Chen, X.; Wheeler, C; Donohue, T; McLean, R; Roberts, A. - Evaluation of dust emissions from conveyor transfer chutes using experimental and CFD simulation, 2012 3 Chen, Xiaoling; Chen, Bin; Donohue, Tim; Wheeler, Craig; Roberts, Alan - Analysis of Passive Dust Control in Transfer Chutes using Computational Techniques. 4 Lueptow, R. M.; Akonur, A.; Shinbrot, T. - PIV for granular flows, 2000
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Applying simulation methods to improve dust control outcomes The exposure of workers to dust continues to be a major issue in Australia, highlighted by the re-emergence of coal workers pneumoconiosis (CWP) in Australian coal mines and increasing rates of silicosis. Jon Roberts, Peter Wypych, and Vitold Ronda outline the results of two systems that were trialled in an underground coal mine to reduce dust generated by previously identified sources. the movement of roof supports upstream of the dust monitor. It should be noted that the 15-minute average dust concentrations measured exceeded the recommended occupational exposure limit (OEL) of 1.5 milligrams per cubic metre, this is only a short-term exposure, however, best practice would suggest that keeping dust concentrations below the OEL at all times should be the objective.
Numerical modelling and application Figure 1: Dust concentrations showing peak measurements coinciding with roof support movements.
THE AUSTRALIAN COAL INDUSTRIES research program (ACARP) has recognised the issues that dust exposure has on workers in the bulk handling industry. It has funded the University of Wollongong and EnviroMist to research practices related to dust control system design, implementation, and validation (Project C26065). Two systems were trialled in an underground coal mine to reduce dust generated by previously identified sources. Firstly, dust generated by the lower,
advance, set roof support sequence, and secondly dust generated by the shearer when cutting the longwall face. Highenergy micro-mist nozzles manufactured by EnviroMist were used for this project. Real time dust monitoring was able to identify dust generated due to the movement of roof supports as being a major contributor to dust levels in the primary walkway. Figure 1 shows dust concentration measured over a two-hour period for which there are four distinct peak concentrations that correspond with
Figure 2: Cross section of longwall showing contours of air velocity.
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Having identified the source of the dust the next step was to analyse the conditions in the area so that an appropriately designed dust suppression system could be implemented. Computational Fluid Dynamics (CFD) was used to analyse the ventilation flow on the longwall and in particular between the roof supports on the walkway. This allowed for peak air velocities to be predicted so that sprays could be selected such that they had sufficient energy to create a mist curtain across the walkway without deflecting excessively. Figure 2 shows the airflow predicted by CFD in the area of interest, a max velocity of two metres per second was predicted and as such the nozzles selected needed to be able to withstand this air velocity. Based on the area to be covered and the air velocity predicted, a standard spray block consisting of five nozzles was deemed suitable, the nozzle size and operating pressure was calculated using the relationships presented in The Dynamics of Dust Suppression Sprays under Cross-Flow Conditions. The ability to relatively quickly estimate air velocities around complex geometries using CFD greatly enhances the design process especially when data is available to predict the coverage a spray will provide at
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Figure 3: Results of CFD modelling of spray dispersion in proposed position.
different air velocities. Full coverage was required to ensure all dust escaping during the operation would flow through the mist curtain, Figure 3 shows the spray positioning as simulated using CFD; the sprays were incorporated into the simulation to predict the mist coverage based on the predicted airflow, this position provided full coverage of the walkway and directs dust and mist into the floor as much as possible. Due to the relatively low air velocity only minor deflection of the mist occurs and as such the nozzle size and pressure was selected based on droplet size and water usage, this allowed for selection of a nozzle producing the optimum droplet size for the lowest water consumption; in this case a high-energy micro-mist nozzle operated at a pressure of 100 bar corresponding to a flow rate of two litres per minute and a mean droplet size of approx. 35 µm was selected. The system was designed as a trial across a section of the longwall with spray blocks installed on a series of roof supports (supports #5-10) which would operate whenever the adjacent upstream support would move. During the underground trials an unloader valve was used to adjust the pressure so that the influence of pressure on the performance of the system could also be investigated. The system was supplied with water at 16, 60, and 100 bar and the concentration of dust on the #11 support was measured for each, as well as with the system turned off completely. The dust monitor was placed on the #11 support so that it would not get significantly wet from the sprays on the #10 support, however, this did mean that the dust generated by the #10 support was being recorded. As well as this dust, because the system was only installed on supports #510, the dust generated by supports #1-3 were also being recorded by the monitor. Figure 4 shows the dust concentrations measured per minute with each configuration of the dust suppression system operating. Again, it needs to be noted that the spray system is only operating on supports #5-10 and thus this data includes all dust generated upstream of the monitor from supports #1, #2, #3 and #10, as well as dust generated by the stage loader, crusher and any other operations upstream of the monitor. Based on this, it is impressive that the system was able to remove almost 50 per cent of dust passing through the walkway when operating at full pressure. The benefits of running the system at full
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TECHNICAL PAPER
Figure 4: Dust concentrations measured during underground trials of roof support sprays.
Figure 5: Dust concentration measured during trial of roof support walkway sprays with the average upstream concentration removed.
Figure 6: Air streams released from shearer cutting drums to predict dust flow, left: Cutting with drums up, right: Cutting with drums down.
pressure is also clear from the data, it was observed during testing that coverage was still relatively good at 60 bar but limited when running at 16 bar. The reduction in dust when increasing the pressure from 60 bar to 100 bar strongly supports previous reports that utilising an increased pressure to produce a greater concentration of finer droplets results in a significant improvement in dust capture efficiency. At 60 bar the droplet size produced is
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approximately double the droplet size produced at 100 bar. It was not possible to utilise two dust monitors to measure the change in dust across the trial section of the longwall, instead the next best option was to undertake testing separately upstream of the system and remove the average dust concentration measured from the measurements taken downstream. To remove the affect of the upstream dust on the results, the dust monitor was placed on the #3 roof support over several shears allowing for a representative average dust concentration to be established. Figure 5 shows the dust concentration readings with the average incoming dust removed, for clarity this has been shown for just the 100 bar and system off readings. This data shows a very positive outcome indicating that over 80 per cent of the dust generated by the movement of supports #4-9 was removed by the implementation of the system. The second stage of the trial was to
evaluate the performance of the micromist nozzles in the canopy of a series of roof supports (supports #5-16) to reduce dust generated by the shearer. For this trial a pair of micro-mist nozzles were mounted on each roof support replacing the OEM provided nozzles. CFD was utilised in this case to analyse airflow around the shearer, firstly to predicted typical air velocity (found to be around three metres per second), and secondly to predict dust flow which was achieved by releasing streamlines of air from the shearer cutting drums under the assumption that the dust particles follow the same path as the air. Figure 7 compares the predicted dust flow between the shearer cutting the roof to when it is cutting the floor; it is evident that the flow is dispersed out from the face by a much greater amount when the shearer is cutting the floor, this would likely contribute to greater levels of dust in the walkway. As this greater dispersion is occurring when the shearer is cutting the floor it was important that the installed sprays have sufficient energy to reach the floor, as such the nozzles installed for this case were operated at 120 bar with a flow of 4.3 litres per minute corresponding to a droplet size of 40 µm. Simulation of spray dispersion also aided in selecting the number of sprays that should be operated at a time; the initial simulation consisted of only two nozzles per drum being operated, however, it was quickly found that this did not provide the required coverage, instead it was found that at least four sprays should be operated to achieve adequate coverage of each drum. Operation of the sprays on each support was controlled based on the position of the shearer with a headway of three in front and behind the shearer centreline, for underground trials it was decided that three canopy spray sets operating in front and two sets operating behind would be tested. To evaluate this system, the dust monitor was placed on the #18 roof support with the monitor probe placed approximately one metre from the outside of the roof support legs towards the face. The dust concentration in this location was then recorded over several shears with the spray system operating at full pressure (120 bar) and with the system off. Data collected from
in dust could be achieved by simply changing some of the nozzles on the shearer to micro-mist nozzles.
Conclusion
Figure 7: Dust concentrations measured during underground trials of roof support canopy sprays for reduction of dust generated by the shearer.
these trials are shown in Figure 7, this data represents dust measured during the period in which the shearer cut from roof support #22 to the main-gate and back, note that the time taken to do this varied from shear to shear. The data recorded does indicate that a reduction in dust concentration was achieved. Overall, a reduction of approximately 40 per cent (57 per cent when dust from upstream sources is
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removed) of dust generated by the shearer was achieved. It should be noted that without the system operating there were already a significant number of sprays (>150 litres per minute) operating on the shearer and the fact that a reduction in dust was still achieved provides evidence to support that fine mist sprays (rather than coarse droplet sprays) are required for effective dust capture; it is entirely possible that a more significant reduction
Solutions do exist to control dust and that with proper design and analysis a positive result can be achieved. The use of CFD has been proven to be an important tool in analysing air and dust flow in a longwall mine so that dust suppression nozzles can be applied at the correct pressure and positions to result in the greatest dust capture. ACKNOWLEDGEMENTS This research has been funded by the Australian Coal Association through their ACARP program and with support from the Australian government research training program and the International Solids Handling Research Institute through the University of Wollongong.
Your Storage & Conveying Specialists
SILOS
Segregation and stratification in granular mixtures Segregation issues can be complex, often requiring tailored solutions. Preventing segregation during vessel filling can be challenging. Jie Guo and Corin Holmes explain how mass flow can be established during discharge, and the associated problems can be mitigated or eliminated. BULK SOLIDS SEGREGATION JIE GUO Dr Jie Guo is a Project Engineer at Jenike & Johanson. Her career in bulk solids handling has focused on bulk material processing, handling, and transportation. She has been involved in numerous research and industry projects, ranging from flow fundamentals to solving practical flow issues and optimising bulk solids handling equipment. Jie is interested in a variety of bulk solids handling topics with particular focus on hopper/feeder design, segregation, eccentric loading and discharging, moisture migration and transportable moisture limit. Her prior research experience equips her with an in-depth understanding of bulk solids flow and handling issues.
is a term used to describe the separation of a mixture of particles into regions that vary in particle size, density, shape or other distinguishing characteristic. Segregation can occur naturally, under the force of gravity, or while external factors such as imposed air flow, vibration, or impact are present. Stratification is one of the phenomena often associated with segregation, for which, different materials overlay each other to form alternating layers depending on the physical properties of the particles. Segregation can cause numerous problems, ranging from difficulty in material handling processes to variations in final product quality resulting in product rejections or even recalls if they have been released to market. Many industries such as food, mining, cosmetics, pharmaceuticals, chemicals, powdered metals, and glass have experienced segregation challenges. Close attention should be
Segregation in a stockpile (dark: coarser particles, white: finer particles).
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Segregation pattern in Bin 1.
paid to planning the processing plants and designing the handling equipment, as segregation and stratification can occur either within the handling devices, such as silo/bins, agglomerators and blenders, or at the transferring
steps, such as from belt conveyors to stockpiles, and from hoppers to feeders.
Examples of Segregation Segregation issues can be complex often requiring tailored solutions. Figure 1 depicts a common segregation mechanism seen in centrally filled stockpiles – a common storage form in the mining industry. As can be seen, the coarser particles (darker material) have rolled to the periphery of the pile, whereas the finer particles have concentrated in the middle, under the piles feed point. Figure 2 illustrates some more complicated segregation patterns generated in two consecutive bins which are validated by sampling materials from different locations. Both bins operate in a funnel
segregation of particulate materials, “the most urgent need with regard to particle segregation is that engineers responsible for the design of solids handling plants should understand the causes of segregation and should be aware of the points in a process at which it is most likely to occur, so that in designing plant they can minimise its effects”. There are several primary mechanisms that have been identified as being responsible for most segregation problems when handling bulk solid materials. Sifting segregation occurs during filling when fine particles concentrate in the centre of a vessel and the coarse particles roll to the periphery (see Figure 1). For sifting segregation to occur, the following conditions must be met: Segregation pattern in Bin 2.
flow pattern of discharge where a flow channel is established above the outlet and stagnant material zones exist along the bin and hopper walls. In funnel flow, materials follow a first in – last out flow sequence. In Bin 1, a flat baffle is featured directly under the fill point. In this case, based on sampling results, an inverse segregation pattern was formed (see Figure 2) where the fines concentrated near the walls and the coarse particles fell into the flow channel. The material discharged from Bin 1 was then fed into Bin 2. The sampling results from this bin indicated that the coarse material flowed out first, followed by finer materials, and then coarse materials again resulting in a segregation pattern as shown in Figure 3. In this example, the segregation issues
experienced occurred in a pharmaceutical process where stringent quality assurance regulations are applied resulting in millions of dollars loss due to product rejection. Bulk solids particles often differ in their resilience, inertia, and other dynamic characteristics which can cause them to segregate, particularly when they are forming a pile such as when charged into a bin or discharged from a chute. The more resilient particles will tend to bounce to the outer area of the pile and the less resilient ones will stay in the centre. Since fines are usually less resilient than coarse particles, dynamic segregation can accentuate a central fines concentration. Regardless of the process, to avoid or mitigate segregation effects, an understanding of how and why segregation occurs in your process, is required to identify the options to improve the situation.
(1) A difference in particle size between individual components. In general, the larger the ratio of particle sizes, the greater the tendency for particles to segregate by sifting. (2) A sufficiently large mean particle diameter. J.C. Williams’ study, The Mixing and Segregation of Particulate Solids of Different Particle Size, shows that the tendency to segregate by sifting for particles below 500 µm decreases substantially. This may be attributed to the fact that the attraction forces acting between finer particles become prominent compared to their weights, which hinders the mobility of the particles. (3) Free-flowing material. For sifting between different sized particles to occur, it is essential that no agglomerates are formed, either between particles of a given size or particles of varying size. Fluidisation segregation.
Segregation and stratification mechanism
Sift segregation and spontaneous stratification.
Some early pioneering work regarding segregation was undertaken in the 1950s, but most of the research focused on differences in colour while the rest of the physical properties remained identical. In the following decades, attention has been given to the fact that materials can become segregated in a handling system if they have differences in particle size, density, shape and resilience. J.C Williams stated in his paper, The
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segregation is no longer caused by the sift mechanism. Air entrainment (fluidisation) segregation generally occurs in powders with an average particle size less than 100 µm. It is very likely to occur when fine materials are fed into a storage container via pneumatic conveying or when air is flowing counter to the flow of solids. In fluidisation segregation the finer, lighter particles rise to the top of the fluidised bed while the larger, heavier particles concentrate at the bottom (see Figure 5).
Dusting segregation.
(4) I nterparticle motion. There should be interparticle movements, in other words, there must exist a velocity gradient between smaller and larger particles. Figure 4 illustrates the spontaneous stratification associated with sifting segregation. As can be seen, the smaller (darker) particles concentrate in the centre and the larger particles (lighter) flow further to the periphery. Meanwhile, the mixture spontaneously stratifies into alternating layers of small and large particles. It is noticed that the stratification in Figure 4 is more signification compared to the one in Figure 1. This is related to the difference in angles of repose between smaller and larger particles. The research conducted by Makse et. Al in Spontaneous Stratification in Granular Mixtures concluded that the stratification can only occur when the larger particles have larger angle of repose than the smaller particles. Otherwise, only segregation and not stratification is obtained. J.R Johanson also pointed out the correlation between angle of repose and segregation. He stated in Particle Segregation and What to do About it that even uniformly sized particles of different materials in a mixture can segregate significantly during pilling if the materials have different angles of repose. The material having a larger angle of repose (measured from horizontal) tends to concentrate in the centre, whereas the one having a smaller angle of repose will settle on the periphery. In this case, the
90 І Australian Bulk Handling Review: July/August 2021
Dusting segregation occurs when dust generated during filling becomes entrained and settles in areas away from the incoming feed stream. The finer the particle size, the longer it may remain suspended in an air stream thus, secondary air currents can carry airborne particles away from a fill point into outer areas of a bin. Dusting segregation starts to become pronounced with particle sizes of 50 µm and is very common with particles below 10 µm. Dusting segregation concentrates the ultrafine and fine particles at a container’s walls or at points farthest from the incoming stream (see Figure 6). Particle velocity differences while sliding on a surface If there are variations in particle size or shape, the smaller particles and/or those that are more irregular in shape will typically have a higher frictional drag on a surface. This higher drag results in a lowered particle velocity. This effect can be accentuated due to stratification on the chute surface because of the sifting mechanism described above. Concentrations of smaller particles close to
Segregation after chute transfer.
the chute surface and larger particles at the top of the bed of material, combined with the typically higher frictional drag of finer particles, often result in a concentration of fine particles falling close to the end of the chute, with coarse particles falling further away as shown in Figure7. This can be particularly detrimental to operations if portions of the pile go to different processing points, as is often the case with multiple outlet bins.
Mitigate against segregation Since segregation can be quite costly in terms of rejected materials, attention should be paid to prevent or mitigate its occurrence during the design phase of a bulk material handling system. A holistic approach can be followed: • D etermine the bulk material’s flow properties • U nderstand how the bulk material flows through bins, hoppers, chutes, feeders, conveyors, and other material handling equipment based on its flow properties • U nderstand segregation mechanisms and analyse the potential for the material to segregate through each process step Discharge pattern affects segregation. Figure8 illustrates funnel flow and mass flow patterns that can develop during discharge. In funnel flow, a first-in lastout flow sequence, an active flow channel forms above the outlet, with non-flowing material at the periphery. As the level of material in the vessel decreases, layers of the non-flowing material may or may not slide into the flowing channel, which can result in the formation of stable ratholes. In mass flow, a firstin-first-out flow sequence, all material is in motion during discharge. Material from the centre and periphery moves
Material flow patterns.
toward the hopper outlet uniformly thus reducing segregation effects.
Corrective actions Consider the following techniques if segregation problems are identified. Note that these techniques can also be applied if segregation problems are present in an existing process/system. (1) Change the material Generally, an easy flowing material is more prone to segregation than a cohesive material. Consider adding liquid or binders to a material to increase its cohesive strength and decrease its segregation tendencies. Note that the change needs to be balanced between segregation and other flow issues (such as ratholing and arching) which may be caused by the increased cohesiveness of the material. Altering the bulk materials’ particle size distribution such as narrowing the particle size range and decreasing the mean diameter of the particles below 100 µm can also be beneficial for improving segregation. (2) Change the process If the mixture being handled consists of
several materials which are uniform in themselves but vary distinctly from one another, consider handling them separately and blending immediately prior to the final processing step. The material stream discharged from a conveyor may be subject to vertical or side to side segregation. Free-fall chutes should not be used to transfer segregating materials unless there is a mixing device downstream of the chute. Maintaining a high material level in a mass flow bin during processing can influence the potential for segregation tendency. For example, the top surface of the material should be at least three quarters of a bin diameter above the transition between the cylindrical section and converging hopper section. (3) Change of design of the equipment The use of mass-flow hoppers can alleviate segregation induced problems significantly as they promote the material flow of the entire cross-section within the bins. They will not necessarily eliminate segregation within the bins, but fines and coarse particles will be discharged simultaneously and the proportion of each can be maintained.
In some instances, a properly designed distributor at the inlet of a bin can be an effective way of reducing segregation. In effect, the distributor generates multiple filling points and creates multiple small piles. The segregation that occurs during pile formation is allowed at a smaller scale.
Conclusion Segregation issues can be complex often requiring tailored solutions. Segregation is a function of the material, equipment, and the process itself. Preventing segregation during vessel filling can be challenging however, when mass flow can be established during discharge, the associated problems can be mitigated or eliminated. Do you have a bulk solids handling question? Jenike & Johanson has developed the science of bulk solids flow and specialises in applying it to solving the most challenging bulk solids handling problems. So why not put them to the test with your question? Note: The advice here is of a general nature. Specific solutions are very sensitive to their circumstances. You should consult with a specialist in the area before proceeding.
Australian Bulk Handling Review: July/August 2021 І 91
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94 І Australian Bulk Handling Review: July/August 2021
I take great pride in welcoming all delegates to BULK2021. This is the first time we have held the exhibition, and I am excited to see it help grow the Australian bulk solids handling industry. At Prime Creative Media, we’re passionate about the industries that strengthen and grow Australia. We know the sector is a vital part of Australia’s future. Without the technology to handle bulk materials, Australia’s successes in mining, agriculture and construction simply would not have been possible. In the initial discussions of launching this event, we recognised that the industry needed an opportunity to come together under one roof to share best practice, innovation, and ideas. At the time, there had not been an expo that focused on this vital industry for years. We decided to launch the event to help the industry to grow through closer collaboration and meet face to face again following more than a year of remote working. We are committed to the future of the Australian Bulk Handling Expo and to growing this conference and exhibition for an industry that deserves further focus and attention through an event such as this one. The show’s conference and exhibition will showcase the latest developments in automation, safety, Industry 4.0, sustainability, and export freight. There will also be ample opportunities for cross-collaboration through this
multi-dimensional and integrated event. We have worked tirelessly to create a conference program which features Australia’s best and brightest minds in the bulk handling sector who will sit down together and discuss some of the most important topics for today’s industry – including dust control, wear, safe storage and handling, and more. In addition, we recognise that throughout the bulk handling industry, collaboration is a key factor in any successful operation and have thus ensured that there is representation from every sector at this event. This year’s event also runs alongside MEGATRANS2021, Australia’s largest multimodal supply chain expo, and I urge you all to connect with this part of your industry and share learnings and best practice with each other across technology and services. I also want to thank our association partners and sponsors, Vega Australia, Premier Tech Systems and Automation, PROK, LEAP Australia and the Australian Society for Bulk Solids Handling. Their contribution and support are greatly valued and appreciated. While this year’s event is just beginning, I am also excited to announce that the Australian Bulk Handling Expo will be back in 2023. Please come and speak to the team about how you can get involved in Australia’s largest bulk handling event for 2023.
BULK2021 Quick Reference Guide 4B Australia
4406
LGPM Process Innovation Inc.
4134
Absafe Group
4343
LINAK
4301
ACOEM
4340
MANNAWAYS PACKING
3501
Aerobelt Australia Pty Ltd
4300
MARC Technologies
4448
Aerzen Australia Pty Ltd
4339
Mideco Jia Pty Ltd
4439
AGI
4044
Minprovise Pty Ltd
4314
Agridry Dryers Pty Ltd
3515
MRA Electrical
4412
Altair
4144
Nelson Silos
3500
AURORA-BULK PACKAGING
4312
PACKWEIGH EQUIPMENT
4306
Azano Pty Ltd
4444
Page Macrae Engineering
3519
Bonfiglioli Transmission (Aust)
4146
Phoenix Mecano
4048
Brelko Conveyor Products (PTY) LTD.
4440
Pneuvay Engineering Pty Ltd
4001
Charter Trade Global
4302
Precisionscreen
4135
Conveyor Products & Solutions
4124
Premier Tech Systems and Automation PTY Ltd.
4010
COREX PLASTICS (Australia Pty Ltd.)
4020
Prime Manufacturing Pty Ltd
4410
Cortex Engineering Pty Ltd
4300
PROK Quality Conveyor Equipment
4118
Crusher & Screen
4452
Rainstorm Dust Control
4437
Donaldson Filtration Solutions
3509
Rotolok Ltd
4307
DSH SYSTEMS LTD
4445
RR Pacific Pty Ltd
3508
DYNA Engineering
4137
SEW-EURODRIVE
4031
Elastotec Pty Ltd
4037
Skala Australasia Pty Ltd
4438
enmach
4422
Slimstock
4345
ESS Engineering Services & Supplies
4100
Smart Pack Ltd
3506
Floveyor
4016
Supplied by Ebro
4337
Flow Force
4148
Terex Jaques
4308
Gough Plastics
4418
ThermAlign Pty Ltd
4404
HE Silos
4344
Treotham Automation P/L
4046
HOSCH International
4319
4443
Kilic Engineering Pty Ltd
4416
TUNRA Bulk Solids Handling Research Associates
Kinder Australia
4002
Vayeron
3518
Koyo Australia Pty. Ltd.
4318
VEGA Australia
4130
LASE/HÜBNER/EMG
3503
vWork
4049
LEAP Australia
4132
Weigh-More Solutions
4131
Australian Bulk Handling Review: July/August 2021 І 95
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06
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6 6
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3
3103
3
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6
6
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3
3203
LOW TV 2370H
3
6
3307
3306
3
3304
6
6
3
3
3
3
3
3
3409 3507
3508
3500
3501
3503
3506
3408
3400
3403
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3 3407
3
3
3
6
Entry/Exit Megatrans 2021 Door 4
STEP DOWN BULKHEAD 2.75m FLOOR TO BULKHEAD HEIGHT
3
3301
3302
3
3303
BULK2021 Floorplan BUILD AREA NO BUILD AREA
4124
4020
4002
4010
4016
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Entry/Exit
STEP DOWN BULKHEAD 2.75m FLOOR TO BULKHEAD HEIGHT
Bulk 2021 Door 5
LOW TV 2370H
BUILD AREA NO BUILD AREA
4118
4114
4108
4100
4312
4318
Queuing Area
4319
4422
4418
4412
4416
4308
4404
4406
4410
4302
4307
4314
4306
4300
CUPBOARD
4301
SINK
Breakfa
96 І Australian Bulk Handling Review: July/August 2021
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3
12
3000
FLOORPLAN
3321
3
3021
3209
6
3211
6
6
21
3018
3016
12
5
7
3
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3416
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3421
6
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3411
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3521
3519 3518
3515
3511
3509
4049 4048
4046
4044
4037
4031
4130
4148
4149
4146
4132
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4144
4137 4135 4131
Networking Lounge
4346
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4445
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4345
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Exit
4452
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Entry
80pax
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3011
3009
Seminar Theatre 2
Australian Bulk Handling Review: July/August 2021 І 97
BULK2021 SHOWGUIDE
Bringing bulk experts together The BULK2021 conference will see industry experts discuss the future of bulk solids handling in Australia. WITH BULK2021 SET TO BRING the leaders of the bulk solids handling sector together for an industry-first expo in September, event organisers have partnered with the Australian Society for Bulk Solids Handling (ASBSH) to deliver an informative conference. The conference will place over two days from 9 to 10 September at the Melbourne Convention and Exhibition Centre. Sessions will cover industry safety, as well as the importance of remote access and reporting - especially after the past 18 months - and what the future of the industry might look like for companies and their employees. Additionally, the conference will feature a technical component driven by the ASBSH, which will see various industry professionals deliver white The conference will feature a technical component driven by the ASBSH.
98 І Australian Bulk Handling Review: July/August 2021
papers on topics ranging from dust suppression to new technologies and pieces of equipment designed to make the industry more efficient. “We’re pleased to be partnering with the ASBSH to deliver the BULK2021 conference,” says Lauren Winterbottom, BULK2021 Show Director. “The program has been designed to provide attendees with information about the latest technologies available for the industry.” “After the past 18 months, we know just how important interconnectivity and remote reporting can be, on top of other safety measures that are specific to the industry. We hope that attendees find the program informative and practical for their businesses.” Conference sponsor Leap Australia
will present a case study focusing on Rocky DEM computational methods. Together with customer Onyx Projects, the case study will show how the methods can positively impact on transfer chute performance. VEGA Australia managing director John Leadbetter will also speak as part of the program, highlighting how his company’s technology can make operations safer and more productive. The full program can be seen on the BULK2021 website, and on the event app that will be available for attendees to download and install before attending. Tickets for the conference are now on sale at www.bulkhandlingexpo. com.au. Conference tickets also include access to both BULK2021 and MEGATRANS2021 expos.
Australasia’s largest dedicated bulk handling conference & exhibition
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8-10 SEPT 2021
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bulkhandlingexpo.com.au
AWARDS
Finalists revealed for bulk awards The Australian Bulk Handling Review is proud to publish the nominees for the Australian Bulk Handling Awards. THE FINALISTS HAVE BEEN announced for the 2021 Australian Bulk Handling Awards (ABHA), with a winner to be selected on Thursday 9 September 2021. The awards are the only program specifically dedicated to recognising the outstanding achievements and successes of companies across the bulk solids handling sector. The ABHA is the official awards program of BULK2021 and was moved due to the 2020 COVID-19 pandemic. All 2020 finalists will remain chosen and will be presented in addition to finalists for 2021 in a combined event. Sponsored by SEW-EURODRIVE, VEGA Australia and Bonfiglioli, the event offers an excellent opportunity to network with other decision makers.
Innovative Technology VEGA Australia - 80 gigahertz series of radars Metso - FMR Pumping Application MMD Australia Pty Ltd - Fully Mobile Surge Loader LINX Port Services - Scrap Shred Vessel Discharge PROK Conveyor Components PROK HDPE
Dust Control Technology, Application or Practice Group Instrumentation - M-Sens 2 in coffee roasting Anval International Pte Ltd - Rotary Floating Shoe (RFS) Valves Mideco Dust Control Pty Ltd - Sun Pharamaceutical – Bat Booth dustsuppression system VEGA Australia - VEGADIF85 Enviromist Pty Ltd & Action Dril&Blast Pty Ltd - Drillrig Dust Suppression System
Excellence in the Application of Gears, Motors or Drives Kilic Engineering - Cargill stockpiling operations optimisation
The Australian Bulk Handling Awards recognise the outstanding achievements in the industry.
Inenco - Lithium operation installation using Nord IGUs SEW-EURODRIVE - Tronox gearbox upgrade
Excellence in Transport and/or Conveying OMC International - Dynamic Under Keel Clearance System LINX Port Services - Scrap Shred Vessel Discharge Fenner Dunlop - Tuff As belt DASH Engineering - SAPO Seal Lincom Group - THOR TOWERSTACKER TS 250 - Telescopic C
Best Practice in Safety – Sponsored by Bonfigilioli AGI - Hi Roller and CMC collaboration Kinder Australia - Preventative Conveyor Maintenance Program Fenner Dunlop - “Splice Without a Knife” Solution Centre for Bulk Solids and Particulate Technologies - Transportable Moisture Limit project LINX Cargo Care Group - Virtual Reality (VR) safety training platform
100 І Australian Bulk Handling Review: July/August 2021
R.Brunone - Sparcric Belt lifter to change rollers
Supplier of the Year – Sponsored by SEW EURODIVE Conveyor Products and Solutions Fenner Dunlop Kinder Australia OMC International TUNRA Bulk Solids
Bulk Handling Facility of the Year – Sponsored by VEGA Australia Metso - Boral Ormeau Fenner Dunlop - Brisbane Idler Plant Ahrens - Coopers Brewery malting facility TUNRA Bulk Solids - Newcastle Institute of Energy and Resources Conveyor Products and Solutions - Conveyor Products and Solutions manufacturing facility
AW Roberts Award – Presented by ASBSH The Australian Society of Bulk Solids Handling awards this to an engineer under the age of 35, who has made an outstanding contribution to the bulk solids handling industry.
Your needs, our tailormade solutions.
For over 40 years, Bonfiglioli, in conjunction with the leading players in the industry, has developed applications for mining such as conveyors, bulk materials handling, crushing, grinding, slurry processes and many more. When high output torque, robust reliability and long operating life must be achieved, choose Bonfiglioli.
Visit us at
BULK2021 8-10 September Melbourne Convention and Exhibition Centre
Stand 4146
www.bonfiglioli.com/australia/en
EXHIBITOR PROFILES
4B AUSTRALIA
4406
4B Australia Pty Limited is a subsidiary of 4B Braime - the international market leader in the field of bucket elevator and conveyor components and electronic monitoring equipment. With its range of components, 4B serves a large range of industries ranging from agricultural to industrial through to mining and heavy-duty industries. 4B Australia maintains high stock levels of all its main products to be able to service its local customers quickly and efficiently.
www.go4b.com
133 Years of Engineering Excellence
Since 1888
BULK 2021 –STAND 4406 Copyright © 2015 4B Components Ltd. - www.go4b.com
ABSAFE GROUP
4343
Absafe Group is a specialist remedial and supply company built around safety. As a multi-disciplined remedial engineering company specialising in working at height, confined space and difficult access, they also offer engineering services including consulting, diagnostic investigation and maintenance, as well as specialist safety equipment supply and support services. They are the exclusive distributor for ATD Cardox pressurised gas systems in Australia, Skyclimber swing stages and Alpha hoists.
www.absafe.com.au
102 І Australian Bulk Handling Review: July/August 2021
ACOEM
4340 As a trusted provider of class-leading, multi-parameter proactive maintenance, reliability and condition monitoring solutions for rotating machinery, ACOEM Reliability Solutions is committed to protecting your critical rotating assets and ensuring that they operate with maximum efficiency — extending the life of your machinery, mitigating risk and avoiding costly repairs or breakdowns. At Acoem, they create environments of possibility.
www.acoem.com
AEROBELT AUSTRALIA PTY LTD
4300
Aerobelt Australia Pty Ltd is based in Appin NSW and was established over 22 years ago. It now has local agencies in six major countries. Aerobelt Australia has 347 conveyors throughout the world across a diverse range of industries. Their services range from supply, design, manufacture, delivery and installation. Their conveyors are supported by a film of air beneath the trough creating smooth movement of product, reduction in power consumption, dust generation, noise and component wear.
www.aerobelt.com.au Australian Bulk Handling Review: July/August 2021 І 103
EXHIBITOR PROFILES
AERZEN AUSTRALIA PTY LTD
4339
Aerzen Australia is a subsidiary of Aerzen Germany and has offices in Melbourne, Perth and Auckland that provide technical, sales and aftersales support. Their oil-free Delta Blower, Delta Hybrid and Delta Screw packages provide industry leading blower and compressor technology that not only perform but push the boundaries in efficiency and sustainability. With over 150 years engineering experience, they are determined to provide you with technology that is at the forefront of every generation.
ALTAIR
AZANO PTY LTD
4144
4444
Altair’s comprehensive, openarchitecture solutions for AI, CAE, and HPC, enable design and optimisation for high performance, innovative, and sustainable products and processes in an increasingly connected world. Using simulation tools early in the development process helps maximise productivity, reliability, safety and comfort. Customers can optimise designs by quickly and accurately simulating the behaviour of bulk materials.
A solutions-based Australian engineering company with over 25 years of experience, Azano specialises in design and manufacture of turnkey automated and semi-automated packaging and filling systems, bulk bag filling and unloading systems, food processing equipment, water treatment systems, chemical metering packages, contamination inspection systems, and dry material batching and liquid chemical batching equipment.
www.altair.com
www.azano.com.au
www.aerzen.com.au
AGI
4044
Feeding the world requires a global network of infrastructure and technology to store, blend, mix, convey, condition, process, and protect hundreds of millions of tons of agriculture inputs and crops flowing around the world daily. AGI equipment, and technology facilitates this global movement, from growing crops and moving them to market, to processing crops into feed for animals and food for people. With over 160 years of combined history and their internationally recognised products, services, and brands, AGI has you covered.
www.aggrowth.com
104 І Australian Bulk Handling Review: July/August 2021
AGRIDRY DRYERS PTY LTD
3515
Agridry design and manufacture bulk commodity dryers and aeration systems for the agricultural and commercial food processing industries. We are the market leader in Australia for mobile and stationary continuous flow, recirculating and batch dryers. Our dryers are designed with versatility at their core, enabling them to process a wide range of commodities. Agridry is firmly focused on the future, with a robust innovation agenda.
www.agridrydryers.com
» Proven, tested material with igus® system guarantee » Resistant to dirt, chemicals & high temperature » Cost-effective with a modular design » Durability with low maintenance » Robust with a long service life » Lightweight & high strength » Conductive Ex version » Simple installation » Lubrication-free » Corrosion-free » TÜV tested
Steel was yesterday - today is motion plastics: igus® energy chains® are kinder to cables, much lighter and cheaper, as well as being reliable and easier to install
Australian owned & managed
|
1300 65 75 64
|
www.treotham.com.au
|
info@treotham.com.au
EXHIBITOR PROFILES
AURORA-BULK PACKAGING
4312
Aurora specialises in preparing and packaging your bulk products for market. Its services include bulk bag filling and unloading, closing, conditioning, conveying, labelling and marking, manual, semi-auto, fully auto and high speed, fertiliser, grain and seed, stock-feed, building and minerals, landscape supplies and more. With services available across Australia and New Zealand, Aurora’s full end-to-end service is your competitive advantage. Let it remove barriers to your business growth.
www.aurora-process.com
BONFIGLIOLI TRANSMISSION (AUST)
4146
F Bonfiglioli is a company with more than 60 years of experience in heavyduty industries. With a global team of over 3,700 professionals around the world, Bonfiglioli designs, produces and distributes a full range of gear motors, drive systems, planetary gearboxes and inverters for clients and partners in the industrial automation, mobile machinery and renewable energy sectors.
www.bonfiglioli.com/australia/en
106 І Australian Bulk Handling Review: July/August 2021
BRELKO CONVEYOR PRODUCTS (PTY) LTD
4440
Brelko designs and manufactures conveyor belt cleaning equipment for a trouble-free flow of materials at transfer and load points. This is backed up by an installation and maintenance package. They have served as a supplier and advisor on spillage control to the bulk materials handling industry, since 1987 and offer proactive maintenance for preventative spillage control and optimum belt cleaning.
www.brelko.com
CHARTER TRADE GLOBAL
4302 Charter Trade Global provides a wide range of solutions in the warehousing and logistics industry including bulk cargo handling equipment like ‘RAPIDPACK’, cargo-ship brokerage, sourcing a wide range of products including bagging plants, bulk loaders, waste management equipment like baling and sorting machines, supply of recycled and reusable products and agro-commodities.
www.chartertrade.com.au
CONVEYOR PRODUCTS & SOLUTIONS
4124 Conveyor Products & Solutions (CPS) is an original equipment manufacturer of Australian-made, premium quality, and superior performing rollers, pulleys, and idlers. From introducing Yeloroll, the first all-polymer roller to the Australian market, CPS has grown to become a world-class leader in innovative conveyor manufacturing and technology.
www.cpsconveyors.com.au
Storing the Nations’ Grains since 1969 www.hesilos.com 1800 046 046
Putting �rain in your Silos is like putting money in the bank
...Because Every Grain Counts.
EXHIBITOR PROFILES
COREX PLASTICS (AUSTRALIA PTY LTD.)
CORTEX ENGINEERING PTY LTD
DONALDSON FILTRATION SOLUTIONS
4020
4300
3509
Corex Plastics is an Australian owned company. They make packaging products from their branded corflute polypropylene, manufacturing everything in a modern facility in Dandenong South, Victoria. Corex make cor-flute IBCs, picking trays, tote boxes and reusable transit boxes suitable for tough conditions and are 100 per cent waterproof. They specialise in bespoke products in high and low volume. Their in-house recycling division can offer a range of programs to suit customer requirements.
CORTEX is a consultant, designer and constructor of bulk materials handling belt conveyors, elevators, storage systems, re-claimers and loaders/un-loaders to suit ships, road and rail wagons for the mining, construction, agricultural and chemical industries. CORTEX is the Australian representative for Euromecc S.R.L. and is the Australasian representative for Dos Santos International high angle snake sandwich belt conveyors.
Donaldson Company helps solve some of the world’s most complex filtration and contamination control challenges and is one of the largest global providers of unique filtration technologies and high-quality filters and parts. Their filtration technologies and products are used every day, in a variety of industries and environments, including aerospace, agriculture, construction, food and beverage, manufacturing, mining, power generation, transportation and many more.
www.corex.net.au
www.cortex.com.au
www.donaldson.com
CRUSHER & SCREEN
4452 Crusher Screen Sales & Hire supply plant and services for the quarry, mining, construction and remediation industries throughout Australia. Plant includes track and modular pugmills, blenders, mixers, mobile cement silos, track and wheel conveyors with automation option and link conveyors up to 45 meters long offering dual power option. They also offer heavy duty high production track conveyors to operate with jaw crushers at the blast face stocking 300mm minus material or feeding downstream plant operating on the quarry floor.
www.crusherscreen.com
108 І Australian Bulk Handling Review: July/August 2021
DSH SYSTEMS LTD
DYNA ENGINEERING
ELASTOTEC PTY LTD
4445
4137
4037
DYNA Engineering is a WA-owned and operated conveyor specialist with over 30 years of experience. DYNA Engineering specialises in the design, manufacture and supply of conveyor equipment, components and related services. DYNA Engineering prides itself on its commitment to innovation, maintaining lasting relationships, and exceeding expectations through quality workmanship, professionalism and reliability.
Elastotec specialises in conveyor pulley lagging. Its approach is different – it believes pulley lagging is an engineered part of the pulley that if chosen, engineered and manufactured correctly, should last longer that the mechanical components. In addition to showing their range of engineered pulley lagging at BULK2021, it will be releasing the Magnefast Wear Panel System that can reduce removal and installation time for wear panels.
www.dynaeng.com.au
www.elastotec.com.au
DSH Systems award winning loading spouts, designed initially for the fertilizer industry, discharge dry goods as a tight solid column through free air into any target repository including trucks, railcars, barges, ships, storage containers, bags or stockpiles. Reduce hazards and health risks - no electricity required - no internal moving parts.
www.dshsystems.com
Built Tough for Harsh Conditions
LA36 CANbus
LINAK actuators are ideal for bulk handling applications and have ATEX/IECEx approval for operation in dust explosive atmospheres.
LINAK.COM.AU/TECHLINE
EXHIBITOR PROFILES
ESS ENGINEERING SERVICES & SUPPLIES
4100
ESS Engineering Services & Supplies and their subsidiary, VSS Vibrations Systems & Solutions, aims to provide Total Material Control at transfer points to enable increased output, reduced clean up and maintenance costs and improved plant safety.
www.esseng.com.au
ENMACH
4422
FLOW FORCE
4148
KILIC ENGINEERING PTY LTD
Enmach is a renowned leader in the design and manufacture of quality engineered poly moulded and steel fabricated products. Enmach has reinvented and redesigned products made from traditional materials and manufactures them from materials such as polyethylene and stainless-steel to extend lifespan and durability. It offers a range of silos that are suitable for bulk storage of a variety of products and can be used in any industry, from mining, farming, fertiliser or coffee bean storage.
Flow Force Technologies Pty Ltd (FFT) is an Australian designer and manufacturer of industrial weighing equipment for the bulk materials handling and processing industries. Impact weighers provide a dust-tight reliable, low maintenance weighing solution for free flowing dry powders and dry bulk materials in applications where there is a continuous flow of particulate material.
Producing Australia’s most innovative and hard-working material handling equipment, Kilic Engineering (KE) leverages its experience to provide custom solutions to address your storage and material handling problems. From concept to installation, KE offers a complete turn-key solution or can manufacture and supply to your design drawings. Industries from consumer goods manufacture, to metal recycling, to the agricultural industry have relied on KE to provide solutions.
www.enmach.com.au
110 І Australian Bulk Handling Review: July/August 2021
www.flowforce.com.au
4416
www.kiliceng.com.au
FLOVEYOR
4016
Floveyor started in 1958, pioneering and patenting the aero-mechanical method of conveying. Known for versatility and longevity, original Floveyor machinery is used for materials handling in food and beverage, manufacturing, agricultural, chemical, and resources industries. Authentic Floveyor conveyors and conveying equipment are designed, engineered and manufactured in our factory outside Perth, Western Australia, and are in operation every day in 52 countries.
www.floveyor.com
We’re reaching new heights in engineering.
The sky’s the limit.
With decades of experience in the field, Kinder Australia supply superior products designed in-house and manufactured from high quality materials to improve your conveyor efficiency.
https://kinder.com.au
EXHIBITOR PROFILES
GOUGH PLASTICS
4418
Gough Plastics is a family-owned business located in Townsville QLD. It manufactures a varied range of products with their high-durability conveyor belt covers and bulk liquid storage tanks servicing countless companies within the bulk handling industry. It also manufactures water storage tanks, waterless toilet systems, durable general storage containers, vehicle underbody toolboxes and water storage, cattle feed troughs, moulded plastic waste entry points and super heavy-duty plastic crane dunnage.
www.gough.com.au
HE SILOS
4344
Supporting Australian Farmers for over 50 years, HE Silos strives to innovate and manufacture sustainable products suited to all grain storage operations. It believes in social responsibility, focusing designs around safety, efficient operations and protecting stored products to minimise losses occurred during post-harvest storage. HE Silos manufacture a wide range of grain, fertiliser, and pellet and mash silos, field bins, kit and bulk storage silos, livestock feeders and custom design silos built to any scope.
www.hesilos.com
112 І Australian Bulk Handling Review: July/August 2021
HOSCH INTERNATIONAL
CLEAN CONVEYOR BELTS.
4319
THE NUMBER ONE WORLDWIDE
hosch.com.au
HOSCH is the worldwide specialist for conveyor belt cleaning systems for the bulk material handling industry. German engineering and decades of experience help the find the best solution for any kind of bulk material. Their range of belt scrapers, ploughs, tracker rollers and skirting help significantly reduce carryback, increase safety, lower operating costs and minimise unexpected downtime.
www.hosch.com.au
KINDER AUSTRALIA
4002
Kinder Australia has earned a reputation delivering excellence in the bulk solids materials handling industries. Kinder Australia is recognised as a leading supplier and manufacturer of innovative and practical solutions to improve and maintain the running efficiency of conveyor and bulk materials handling equipment used to convey a variety of products. Imaginative design capabilities, lateral thinking, rigid benchmarking and ability to overcome problems makes Kinder Australia an industry leader.
www.kinder.com.au
Australian Bulk Handling Review: July/August 2021 І 113
EXHIBITOR PROFILES
KOYO AUSTRALIA PTY. LTD.
LASE/HÜBNER/EMG
MANNAWAYS PACKING
Koyo Australia is a group company of JTEKT Corporation. The company’s principal activities consist of the importation and wholesale distribution of anti-friction ball and roller bearings. In addition, the company supplies drive shafts, oil seals and universal joints to a wide range of industries in Australia and New Zealand. Equipped with a warehouse facility in Sydney and a staff of qualified engineers and experienced sales representatives, Koyo Australia can provide service to meet customer expectations
LASE is a global player in the field of industrial laser measurement technology. Their solutions support the logistic processes of companies. They ensure the automatic handling of products and provide exact dimensional data of products and goods. The products are used in freight logistics, mining, the timber industry and many other areas.
Mannaways Packing is a wholesaler and distributor of packaging products, such as FIBC bulk bags, hand and machine stretch film, with customised packaging in Australia. They strive to supply quality packaging products and provide excellent service while maintaining a very competitive price. They have teamed up with known vendors and manufacturers in the country to fulfill their customer’s requirements.
4318
www.koyoaust.com.au
LEAP AUSTRALIA
4132
For 25 years, LEAP has assisted thousands of companies from across Australia and NZ to implement digital solutions for industries such as bulk materials handling. Its goal is to help optimise product design and performance using engineering software solutions from Rocky DEM, Ansys and PTC. Talk to LEAP about implementing particle simulation, DEM simulation of bulk materials handling processes and equipment.
www.leapaust.com.au
114 І Australian Bulk Handling Review: July/August 2021
3503
www.lase-solutions.com
3501
www.mannawayspacking.com.au
LINAK
4301
LINAK produces electric linear actuator solutions to create smooth movement in a vast range of applications. TECHLINE is a LINAK segment with a focus on reliable and precise movement in extreme conditions, including within the bulk handling industry. By working closely with their customers, they create durable solutions that are capable of heavy and repetitive movements in even the harshest environments. LINAK offers products that have been tested and certified for electrical operation in dust explosive atmospheres and are IECEx approved.
www.linak.com.au
MARC TECHNOLOGIES
4448
MARC Technologies has been successfully delivering dust control solutions to the mining and industrial sectors since 1995. MARC provides innovative and specialised engineered products and Services for the mining and industrial sectors for dust control, including specialist Dry Fogging, NESCO misting and DustTamer windfences supplied by Dust Solutions Inc. These systems offer unique and comprehensive dust control technologies to provide effective solutions across the mine process andbulk handling operations.
www.marctech.com.au Australian Bulk Handling Review: July/August 2021 І 115
EXHIBITOR PROFILES
MRA ELECTRICAL
4439
MINPROVISE PTY LTD
4314
Mideco offers dust control solutions for mines, quarries and any industrial environment. The company’s products are specifically designed to manage dust particles and ensure that workers and the operating environment are protected from harmful elements. Mideco products such as Bat Boot and Burnley Baffles have been successfully tested and implemented in a wide range of applications both locally and internationally.
MINPROVISE are a specialist products, engineering and services company providing expert support to the mining, oil and gas and construction industries. Its capabilities include the supply of mineral processing equipment, onsite installations, maintenance, repairs and shutdowns, offsite repairs and fabrication, corrosion control and abrasive blasting and scaffolding services, equipment and solutions. It aims to be a solutions provider for clients to enable the safe optimisation of projects.
MRA is a specialist in machine automation for mine-to-port materials handling and has developed of a suite of awardwinning smart automation products that use laser data and analytics for smarter decision making and automation control. The smart products include train load-out and dump station automation, stockyard and quality management, machine-to-machine anti-collision‚ ship loader anti-collision and automation.
MIDECO JIA PTY LTD
www.midecohse.com
www.minprovise.com.au
PAGE MACRAE ENGINEERING
3519
Page Macrae Engineering have been providing engineering solutions since 1955. Their exciting new generation of port products range from bulk chain grabs to their new generation of EDG diesel hydraulic grabs and electric hydraulic. The movement in the log industry has also seen solutions in the Log Loader and Grapple areas. Their presence in Australia will see full support in spares, commissioning and product development through industry relationships. Engineering a better tomorrow!
www.page-macrae.co.nz
116 І Australian Bulk Handling Review: July/August 2021
4412
www.mra.com.au
PHOENIX MECANO
NELSON SILOS
PACKWEIGH EQUIPMENT
Established in 1977, Phoenix Mecano Group comprises of divisions specialising in industrial / electronic enclosures, linear technology (linear units, lifting columns, electric cylinders) and mechanical connection systems (tube connectors, aluminium profiles). Geared towards the professional and cost-effective manufacture of niche products, they help to ensure the smooth operation of processes and connections in the machine industry and industrial electronics.
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.
Packweigh Equipment is a proudly Australian owned manufacturer of equipment for weighing, bag filling, bag closing, palletising and wrapping of bags from 200g to 2,000kg. They design systems from manual operation through to full turnkey automated systems for all types of industries. If you put your product into bags, Packweigh Equipment can help.
4048
3500
www.nelsonsilos.com.au
4306
www.packweigh.com.au
www.phoenix-mecano.com.au
PNEUVAY ENGINEERING PTY LTD
4001
PRECISIONSCREEN
4135
Pneuvay Engineering is a specialist in pneumatic conveying, powder handling, industrial vacuum and dust collector systems. From small supply-only component jobs to large projects that involve the full design, construction, installation and commissioning of multi-million dollar plant, it has you covered. Pneuvay strives to meet and exceed customer expectations by supplying quality pneumatic conveying components, designing reliable pneumatic conveying systems.
Precisionscreen are leaders in the design and manufacture of mobile screening, washing, crushing and recycling equipment for the quarry, mining, extractive, materials handling and recycling industries. Precisionscreen prides itself on its innovative design and ability to meet the specific needs of a diverse range of clients. They are leading the way in research and development, with a commitment to developing innovative products in the traditional washing, screening and crushing market, and the recycling market.
www.pneuvay.com.au
www.precisionscreen.com.au
PRIME MANUFACTURING PTY LTD
4410
Prime Manufacturing is a competitive Australian supplier specialising in bulk material handling components, conveying systems, food processing and packaging equipment. Prime has over 30 years of experience developing and manufacturing handling components.
www.prime-mfg.com.au
Australian Bulk Handling Review: July/August 2021 І 117
EXHIBITOR PROFILES
PREMIER TECH SYSTEMS AND AUTOMATION PTY LTD
4010
Premier Tech is committed to creating sustainable solutions that help improve the efficiency of manufacturing facilities in the nutrition, industrial, agricultural and organics market sectors. It offers a wide range of solutions, ranging from weighing, feeding, bagging, case packing, palletising and load securing, bulk handling, and lifting solution. Premier Tech believes the true value of its worldwide presence rests in the deep roots its teams have established locally.
www.premiertech.com/en
PROK QUALITY CONVEYOR EQUIPMENT
4118
With more than 50 years of experience, PROK’s focus on developing and manufacturing conveyor equipment has grown its reputation in the industry as the quality standard in bulk material handling applications. Its complete offering includes rollers, frames, pulleys and belt cleaners, safety and control devices. As PROK continues to grow, its vision remains the same; to become the company that customers prefer to do business with.
www.prok.com
118 І Australian Bulk Handling Review: July/August 2021
RAINSTORM DUST CONTROL
4437
Rainstorm is a specialist dust control company that offers a suite of products and specialist services to mines, civil contractors, agriculture, military and local governments. Since their inception in Australia in the early 90’s, Rainstorm have been focused on the dust control, soil stabilisation and rehabilitation industries. As an industry leader with onsite experience, its product range and services extend through all areas of dust mitigation.
www.rainstorm.com.au
ROTOLOK LTD
RR PACIFIC PTY LTD
Rotolok provides a range of economical valve and diverter products with one single group ethos: exceeding all of their customers’ expectations. They have a policy of continued investment in advanced machinery which ensures quality control. By employing batch production techniques that create efficiency savings, they are able to offer the most competitive pricing. Rotolok incorporates volume production methods with built-in flexibility, giving customers options and bespoke solutions.
For more than 40 years Reggiana Riduttori have been passionately dedicated to producing planetary gears and wheel gears made entirely in Italy. Top quality raw materials, assembly and storing phases are strongly influenced by a high innovation level backed by constant investments in research and development. Their mission is to remain on their quality path, provide exceptional and professional sales and after-sales service on time.
4307
3508
www.reggianariduttori.com
www.rotolok.com.au
SEW-EURODRIVE
4031
SEW-EURODRIVE is a global designer, developer and manufacturer of mechanical power transmission equipment, systems and motor control electronics, headquartered in Bruchsal, Germany. Its broad spectrum of integrated solutions includes geared motors and gear units, high torque industrial gear units, high-efficiency motors, electronic frequency inverters and servo drive systems, decentralised drive systems. Plus it has complete engineered solutions and after-sales technical support / training.
SKALA AUSTRALASIA PTY LTD
4438
Skala is a service and equipment supplier specialising in bulk material handling, vibratory and vacuum process equipment. They provide sales, parts, support, installation and commissioning services to mining, power stations, recycling, biomass, pharmaceutical, chemical and industrial manufacturing industries. Their key capability is to provide innovative, efficient and value solutions to enhance bulk material handling processes.
SLIMSTOCK
4345 Slimstock makes sure you get your stock management, forecasting, and demand planning back in control, allowing you to reduce your inventory value and increase the service level towards your customers at the same time. Slimstock ensures that the companies’ supply chain strategy is in line with the overall strategy.
www.slimstock.com/au
www.skala.com.au
www.sew-eurodrive.com.au
Australian Bulk Handling Review: July/August 2021 І 119
EXHIBITOR PROFILES
SMART PACK LTD
SUPPLIED BY EBRO
TEREX JAQUES
3506
4337
4308
Smart Pack is bringing a fresh approach to specialist bag and sack supply, creating partnerships that last. They supply an extensive range of customised solutions to a wide range of industries, right across Australia.
Ebro Armaturen is a privately owned and operated German company manufacturing high-quality precision-engineered butterfly and knife gate valves, valve actuation and valve accessories. They produce a range of products with wear and abrasion-resistant components for applications requiring product isolation, control and metering.
Terex Jaques specializes in the design, supply and servicing of crushing, screening, washing, conveying and materials handling equipment for quarrying, mining, recycling and sand operations. A sales and service branch network throughout Australia and a global presence through Terex Corporation builds the framework for Terex Jaques’ strong reputation for technical excellence and aftersales support.
www.smartpack.co.nz
www.ebro-armaturen.com
www.terexmps.com.au
TREOTHAM AUTOMATION P/L
4046
Treotham Automation is a leading supplier of high-quality components and products to all industrial markets. As the exclusive distributor for international product lines, Treotham’s customers gain from their local presence, extensive knowledge and experienced staff. Its suppliers include Igus energy chains, Chainflex cables, polymer bearings and linear bearings, LAPP flexible cables and spiral/curly cords, Ilme multipole connectors, and Euchner safety switches.
www.treotham.com.au
120 І Australian Bulk Handling Review: July/August 2021
TUNRA BULK SOLIDS HANDLING RESEARCH ASSOCIATES
4443
TUNRA Bulk Solids provides professional consulting services to industry and has a strong reputation for its cutting-edge research and technological developments in bulk solids handling, processing and conveying. A wide range of material testing services are available as well as conceptual solutions to bulk materials challenges, from fundamental characterisation to development of optimal designs.
www.bulksolids.com.au
VEGA AUSTRALIA
4130
Production processes are becoming ever more complex. So it’s really important that the measurement technology used to control and monitor the processes is all the more understandable and intuitive. VEGA has set itself the goal of developing innovative measurement technology that is easy to install and operate and offers maximum safety and reliability. VEGA employs over 1,480 people worldwide, 730 of whom work at its headquarters in Schiltach in the Black Forest.
www.vega.com.au
Australian Bulk Handling Review: July/August 2021 І 121
EXHIBITOR PROFILES
THERMALIGN PTY LTD
VAYERON
WEIGH-MORE SOLUTIONS
3518
ThermAlign Pty Ltd is a predictive, proactive and preventative service provider that specialises in vibration analysis, thermography, motion amplification, laser alignment, in situ dynamic balancing, mechanical services and reliability and lubrication studies. ThermAlign will be demonstrating its MEDUSA asset diagnostics system and motion amplification. MEDUSA is a portable asset condition assessment tool which integrates condition monitoring, asset telemetry, SCADA and mobile and cloud computing.
Vayeron is a leading Industrial IoT technology company providing solutions to the challenges faced by bulk materials handling processes. Their solutions anchor physical plant & equipment to the digital world. Innovations that enable agility, reliability and scalability of engineering operations.
4131
4404
www.thermalign.com.au
VWORK
4049 vWork is cloud-based job scheduling and dispatch software for businesses that transport goods around the country, making dispatchers and drivers more efficient and improving service reliability. Dispatchers allocate tasks more efficiently, drivers know where and when each job is scheduled in an easy-to-use iOS or Android app and customers are kept informed through reminders and eta alerts. Improve your job scheduling decisions, maximise your truck utilisation and reduce driver down time using vWork software.
www.vworkapp.com
122 І Australian Bulk Handling Review: July/August 2021
www.vayeron.com
Weigh-More Solutions has grown to become one of Australia’s largest and most respected industrial weighing specialist suppliers – with a principal focus on weighbridge systems instrumentation and manufacture. The company invests in ongoing R&D to stay relevant in weighbridge design complemented by their sophisticated cloud software solutions. Their aftersales technical team is licensed by NMI and provides service, calibration and verification of industrial scales, weighing systems and weighbridges.
www.weigh-more.com.au
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bulk equipment and systems from Flexicon
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VOLUME 26, ISSUE 4 | JULY/AUGUST 2021
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has registrations and pending applications for the trademark FLEXICON throughout the world.
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Reduce and Distance Plant Personnel while Boosting Output and Preventing Contamination with automated, enclosed bulk equipment and systems from Flexicon
Automated, sealed BULK-OUT® Discharger-Conveyor Systems replace multiple workers dumping hand-held bags manually, while preventing contamination.
Enclosed Bulk Bag Weigh Batch Systems feed a central weigh hopper mechanically, and remove weighed batches pneumatically, requiring labour only to attach/detach bulk bags.
Bulk Bag Discharging Systems can loosen solidified material and meter it into liquid streams (shown), screeners, size reduction equipment and continuous blenders—automatically.
Dual SWING-DOWN® Bulk Bag Fillers fed by weigh hoppers fill up to 40 bags per hour with only one operator connecting empty bags and one forklift removing full bags.
Flexicon Bulk Bag Filling Lines automatically dispense pallets, fill bulk bags, and disconnect/accumulate filled bags, minimising operator involvement.
TIP-TITE® Drum/Box Tippers seal, tip and mate a discharge cone to a gasketted hopper lid, open a slide gate and feed downstream processes— automatically and dust-free.
Flexicon automated equipment and systems can move your bulk materials at higher capacities with fewer personnel, cutting costs while distancing operators from one another. AUSTRALIA sales@flexicon.com.au 1 300 FLEXICON +61 (0)7 3879 4180
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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 3rd October 2021) 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
Mastercard
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 3rd - 5th November 2021 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
Presented at
THE MERCURE PERTH, W.A
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
3 DAY COURSE INFORMATION 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
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
• 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
TUNRA Bulk Solids The University of Newcastle Callaghan NSW 2308, Australia Tel: +61 2 4033 9055 www.bulksolids.com.au