www.bulkhandlingreview.com
VOLUME 23, ISSUE 6 | NOVEMBER/DECEMBER 2018
Food & powder handling feature: Advanced valve bag technology New innovation in 3D scanners Processing hemp for nutrition
MASTER OF WASTE The new revolution in screening.
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CONTENTS NOVEMBER/DECEMBER 2018
Published by:
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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 Paula Wallace E: paula.wallace@primecreative.com.au Business Development Manager Luke Ronca E: luke.ronca@primecreative.com.au Client Success Manager Natsha Shekar E: natasha.shekar@primecreative.com.au Art Director Michelle Weston E: michelle.weston@primecreative.com.au Design Blake Storey, Kerry Pert, Madeline McCarty Subscriptions Gordon Watson T:03 9690 8766 E: gordon.watson@primecreative.com.au
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6 E nvironmental green light for lithium jobs in the south-west
16 GeelongPort and Boral cement partnership
30 Metso: Questions and answers on grinding technology
7 Derailments in Tasmania and Western Australia
17 Moves to energise battery minerals industry
34 Shareholders support Nufarm capital raising program
8 ABB to build the world’s most advanced robotics factory
17 New materials ‘futures’institute for UNSW
36 Kinder conveyor covers – offering all-round protection
10 GR Eng wins $366m contract
18 Case Study: Oji Fibre Solutions’ Yatala plant
37 Bintech’s Pulsar rock crusher
11 Australian Graphene Industry Association launched
21 Member Profile: Angus Pidgeon
38 BULK TALK: Tales in bulk materials storage
12 Townsville processing plant on cards for Port Minerals
22 Fenner Dunlop’s fast supply of Modulaveyor to iron ore mine
57 Preventing port crane failure through rope monitoring
13 Sedgman wins $100m in CHPP contracts
24 T he value of seeing “inside” mine tailings onsite
62 Meet BHP Escondida’s giant robotic arm
14 R abobank recognises agribusiness visionary
25 Using Enerpac hydraulic power to assemble heavy chains
65 Data analysis has a new name: Rema Tip Top
FOOD & POWDER HANDLING 42 Australian Primary Hemp: Planting the seed for a thriving new industry
54 Flexicon: drawing on a global wealth of experience
46 BinMaster uses 3D level sensors to solve food storage challenges
56 New twin flexible screw conveyor from Flexicon
50 H&V using advanced valve bag technology for flour packing
58 Improved design for diverter handling abrasives
www.bulkhandlingreview.com The Publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from the advertisers and contributors against damages or liabilities that may arise from material published. © Copyright – No part of this publication may be reproduced, stored in a retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.
COVER STORY Flip Screen: Masters of innovation
www.bulkhandlingreview.com
VOLUME 23, ISSUE 6 | NOVEMBER/DECEMBER 2018
Food & powder handling feature: Advanced valve bag technology New innovation in 3D scanners Processing hemp for nutrition
MASTER OF WASTE The new revolution in screening.
Australian Bulk Handling Review: November/December 2018 І 59
Flip Screen Australia has created a series of tough, portable attachments that screen in seconds. They offer endless potential, being able to screen any material from heavy rock, concrete and scrap metal to topsoil and sand. The company has just released its newest creation, the WL285 Waste Master FlipScreen, specifically designed for waste and recycling applications. Its enormous capacity and specialised screens mean that it can be used across all council waste applications, from screening FOGO greenwaste and compost to concrete and metal. For the full story, see page 28.
Australian Bulk Handling Review: November/December 2018 І 3
KEEP YOUR KEEP KEEP YOUR YOUR DUST DOWN DUST DUST DOWN DOWN
Dust emissions constitute a significant operating,environmental Dust emissions constitute a significant operating,environmental and occupational health hazard that is unacceptable to the Dust emissions constitute a significant operating,environmental and occupational healthHandling hazard that is unacceptable to the modern Bulk Materials Industry. and occupational healthHandling hazard that is unacceptable to the modern Bulk Materials Industry. modern Bulk Materials Handling Industry. The ESS Dust Suppression systems generate a spray of fine The ESS Dust Suppression systems generatetoaprevent spray ofthe fine water droplets to encapsulate dust particles The ESS Dust Suppression systems generate spray fine water droplets to encapsulate dustoutside particles toaprevent material from becoming airborne chute areas.ofthe water droplets to encapsulate dustoutside particles to prevent material from becoming airborne chute areas. the material from becoming airborne outside chute areas.
The ESS Dust Suppression system is suitable for use with The Suppression system is suitable for use mostESS dustDust producing materials where the process willwith allow The ESS Dust Suppression system is suitable for use most dust producing materials where the process willwith allow for small amounts of added moisture. most dustamounts producing where the process will allow for small of materials added moisture. for amounts of addedsystem moisture. Thesmall ESS Dust Suppression is: The ESS Dust Suppression system is: The ESS Dust system is:as all maintenance is - Simple, SafeSuppression and Easy to Maintain - performed Simple, Safe and Easy to Maintain as all maintenance is from the outside of the chute. - performed Simple, Safe andthe Easy to Maintain as all maintenance is from outside of the chute. from the outside of the chute. - performed Low Maintenance when the Quickfit Nozzle is combined - with Low Maintenance when Quickfit Nozzle is combined an appropriate filter,the decreasing blockages and - maintenance. Low Maintenance when Quickfit Nozzle is combined with an appropriate filter,the decreasing blockages and with an appropriate filter, decreasing blockages and maintenance. - maintenance. A Low Water Consumption Unit as it uses 2 litres of water -a A minute Low Water Unit as itMaking uses 2 litres of water overConsumption a range of pressures. it suitable for -drier A minute Low Water Consumption Unit as it uses 2 litres of water a over a range of pressures. Making it suitable for environments. a minute over a range of pressures. Making it suitable for drier environments. environments. -drier Supplied in Kit Form, comprising 2, 4 or 6 Quickfit nozzles, -aSupplied inpush Kit Form, comprising 2, 4 or 6 Quickfit nozzles, manifold, fit hoses and fitting. -aSupplied inpush Kit Form, comprising 2, 4 or 6 Quickfit nozzles, manifold, fit hoses and fitting. a manifold, push fit hoses and fitting.
Proudly Proudly Manufactured Manufactured in in Australia Australia Proudly Manufactured in Australia
EDITORIAL
A path for growth It has been a busy time over the past few months, since Australian Bulk Handling Review joined the Prime Creative stable. We’ve enjoyed learning more about the industry and getting out and about to meet all those involved in the handling of bulk materials. We’re making long-term plans to support the industry not just through ABHR but also through developing a bulk handling expo and conference to take place in 2020. There will be more information on that to come. In the meantime, please enjoy the wide variety of stories on offer in this issue of the magazine. You will find an in-depth feature on food and powder handling, starting on page 42. To kick off the feature, there is an interview with new kid on the block in food processing, Australian Primary Hemp. Winners at the recent Food & Beverage Industry Awards, the company tells ABHR about its ‘paddock to plate’ approach. It also takes us behind the scenes of its manufacturing facility in Geelong, the home of its impressive de-hulling machine, standing nearly three storeys high. We find out how Australian Primary Hemp’s processing ability really sets it apart from its competitors. In this issue you can also get a sneak peak into the new Oji Fibre Solutions manufacturing plant for corrugated board in Yatala Central, Brisbane. The company’s Philip Nuttall spoke to ABHR about the state-of-the-art technology employed at the plant that places it at the cutting edge both from an automation and environmental sustainability perspective. Read more on page 18. You can also find out more about the versatility and sheer innovation of the FlipScreen and what motivates its inventor Sam Turnbull, on page 28. And while you’re there you can read ABHR’s interview with a number of Metso’s experts from around the world on the trends they are seeing in crushing and grinding – page 30. In the next edition, the first one for the New Year, we’ll be featuring stories on pneumatic conveying. Please get in touch if you would like to get involved.
Christine Clancy Publisher - ABHR
ogether Piecing Solutions T
For More Information Visit
www.kockumsbulk.com.au Call 03 9457 8200 to speak to your local representative
NEWS
Environmental green light for lithium jobs in the south-west The McGowan Labor government has given environmental approval for a lithium manufacturing plant in the Western Australia’s southwest, paving the way for more than 500 construction jobs and up to 500 permanent jobs. THE ALBEMARLE LITHIUM PLANT WILL BE located in the Kemerton Strategic Industrial Area, 17 kilometres north east of Bunbury. The project has received its Ministerial Statement from the State Government. When in operation, the Albemarle Kemerton Plant will process spodumene ore concentrate, through five process trains, to produce up to 100,000 tonnes of lithium hydroxide product. Spodumene ore will be sourced from the Talison Lithium’s Greenbushes mine, which in March announced an expansion to supply the rapidly expanding global lithium market. Once constructed, the Albemarle Kemerton Plant will be the second, and largest, lithium hydroxide manufacturing plant to invest in Western Australia in two years.
Earlier this year, the WA government established a Lithium and Energy Materials Industry Taskforce to capitalise on the state’s unique resources and growth in the lithium-ion battery sector. The taskforce is working across government and closely with industry and research organisations to develop a Lithium and Energy Materials Strategy that unlocks the State’s potential in the sector and delivers local jobs, economic diversification and benefits regional communities. LEFT: Spodumene concentrate.
Kwinana waste-to-energy plant announced A new $668 million renewable energy project is aiming to produce enough energy to power up to 50,000 homes by converting WA’s waste streams. CO-DEVELOPED BY A CONSORTIUM OF THE Dutch Infrastructure Fund, Macquarie Capital and Phoenix Energy Australia, the Kwinana project is also part-funded by a $23 million grant from the Australian Renewable Energy Agency. Up to 400,000 tonnes of household, commercial and industrial waste — one quarter of Perth’s post recycling rubbish — will be diverted from landfill to be thermally treated and converted into steam to produce electricity. Remaining ash will be used to make construction materials. The project is expected to reduce CO2 emissions by 200,000 tonnes a year, equivalent to taking 43,000 cars off the road. The plant’s 36MW capacity will also contribute to grid stability in WA’s South West Interconnected System. The City of Kwinana signed a contract with Phoenix in December 2013 and had agreed to new deadlines for the consortium to reach financial closure. The last one expired on September 30.
6 І Australian Bulk Handling Review: November/December 2018
Rivers Regional Council, which comprises the cities of Armadale, Gosnells, Mandurah, South Perth and the shires of Murray and Serpentine Jarrahdale, plus the City of Canning have also signed 20-year waste supply agreements. Construction on the Leath Road facility will begin later this month, with completion expected by 2021. More than 800 construction jobs will be available, and 60 people will be employed to run the facility through Veolia under a 25-year agreement. DIF will have a 60 per cent stake in the project through two of its funds. DIF Australia managing director Marko Kremer described it as a landmark facility. “European countries have long embraced the conversion of waste into energy, which has proven to deliver multiple benefits in terms of managing waste and contributing to a sustainable and secure energy supply,”he said. Up to $90 million from the Clean Energy Finance Corporation will be available for debt finance.
Derailments in Tasmania and Western Australia In separate incidents, trains have derailed in recent months in the regions of Devonport, Tasmania; Port Hedland and the Yilgarn in Western Australia. Runaway iron ore trains
TasRail train stopped working, and its operator was unable to force an emergency stop, before it ran away uncontrolled and was eventually derailed, injuring two bystanders in September. The Australian Transport Safety Bureau has published its preliminary report into the incident, where a TasRail bulk cement service ran away from its loading facility at Railton just prior to 9am on 21 September, 2018. The train, weighing 1,132 tonnes and 220 metres long, travelled roughly 21 kilometres in 23 minutes and was then routed into a dead-end siding in Devonport, where it derailed. Two bystanders sustained minor injuries from fence debris. The train travelled in a derailed state for roughly 60 metres in a public area beyond the dead-end siding. According to the preliminary report into the incident, the train was being controlled at the cement loading facility by its driver from within the facility, via a remote control. The train consisted of a TR class locomotive, 16 THFY class bulk cement wagons and trailing driver’s van. According to the report, the driver says he tried multiple times to reset the remote equipment, before deciding to walk towards the lead locomotive to attempt a cold restart of the remote control receiver. “Before he started to walk… the train slowly began rolling away towards Devonport,” the report states. TasRail says it has suspended use of the locomotive remote control system – which was only used on the Devonport cement service – until the investigation is concluded.
BHP’s control centre in Perth was forced to derail the loaded train at a set of points 119 kilometres from Port Hedland on 5 November. According to the Australian Transport Safety Bureau (ATSB), which has launched an investigation, the train consisted of 268 wagons and four locomotives. The number of wagons and locomotives derailed in the incident is yet to be reported. The train, loaded with iron ore from BHP’s Newman hub, had runaway 92 kilometres up the track from the derailment site. The train’s driver had alighted to inspect an issue with an ore car near Hesta, 211 kilometres from Port Hedland. While the driver was outside the locomotive, the train began moving. Mineral Resources (MinRes) also revealed about 30 iron ore wagons travelling to its Koolyanobbing iron ore mine in the Yilgarn region of Western Australia had derailed. MinRes confirmed its locomotives and rolling stock were south of Norseman returning to the mine from the Esperance Port when the train derailed. The train had delivered 7488 tonnes of iron ore fines across 106 wagons to the port. MinRes said in a statement that no one was injured as a result of the derailment. There was damage to some of the derailed wagons but not to MinRes’ locomotives. The company believes heavy rainfall and flash flooding in the region washed out some ballast from under a small section of the track, causing the incident. Photo credit: TasRail
THE REMOTE BEING USED TO CONTROL A
Australian Bulk Handling Review: November/December 2018 І 7
NEWS
ABB to build the world’s most advanced robotics factory ABB consolidates its position in the world’s robotics market with US$150 million investment in Shanghai factory. THE NEW KANGQIAO MANUFACTURING centre, near ABB’s expansive China robotics campus, will combine the company’s connected digital technologies. These include ABB Ability™ solutions, state-of-the-art collaborative robotics and innovative artificial intelligence research, to create the most sophisticated and environmentally sustainable “factory of the future.” The factory, which is expected to begin operation by the end of 2020, will be “a cutting-edge centre where robots make robots”, according to ABB. In 2017, one of every three robots sold in the world went to China, which purchased nearly 138,000 units. Today, ABB employs approximately 5,000 people in Shanghai, and the company’s robotics businesses in China employ more than 2,000 engineers, technology experts and operational leaders in 20 locations across the country. ABB has invested more than US$2.4 billion in China since 1992, with more than 18,000 employees in total. The new Shanghai factory will feature a number of machine learning, digital and collaborative solutions to make it the most advanced, automated and flexible factory in the robotics industry, and an onsite research and development centre will help accelerate innovations in artificial intelligence. Using a new, global design approach that ABB announced earlier this year, the factory will be able to dramatically increase both the breadth (type of robots) and depth (variants of each type) of robots that can be made onsite, allowing greater and faster customisation to meet the needs of customers. ABB will also be able to combine this expanded
8 І Australian Bulk Handling Review: November/December 2018
portfolio of robotics into an almost limitless number of tailored solutions. “The concept behind this factory is the same advice we give our customers every day: invest in automation solutions that provide flexibility and agility to grow in whichever direction the market goes,”said Sami Atiya, president of ABB’s robotics and motion division. “ABB is proud to help our customers in China and around the world with solutions that take full advantage of the latest technologies to meet the challenges of mass customisation, faster cycles and constant change which have become the new normal – even in our own factories.” The new factory will have an innovative, flexible floorplan based on interlinked islands of automation rather than fixed assembly lines. ABB logistics automation solutions will be used throughout the plant, including automatic guided vehicles that can autonomously follow robots as they move through production, supplying them with parts from localised stations. This will allow production to adapt and scale efficiently to changes in China’s robot market without additional capacity expansions. Per Vegard Nerseth, managing director of ABB’s robotics business, said “There’s a large shift away from looking at factory size and CAPEX investments as the way to meet future demand. “The concept behind our new factory is to make the smartest and most flexible use of every metre of production. That comes from combining agile automation solutions with the great capabilities of our people.”
ABOVE: ABB plans to create the most sophisticated and environmentally sustainable “factory of the future”.
WHICH OF THE TOP 4 ELBOW PROBLEMS DO YOU NEED TO SOLVE IN YOUR PNEUMATIC CONVEYING SYSTEM?
PROBLEM
1
Wear and failure when conveying abrasives
such as sand, glass, alumina or mineral filled plastic pellets incur never-ending costs of replacement elbows, labour and downtime.
CAUSE
Abrasives hit the outside radius of conventional impact elbows at high speed, continually wearing through the elbow wall.
2
3
4
when conveying pelletised resins and compounds causes downstream quality problems.
such as pet food, coffee beans or grains, decrease product quality, consistency and salability while increasing waste.
when conveying sugar, rubber pellets, hot melt adhesives, clay and other pressureand heat-sensitive materials prone to build-up.
Pellets skidding and/or bouncing against the outside radius of sweep elbows create friction and heat, melting pellet surfaces, forming streamers.
Friable materials hit the outside radius of conventional impact elbows at high speed, degrading the material and generating fines.
Materials skidding against the outside radius of conventional elbows create friction and heat, causing product build-up.
Formation of streamers, angel hair and snake skins
Breakage and dusting of fragile materials
Plugging and build-up
SOLUTION Smart Elbow® Deflection Elbow
from HammerTek® ends problems by eliminating impact and frictional heat Unlike conventional “impact” elbows and “plugged-tee” elbows that rely on material impact to change direction, HammerTek’s Smart Elbow® design employs a spherical chamber that protrudes partially beyond the desired 90º or 45º pathway, causing a ball of material suspended in air to rotate. Since the ball of material rotates in the same direction as the airstream that powers it, incoming material is cushioned by the ball’s rotation, and is gently deflected around the bend. By preventing impact with the elbow wall, HammerTek’s Smart Elbow® deflection elbow virtually eliminates costly elbow wear, material degradation, melting and plugging.
Free, No-Risk Trial Offer See how Smart Elbow® deflection elbows eliminate conventional and plugged-tee impact elbow problems—at no cost or obligation.
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NEWS
GR Engineering wins $366m contract GR Engineering will be responsible for the engineering design, procurement and construction (EPC) of Sheffield Resources’ Thunderbird mineral sands project’s 7.5 million tonnes a year (Mt/y) mineral processing plant and associated facilities. THE CONTRACT’S SCOPE OF WORK EXTENDS to the commissioning and testing of Thunderbird’s wet concentrate plant, mineral separation plant, low temperature roasting plant, administration buildings, bore fields and high voltage power distribution.
This represents a two-year agreement, following site mobilisation, and is scheduled to commence in the second quarter of 2019 after the wet season. GR Engineering managing director Geoff Jones said, “This contract represents an important milestone in the development of the world-class Thunderbird mineral sands project. “GR Engineering has welcomed the opportunity to contribute towards bringing the project to an advanced pre-execution phase and is now committed to progressing its safe and successful delivery for Sheffield.” Sheffield Resources has also secured a $240 million seven-year loan from Taurus Funds that will be used to reduce the miner’s operating costs by at least $7.5 million every year over a 42-year life of mine. Bruce McFadzean, Sheffield managing director, said, “These agreements are a tremendous result for Sheffield shareholders as they substantially de-risk Thunderbird.”
LEFT: Sheffield Minerals’ Thunderbird mineral sands project. Image: Sheffield Resources.
Mining jobs reach new heights in 2017-18 More than 112,000 people were directly employed in Western Australia’s mining industry in 2017-18, more people than at any other time in the State’s history. THE EMPLOYMENT FIGURES WERE REVEALED in the Department of Mines, Industry Regulation and Safety’s latest statistics release covering 2017-18. Western Australia’s mineral and petroleum industry reported sales of $114.9 billion, up $10 billion from the previous year. The amount was the second highest financial year sales value on record, behind only the $123 billion achieved in 2013-14, with a number of commodities reaching record production levels including gold, iron ore, LNG and lithium. Liquefied natural gas saw the largest increase in value, climbing from $12.7 billion to $19.1 billion, coming off the back of a 32 per cent increase in production. Lithium continued to see significant increases in both production and value, with sales rising 167 per cent to reach $1.6 billion from production of 2.1 million tonnes. The global coal mining market is also growing,
10 І Australian Bulk Handling Review: November/December 2018
with a CAGR of close to 2 per cent from 2018-2022, according to a coal mining report published by Technavio. Technavio states the industry is largely driven by coal requirements and a rise in electricity generation, and has seen an overwhelming response due to an increase in mining techniques and developing coal mine sites. The global market is witnessing upward traction as the industry scope is exhibiting vast labor, but market challenges such as illegal possession, fraud and government policies are obstacles.
Australian Graphene Industry Association launched A new peak body — the Australian Graphene Industry Association (AGIA) — has been formed to assist and promote the graphene industry in Australia. THE AGIA HAS BEEN ESTABLISHED to act as a point of contact and information for businesses interested in pursuing the use of graphene to improve their products. The Victorian Government has provided the initial funding for the establishment of the AGIA. Graphene is a transformative material. It is called a ‘super material’ because of its incredible characteristics: stronger than steel, harder than diamond, impervious to all gases, and the most electrically conductive material known to man. Not only is graphene a super material, its qualities can be transferred into other materials that it is compounded with. Australia, and Victoria in particular, has become a hotbed of research into graphene, and the development of commercial applications using this material. Geelong is home to one of the first facilities in the world that can manufacture affordable graphene at scale. “The AGIA has been formed to provide a focal point for everyone who has an interest in graphene – from industry to researchers, to government and the public,” says AGIA Chair Chris Gilbey OAM. “The AGIA will not only be an information source on every aspect of the commercial potential for graphene, it will also link companies to future employees, venture capital to start ups, and researchers to industry. “It will also facilitate the development of the industry by providing a jobs portal on the AGIA website, which will be operational before the end of the year.”
Unlike the EU, in Australia there has been no structure and directed governmental support focused on graphene commercialisation. Nevertheless, Australia is among the leading nations in investment into graphene research. Since 2009 almost $30 million has been awarded to graphene research via grants from the Australian Research Council (ARC), with 49.5 per cent of the ARC graphene grants going to Victorian universities. “The Victorian Government has recognised the importance of graphene to the state’s economy, and as a result has provided the initial seed funding for the AGIA,” Mr Gilbey said. “It also understands that new businesses will be spun out from universities in the field of advanced materials and that the CRC grants are likely to be a predictor of new business formation in Victoria.”
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NEWS
Townsville processing plant on cards Pure Minerals may develop an ore processing plant in Townsville, Queensland following its acquisition of emerging nickel-cobalt company Queensland Pacific Metals (QPM). THE COMPANY ANNOUNCED IT WOULD purchase 100 per cent of QPM pending a 45-day due diligence period. Small cap QPM has an ore supply agreement for the purchase of nickel-cobalt in place with two companies — Societe des Mines de la Tontouta (SMT) and Societe Miniere Georges Montagnat (SMGM) — in the South Pacific territory of New Caledonia. In addition, QPM holds a nickel-cobalt exploration venture in Marlborough, Queensland, the Eden Garry project. QPM is also collaborating with the Queensland State Development Authority regarding the development of the Townsville processing plant and intends to produce a feasibility study in future. The company plans to use ore supplied from SMT and SMGM from their mines in New Caledonia as feed for the plant should it go ahead. The three companies are participants in a fiveyear shipping agreement (commencing June 2020) for the supply of 600,000t/y nickel-cobalt, subject to completion of QPM’s intended feasibility study. This ore would be used to produce around 25,000t of nickel sulphide and 3000t of cobalt sulphate per year. According to a report released by Pure Minerals,“Townsville is considered a preferred location as it is well supported by existing infrastructure, skilled labour, engineering support proximity and a long history in handling New Caledonia ore.” The report also said Townsville’s relatively close proximity to New Caledonia, located around 2000km away, was advantageous. Pure Minerals paid $75,000 deposit for its QPM exclusivity rights and due diligence period. Overall payment includes $870,000 in Pure Minerals shares, $500,000 in cash and over 333 million deferred consideration shares subject to four performance milestones.
DNi process approved QPM has obtained permission to use Direct Nickel Projects (DNP)’s nickel and cobalt processing method. QPM will apply the DNi process, with the assistance of CSIRO, at its proposed nickel-cobalt processing facility in Townsville in north Queensland. The method will be used to extract nickel sulphate and cobalt sulphate for the emerging electric vehicles battery market.
12 І Australian Bulk Handling Review: November/December 2018
CSIRO will assist in upgrading the product to meet purity requirements for battery grade nickel and cobalt sulphate, following its success with over 19 campaigns as well as in treating a range of ore types and blends from Indonesia and Brazil. With the technology, QPM anticipates a production of around 25,000 tonnes per year (t/y) nickel sulphate and 3000t/y cobalt sulphate a year. Feasibility studies will first be conducted on 600,000 wet metric tonnes (wmt) per annum processing plant. QPM director John Downie said, “The DNi process will assist us in reducing the amount of capital required compared with traditional nickel high pressure acid leach (HPAL) operations.” The oft-used HPAL requires lots of sulphuric acid as well as producing significant amount of waste. In turn, DNP will get a percentage of revenue earned by QPM, determined by the underlying commodity prices of nickel and cobalt. DNP chairman Andrew Vickerman said, “We welcome the opportunity to work together with QPM on the use of the DNi process in a new plant in Queensland. “The DNi process provides a lower cost and more environmentally sympathetic route for the production of nickel and cobalt for the expanding battery market.” The technology has a tailings footprint around one-third of that of a HPAL plant of equal capacity. It is also able to extract remaining nickel, cobalt and other co-products from tailings.
ABOVE: Outcropping ridgeline of stratiform manganese-cobalt mineralisation. Image: Pure Minerals.
Sedgman wins $100m in CHPP contracts Mineral processing firm Sedgman has won $100 million in contracts to operate coal handling and preparation plants in NSW and Queensland. SEDGMAN PARENT COMPANY CIMIC GROUP said on 6 November a pair of contracts had been won – one with Mach Energy, and another with QCoal. The Mach Energy contract, worth $75 million over three years, is to operate and maintain facilities at Mach’s Mount Pleasant site at Muswellbrook. For the $25 million, one-year QCoal contract,
Sedgman will deliver maintenance and operations at QCoal’s Byerwen site at Glenden. CIMIC said the contracts maintained Sedgman’s strong track record of reliably operating CHPPs. “Sedgman’s strong working relationship with QCoal has developed over many years,” Sedgman managing director Grant Fraser said. “We have been closely involved throughout the Byerwen project from the engineering, procurement and construction of the stockpile, train load-out and CHPP. We are pleased to be completing the cycle by operating the plant.” Mr Fraser said at Mount Pleasant, Sedgman would be drawing on the long partnership between Mach Energy and fellow CIMIC Group member Thiess,“to deliver a seamless service that will maximise the value from that site.” The Mount Pleasant contract will begin towards the end of 2018. The Byerwen CHPP is currently being commissioned.
“We are pleased to be completing the cycle by operating the plant.”
Extremely rare mineral found in meteorite impact crater A group of scientists has discovered one of the rarest minerals on Earth buried deep within what may be the largest-known meteorite impact crater in Australia. THE ULTRA-RARE MINERAL KNOWN AS reidite was found by Curtin University researchers in the long-buried Woodleigh Crater near Shark Bay, Western Australia, about 750 km north of Perth. Reidite only forms in rocks that experience the incredible pressure created when rocks from space slam into the Earth’s crust, the team explains in a paper published in the Geology journal. The mineral starts as zircon and transforms to reidite during the pressure of impact, making it incredibly rare and only the sixth- known crater on Earth where the mineral has been found. The chance find of reidite gave the team new insights into how the Earth responds to the dramatic changes created by meteorite impact, a process that violently lifts deep-seated rocks to the surface in seconds.
According to Curtis University it’s only the sixth time the mineral has been discovered on Earth. Research supervisor Aaron Cavosie noted the drill core sampled the middle of the impact crater, a region called the central uplift. The discovery suggest that the Woodleigh Crater may be much larger than previously thought. It has long been buried beneath younger sedimentary rocks, so its size is not yet known and remains debated. Previous research estimated the crater to be between 60–120km in diameter. The team from Curtis University is currently using numerical modelling to refine the size of the crater.
ABOVE: Woodleigh Crater.
Australian Bulk Handling Review: November/December 2018 І 13
NEWS
Rabobank Leadership Award recognises agribusiness visionary The CEO of Nuffield International Jim Geltch has taken out the 2018 Rabobank Leadership Award. NUFFIELD INTERNATIONAL OFFERS scholarships to individuals who will shape the future of agriculture in communities both local and global. With more than 1,700 Nuffield Scholars around the world, these individuals are running farms and agribusinesses, leading communities, serving as elected officials, and shaping global agriculture practices and policies. AACo chief operating officer Anna Speer took out the 2018 Rabobank Emerging Leader award, recognising developing leaders in the sector. Presenting the awards, Rabobank Australia & New Zealand Group managing director Peter Knoblanche said in his work leading Nuffield, Mr Geltch was making one of the most fundamentally important contributions to leadership in the food and agribusiness sector. “Jim is one of the great unsung heroes of the sector, whose enormous contribution to agriculture and the food and agribusiness industries is truly deserving of recognition. “Not only is he an extremely accomplished leader in his own right, he has had a huge impact on the sector and done great good by fostering and developing leadership in others,” said Mr Knoblanche. RIGHT: Nuffield International CEO Jim Geltch
14 І Australian Bulk Handling Review: November/December 2018
“Through his own leadership of the Nuffield organisation, Jim has played, and continues to play, an invaluable role in the future growth and prosperity of the sector, by facilitating the development and engagement of the talented young people in our agricultural and agribusiness industries.” Mr Knoblanche said, as a capacity-building program, Nuffield farming scholarships provide innovative and progressive young farmers and agriculturalists in Australia and New Zealand – and in a number of other countries – with the opportunity to travel the world to learn best practice and gain a global view on agriculture. “And this plays an enormously valuable role in helping them manage and drive their businesses, and our sector, into the future,”he said. “Indeed, in leading Nuffield Australia and now Nuffield International for almost a decade and a half, Jim is quite likely responsible for mentoring more agricultural leaders than any other individual in the sector in Australia today.” Nuffield Scholars who have completed the program during Mr Geltch’s tenure have gone on to become federal and state members of parliament, to sit on numerous industry boards, to become community and business leaders and to develop and demonstrate best farming practice. “And indeed, in some cases, to go on to develop entirely new agricultural industries, like Australian chia industry pioneer John Foss,” said Mr Knoblanche. He said it was particularly impressive that Mr Geltch – a farmer himself, based in Moama in the New South Wales Riverina – had contributed so much to developing others in the sector, while simultaneously operating, with his family, an operation growing 30,000 tonnes annually of processing tomatoes. Also a Nuffield Scholar in his own right, Mr Geltch was awarded his scholarship in 1986 to explore farmer education, advances in irrigation technology and computer-based crop modelling in Europe and Israel.
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Australian Bulk Handling Review: November/December 2018 І 15
INDUSTRY DEVELOPMENT
GeelongPort and Boral cement partnership A milestone 25-year agreement has been reached between GeelongPort and Boral Cement that will see the latter invest $130 million to construct a new clinker grinding and cement facility at the port.
Photo credit: GeelongPort.
for construction materials in the Victorian region, the new facility has been designed to handle up to 1.3 million tonnes of cementitious products per annum. The facility will be connected by a conveyor system to Lascelles Wharf, providing substantial discharge and processing efficiencies. “We are excited to extend our partnership with Boral Cement who has operated at GeelongPort for more than seven years,” Brett Winter, CEO of GeelongPort said. “Our facilities, complemented by our experienced people and freight connections, offer Boral Cement advantages to their long-term business outlook and supports their customers.” GeelongPort is the second largest bulk port in Victoria, managing in excess of $7 billion of trade and generating more than 1,800 jobs across the state. “Securing long-term sustainable solutions through visionary partnerships enhances our capacity to continue to drive the region’s economy,” said Mr Winter. Boral sees the move as reaffirming its presence and ongoing investment in the Geelong community. Ross Harper, executive general manager Boral Cement said, “Our substantial investment in a new cement grinding and storage facility at GeelongPort will deliver a world class operation, and reinforces our long term commitment to the Victorian construction market. “It will have the capacity and operational
16 І Australian Bulk Handling Review: November/December 2018
Photo credit: Boral Cement.
IN ANTICIPATION OF THE FUTURE DEMAND
flexibility to provide our customers with secure supply of a broad range of products that supports their growth,” he said. Boral employs more than 17,000 people globally including in the production and supply of concrete, quarry products, asphalt, cement, bricks, plasterboard, roof tiles, timber and masonry to build infrastructure, residential construction and other commercial buildings in Australia. The new facility will allow Boral to increase its capacity to meet future Victorian infrastructure demand, and expand Boral’s product offering to its customers. The Geelong and greater Victorian market is experiencing unprecedented growth driven by population surges and associated government infrastructure programs. Construction works will commence soon on building the new grinding, storage and dispatch facility. Wharf side works will incorporate ship unloading equipment, including wharf side hoppers and a conveying system linked directly to the facility. “GeelongPort is committed to building infrastructure to foster growth and prosperity for our city and the region,” said Mr Winter. The facility is expected to be operational in 2020.
ABOVE: Image: Boral Cement. BELOW: Image: GeelongPort.
INDUSTRY DEVELOPMENT
Moves to energise battery minerals industry The Association of Mining and Exploration Companies (AMEC) has welcomed the commitment from Federal Labor to ‘supercharge battery metal manufacturing’ in Australia. IN COMMITTING ITS SUPPORT FOR BATTERY metal manufacturing in Australia, Federal Labor has cited AMEC’s recent report on the lithium industry in Australia. The September edition of the Commonwealth Government’s Resource and Energy Quarterly also identified a once in a generation opportunity for Australia to further downstream value-add battery minerals. It reported that global lithium demand is expected to rise from 149,000 tonnes LCE to 1,300,000 tonnes LCE in 2027, with 90 per cent of growth driven by electric vehicles. Australia has structural advantages that benefit from this growth, with locally mined spodumene at a 10-15 per cent cost advantage over brine producers in the process to refine to lithium hydroxide. By 2019, Australia will account for 80 per cent of the world’s supply from hard rock deposits.
Lithium hydroxide will account for 25 per cent of lithium compounds used in batteries by 2021 and is predicted to rise to over 60 per cent in the coming decade. Federal Labor has now committed to partner with state and territory governments to support further growth in battery metal processing and battery manufacture. It is tasking Austrade to develop a manufacturing, export and investment strategy – starting with a review of the future of battery metal extraction and advanced processing. Federal Labor will also make research into battery metal processing and battery manufacture a funding priority for the Australian Research Council. Warren Pearce, CEO of AMEC, said: “This is a modern nation building opportunity, a chance to secure a significant position in a new emerging industry for Australia in what will quickly become one of the largest industries in the world”.
New materials ‘futures’institute for UNSW UNSW Sydney has established four new institutes focused on finding solutions to major scientific and social challenges confronting society through cross-disciplinary research. THE UNSW FUTURES INSTITUTES ARE PART OF the UNSW Futures initiative, a major component of the university’s 2025 Strategy. UNSW Futures provides a framework for facilitating cross-faculty and interdisciplinary work, driving innovative approaches to research, and addressing scientific and social challenges. As part of the initiative, UNSW will invest up to $200 million in new and emerging areas from across faculties. These virtual Institutes will receive core funding to support operations, seed-funding for new research projects, and a commitment of funding for Strategic Hires and Retention Program (SHARP) hires. UNSW president and vice-chancellor Professor Ian Jacobs and deputy vice-chancellor research, Professor Nicholas Fisk, announced the first four Futures Institutes, as follows: • UNSW Materials and Manufacturing Futures Institute: transforming the future of materials and manufacturing research in energy, transport, information technology, and healthcare – initially led by Professor Sean Li pending a definitive appointment.
• UNSW Ageing Futures Institute: enabling optimal ageing for individuals and society – led by Professor Kaarin Anstey. • UNSW Cellular Genomics Futures Institute: inventing technologies to decode individual cell DNA, chromatin, RNA, and protein outputs that will be used for precise diagnosis and more precision treatment of human disease – led by Professor Chris Goodnow. • UNSW Digital Grid Futures Institute: future-proofing global energy systems to ensure reliable, secure, affordable, sustainable energy supply – led by Professor Joe Dong. Professor Fisk said that these Institutes position UNSW as a big picture visionary university of the future. “The Institutes will enhance UNSW’s focus on innovative interdisciplinary and cross-faculty research that impacts society and policy,” said Professor Fisk. “The Institutes build on our existing strengths and will act as a drawcard for international recruitment, government and industry links, while harnessing academic excellence to address humanity’s major challenges.”
Australian Bulk Handling Review: November/December 2018 І 17
CASE STUDY
New plant features fully automated manufacturing
ABOVE: An external shot on the new OjiFS Yatala facility.
Oji Fibre Solutions (OjiFS) speaks to Paula Wallace about its new manufacturing plant for corrugated board in Yatala Central, Brisbane. ON THE 25 OCTOBER 2017, THE OJIFS Yatala facility produced its first corrugated box. It was a significant moment for the company and the team that had designed a highly automated plant with the capacity to convert 55,000 tonnes of paper. Winning the Best in Design category at this year’s Food & Beverage Industry Awards, it’s easy to see why. The state-of-the-art plant has some of the most advanced materials handling and manufacturing equipment available. The $72 million plant was first announced by the company following its acquisition by Oji Holdings and Innovation Network Corporation of Japan. The Queensland government and Gold Coast City Council also backed the project, providing incentives and funds totalling $65 million. OjiFS purchased a 24,126 square metre property owned by Frasers Property to develop the new facility. Spread over 32 hectares, the property provides manufacturing companies with links to key end-use markets through the M1 motorway and major interstate roads. OjiFS introduced the state-of-the-art manufacturing technology to produce a variety of paper-based products to mainly target the horticultural, meat, dairy, and seafood
18 І Australian Bulk Handling Review: November/December 2018
markets in Queensland, New South Wales and the Northern Territory. Corrugated packaging products are one of the fastest growing segments of the wider OjiFS business, with its high performance paper and product specifications being well suited to challenging supply chains. National sales marketing manager at OjiFS, Philip Nuttall, said: “Long-term growth in the horticulture and meat sectors of Queensland is projected to increase the demand for corrugated packaging in the future. The new plant enables OjiFS to meet the anticipated growth in demand.” The plant aims to produce packaging that is suited to Australian weather conditions. The packaging will enable fresh food to be packaged and efficiently dispatched to export markets.
The production process The plant will move into full production capacity in phases and in 2018 will convert nearly 12,000 tonnes of paper. The main feedstocks required to make OjiFS’ paper products include paper starch, glue, ink, water, strapping, shrink-wrap and pallets. All materials involved in the manufacture are delivered into the goods inwards areas in preparation for manufacturing.
ABOVE: OjiFS’ Philip Nuttall at the recent Food & Beverage Industry Awards.
“The manufacturing process at the plant is fully automated. The start of the process is the manufacture of the board which is done on a machine which we call the corrugator,” said Mr Nuttall. Paper is fed in automatically and converted into corrugated board, to a specification, which is then slitted and creased to the appropriate size. “The work in progress is then automatically stacked and fed through conveyers and automated cars to stage two of the process which we refer to as conversion.” At this stage the product is printed, die-cut and/or glued into the customers finished product, which is then bundled, tied if required and stacked on the pallet as per specification. “The final stage of the process involves the pallet being automatically introduced and the pallet strapped, shrink-wrapped, if required, and pallet flags applied,” said Mr Nuttall. At this stage the product is then moved by forklift into the despatch area for delivery to the customer. The plant features an automated materials handling and paperless tracking system from the corrugator through to finished goods, supplied by Emmepi.
LEFT: A close up of finished product being moved on a slip through the process.
The BHS Corrugator is 2.5 metres wide and capable of 350 lineal metres per minute. As far as conversion equipment goes, the plant has a Mitsubishi EVOL Flexo folder gluing machine for making regular slotted cartons; a Bobst DRO – die cutting machine capable of any carton flat shape; and a multi-point specialty gluer to add manufacturer’s joints to closed diecut styles.
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Australian Bulk Handling Review: November/December 2018 І 19
CASE STUDY
on sustainability. “Some of the sustainability features include a rainwater harvesting system, which will reduce potable water consumption by 80 per cent,” said Mr Nuttall. A 100kW solar PV system, daylight sensors and an efficient lighting control system in the warehouse are also part of the facility. To meet the standard – ISO/TS 22002-4: 2013, Good Manufacturing Practices/Food Safety - the company had louvres fitted on external walls. Louvreclad and De Luca were contracted to manufacture and install the Louvreclad Varsity Series ventilation louvres for the facility’s warehouse. The louvres provide sufficient aeration to achieve desirable ambient air and control indoor air quality in the warehouse.
LEFT: Finished product entering the palletisation process.
Project benefits It also has a design facility with full ComputerAided Design capability and Computer-Aided Manufacture of prototype boxes. And, a lab facility with box compression test as well as board and paper testing capabilities. “An extensive range of corrugator flute options are available to provide high performance solutions for challenging supply chains,” said Mr Nuttall. For example, OjiFS Yatala has on its corrugator an applicator for manufacturing PowerPly board which is a high strength, barrier board ideal for challenging supply chains such as in the meat and horticultural segments that require packaging for cool-storage and high humidity environments.
Sustainability features OjiFS built the plant with a five- star GreenStar environmental rating. The plant is designed to consume reduced amounts of water and electricity as part of the company’s focus
OjiFS already operates packaging plants in Melbourne and Sydney, in addition to five plants in New Zealand. The packaging facilities manufacture a range of products made from sustainable wood fibre procured from New Zealand. The new plant is aimed at providing OjiFS’ customers with innovative and environmentally sustainable products that enhance their competitiveness, while attracting new customers. “It will enable the company to expand its operations in Australia and provide customers with innovative products,” said Mr Nuttall. “The project also fits into OjiFS’ strategy aimed at achieving vertical integration across its pulp, paper and packaging segments.” The Yatala site was chosen due to its central location between Brisbane and the Gold Coast, and vicinity to key end-use markets. Yatala’s location is also attractive to potential employees and customers in South East Queensland. LEFT: Converted corrugated cases moving on automated conveyers towards the palletisation area.
20 І Australian Bulk Handling Review: November/December 2018
MEMBER PROFILE I have a been a member of ASBSH since… I have been a member since 2001.
MEMBER PROFILE:
Angus Pidgeon In each issue, ABHR profiles a member of the Australian Society for Bulk Solids Handling (ASBSH). This time, we speak to Angus Pidgeon, who is the technology manager at Advisian, the independent consulting arm of the WorleyParsons Group.
The technology is rapidly advancing, both with the tools we engineer with and new equipment available.
I am a member of ASBSH because…
The project of which I’m most proud…
I receive a copy of the ABHR and I get the opportunity to network with other materials handling engineers.
The Dampier Port Upgrade, was a large bulk handling port development. This project had a number of technical and schedule challenges that were solved by a collaborative effort from all involved and resulted in a number of ‘firsts’.
I got into bulk handling… Working on site in the iron ore mining industry, which has included work on process plants, product handling, train loading/unloading and ports.
I love my current work because… In consulting engineering we are challenged to solve complex problems which requires people with different skills and experiences working together.
In my role it’s important to… As the industry requires improved safety and productivity my team needs to be aware of the latest developments and how our engineering team may be able to incorporate these into design solutions.
My career highlight… Managing a commissioning team to start up and ramp up a new process plant while recovering schedule, handing over to operations without any injuries.
I am inspired by… Our ability to develop new solutions when faced with the need to solve a problem.
When I am not working you will probably find me… Helping with the junior robotics at my daughter’s school or walking the dog.
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CONVEYORS
Fast supply of Modulaveyor to iron ore mine
ABOVE: Fenner Dunlop was the only company in the region that could guarantee quick delivery and installation of the conveyor.
When a surge pile of 200 tonnes of mined material collapsed in a mine in Tasmania, the existing modular conveyor system had to be replaced as quickly as possible. FENNER DUNLOP WAS THE ONLY COMPANY in the region that could guarantee quick delivery and installation of a 450mm wide and 30m long modular-built belt conveyor to the iron ore mine. Designed for the quarrying and mining industries, the new Modulaveyor is available in widths of 350mm, 450mm, 600mm and 750mm and features a flat and trough profile with belt speed and power selection to suit the application with a plain or cleated conveyor belt. The Modulaveyor conveyor design is based on Fenner Dunlop’s 50-year history in the sector. It has designed a unique system that allows for a quick turnaround with different lengths, widths, motor and speed options. Because of its modular design, the Modulaveyor can be installed by using a manual handling method if necessary. The conveyor for the iron ore operation was manually handled into position down the tunnel and fastened together in a number of hours, as the use of a crane or lifting was just not an option. Due to restricted access, a traditional conveyor design would not have worked in this situation. The Modulaveyor was assembled and dispatched in only 48 hours, and it was
22 І Australian Bulk Handling Review: November/December 2018
already on-site and hard at work by the end of the same week. Fenner Dunlop was able to meet the client’s expectations on a number of levels. At the local level, Statewide Belting (TAS) was able to visit the site quickly to access the issue and offer a quick solution. At the branch level, Belle Banne Conveyor Services able to meet clients quick turnaround requirement through great stock volume and staff able to work around the clock to build, assemble and package. At a national level, Fenner Dunlop’s buying power enables it to offer a cost effective solution in all areas of material handling. “It’s with great pride we can offer our customers a quick and reliable solution so they can get back to operations with minimal downtime and impact on productivity,” said Belle Banne project manager, Grant Potter. “The modulaveyor unique design enables us to meet any client specification demands on a short deadline. Don’t underestimate the power of this conveyor as it will handle more than 200 tonne per hour with ease,” he said. The Modulaveyor system also allows variable speed drives (VSD), safety lanyards and fully-
“It’s with great pride we can offer our customers a quick and reliable solution so they can get back to operations with minimal downtime”
customisable head and tail sections to incorporate loading options and belt cleaning solutions. A triple labyrinth seal on all rollers is standard on the Modulaveyors, which has become industry standard in the quarry sector. Roller shells are UHMWPE, to minimise the risk of belt damage. Moreover, stainless steel shafts and bearings are available on request. The outcome of the project in Tasmania demonstrates Fenner Dunlop’s ability to deliver headto-tail engineered conveyor solutions, in this case through subsidiaries Statewide Belting Service (TAS) and Belle Banne Conveyor Services (VIC). The Modulaveyor has a wide range of applications including coal, concrete, recycling, grain, sand, and water treatment, to name a few.
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LEFT: The new Modulaveyor is available in widths of 350mm, 450mm, 600mm and 750mm.
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MINE TAILINGS
The value of seeing “inside” mine tailings onsite It is no secret that mining produces waste that can be damaging to the environment, but advances in technology and knowledge are making a difference. LEFT: Theoretical knowledge becomes meaningful for students once they are in the field to gain understanding of what is happening in the real world.
THE USE OF X-RAY DIFFRACTION (XRD) and fluorescence (XRF) is enabling environmental scientists to not only identify potential risks in mine tailings but also offer advice on the potential for re-processing. Tasmania’s historic gold and copper mines are notorious for the damage that waste has caused to the environment, to the point where in one particular region the damage itself was a tourist attraction. The visible signs of damage are the red stains, waste rock and tailing heaps that surround the mine, all of which can affect the water supply and river systems through leaching and run-off. Almost all of these mine sites contain sulfide minerals (such as pyrite), which are oxidised under weathering conditions producing acid. This mine waste can have devastating effects on the environment, which can be costly to clean up, but may be a lucrative source for re-processing as older mining techniques left much of the mineral resources behind. To quantify the potential re-processing value or the extent to which mine tailing remediation is needed requires extensive testing of the waste material. In the past, samples would be gathered and sent to laboratories – with several weeks passing before the results were available. Dr Anita Parbhakar-Fox, senior research fellow with the ARC Transforming the Mining Value Chain Research Hub, University of Tasmania has used portable XRD (pXRD) and portable XRF (pXRF) analysers from Olympus to identify and quantify the sulfide, carbonate and clay mineralogy, and characterise the geochemistry, onsite. With this information Dr Parbhakar-Fox is able to determine the acid forming potential at a given site as well as the ability of 24 І Australian Bulk Handling Review: November/December 2018
the carbonate and clay minerals to naturally buffer the system. She is also able to use these portable devices as a screening tool for determining which samples merit further analysis by more expensive laboratory analytical methods. Moreover, as a lecturer, it has given her the ability to give onsite education to students on field trips to understand what they are visually witnessing. This technology allows the user to make more informed decisions onsite and can significantly reduce the number of samples which are sent offsite for analysis by other more costly, analytical techniques. “When you are in the field it can be frustrating not having a clear idea of what the samples contain,” said Dr ParbhakarFox. “A basic understanding of the geochemistry provided by the Vanta pXRF goes a long way, but does not reveal the types of sulfide minerals present or how metal transfers may occur. “Using the TERRA pXRD in conjunction with the pXRF you have a greater idea of what is going on and it saves having to take a sample back to the lab.” Dr Parbhakar-Fox said that at a recent field trip with undergraduate students to an old gold mine on Tasmania’s east coast showed that the tailings had a high sulfide – pyrite – content, the host for the gold and with modern extraction technology could be worth re-processing. “It also highlights the potential for further acid rock drainage. Being able to determine the carbonate and clay mineralogy within the tailings – both qualitatively and quantitatively with pXRD – also allowed the students to assess the ability of the tailings to naturally buffer the acidity caused by oxidation of sulphides,” she said.
HYDRAULIC POWER
Using hydraulic power to assemble heavy chains Farewell to flogging hammers as safety-oriented GIS develops a better, faster, cost-efficient way to assemble heavy, awkward chains. AN ENTERPRISING QUEENSLAND CONTRACTING company has developed a safer, faster and more costefficient way to assemble heavy ABON coal feeder chain links by replacing strenuous manual labour with compact and powerful Enerpac hydraulic power. Gibson Instrumentation Services (GIS) has eliminated the need to use flogging tools during on-site assembly by introducing into its workshop a neatly portable Enerpac combination of C-clamp, 10-tonne cylinder and lightweight PU series Electric Economy Pump with pendant control and pressure gauge for safety. The new combination is used in ABON OEM work in the workshop to precisely assemble chain lengths often weighing more than a tonne, typically achieving tasks in one day that previously might have taken several days. The Enerpac combination – developed by a GIS team led by Manager Paul Keenan – weighs less than half the 37kg of the previous customised tool that took two people to lift safely and required a crane for positioning. The new tool is also light enough to be taken on-site for RIGHT: Placement of the Enerpac C clamp used in combination with an RC106 10-tonne singleacting cylinder, PUJ1201E economy pump with pendant and G253L pressure gauge for safety and control.
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Australian Bulk Handling Review: November/December 2018 І 25
HYDRAULIC POWER
Next-generation Enerpac ZUTP-S tensioning pumps New pendant-operated electric tensioning pumps being introduced by Enerpac allow safe and swift single-person operation in multiple-bolt applications, including gas turbine machinery, compressors, wind power plants and oil, mining and energy industries tasks. The rugged and compact ZUTP-S 1500 bar series pumps feature two-stage operation that provides high flow at low pressure for fast system fills, then controlled flow at high pressure for precise operation. Operators of the ZUTP-S can pressurise and depressurise the tensioner directly from the 6m pendant. The pump achieves high-pressure without the need for an intensifier. This allows for low maintenance and less cost for the end user, says Enerpac engineer Tony Cooper, who is Asia-Pacific marketing manager responsible for introducing a stream of new Enerpac technology throughout the region. “The ZUTP-S Series is typically used in oil and gas, wind power and power plant applications, it works well when used for critical joints in the assembly of gas and wind turbines, compressors, power shaft couplings and oil and gas pipelines. This tensioning pump is extremely reliable and provides great power and precision that our customers value,” he said. Key features include: • 1.25 kW heavy-duty universal motor that provides the best performance-to-weight ratio in a range of six compact pumps, all of which meet CE safety requirements and internationally respected TUV product standards. • Easy access manual override valve, which quickly releases pressure if power is lost. The pump’s safety relief valve limits output pressure. • Panel-mounted 153mm pressure gauge with polycarbonate cover is set into a protective metal shroud for improved visibility. • Replaceable 10-micron reservoir breather and inline high-pressure filter helps maintain oil cleanliness for optimum performance. Enerpac is wholly owned by Actuant Corporation.
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26 І Australian Bulk Handling Review: November/December 2018
BELOW: The compact and powerful 700-bar high-pressure hydraulic equipment is used to assemble the chain links to form ABON conveyors.
maintenance tasks, where it also increases the safety of the job and cuts the time taken to do it. The old customised tool was too heavy and awkward to take on-site for work on the ABON chain feeders, which transfer material from the feed side of machinery towards the discharge head chute side of the feeder at a constant volumetric rate. The compact and powerful 700-bar highpressure hydraulic equipment – supplied by Enerpac distributor Cooper Fluid Systems in Mackay – is used to assemble the chain links to form ABON conveyors of a type produced by FLSmidth Group for extensive use in the mining and energy, coal, cement and aggregate industries. With extensive experience in the FLSmidth ABON product, GIS is the only company that has been authorised to provide contract labour and tooling for OEM work on the product. “GIS places a high value on safety and efficiency and are very open to new ideas that will help achieve these aims,” says Enerpac North Queensland territory manager Tammy Wood, who worked with GIS and Cooper Fluid Systems to understand workplace needs and provide a practical and cost-efficient solution. Guided by Mr Keenan and his team, the search
HYDRAULIC POWER
for an optimum solution focused initially on an application where ABON chains were used at a Queensland coal handling preparation plant (CHPP) to feed raw coal to crushers. The 1.8m chain lengths each involved 108 links holding flight bars together as one long conveyor for the plant. The job involved assembling chain links using pin holding links (backing plate pins) measuring 28mm x 110mm. These are fitted to steel bars to form a conveyor consisting of bars and chain. “Traditionally the job has been done on-site by flogging in place with a sledge hammer, which is tough and potentially hazardous work,” says Tammy Wood. “Manual onsite methods are also subject to potential error, because the alignments of the pins on the backing plate are communicated to the person wielding the sledge hammer by the trusting person holding the plate. This person is laying on the ground, hoping the pins don’t mushroom or swell, because that makes getting those pins into place nearly impossible.” Between the edge of the chain and the side of the chain feeder there is about 75mm space to put the links on, says GIS team member Rob Gibson. Print “You - Bulkhave Handling Tru Tracthe Ad end - 1-2ofPage.pdf 29/10/18 got to have the tool in1 the
gap, so you can get behind the chain to push the link on. “The new C-clamp press, weighing about 17kg, is a perfect size, because the job without it can be such a heavy and awkward task,”says Mr Gibson.
12:16 pm
Australian Bulk Handling Review: November/December 2018 І 27
COVER STORY
Flip Screen: masters of innovation One Australian company is taking on the world’s screening industry and creating a name for itself for producing the best technology in screening attachments. FLIP SCREEN AUSTRALIA HAS CREATED a series of tough, portable attachments that screen in seconds. They offer endless potential, being able to screen any material from heavy rock, concrete and scrap metal to topsoil and sand. Flip Screen started as a humble idea with a bit of mesh on the back of a bucket, some creative genius and a lot of persistence in a farm shed owned by the company’s managing director, Sam Turnbull. Frustrated with the lack of compact and portable screening equipment, he set to work on creating the ingenious device that is now the centre of a successful global enterprise and considered one of the most interesting Australian manufacturing success stories in recent years. The company is now exporting to more than 41 countries across the globe, with all design and manufacturing proudly taking place in Wagga Wagga, NSW. The world-class plant includes five CNC machines and other pieces of high precision equipment, which now produce 26 models of Flipscreen for skid steers, excavators, wheel loaders, backhoes and telehandlers.
Release of the WL285 Waste Master Successful American businessman and FlipScreen distributor, Rick Wilson says, “There is not one municipality or council that should not have a FlipScreen” and it’s hard to disagree. With its outstanding versatility, the FlipScreen can be used for a variety of council applications such as waste and recycling, roadbase, pipelines and other civil projects as well as landscaping and construction/ demolition purposes.
28 І Australian Bulk Handling Review: November/December 2018
Flip Screen has just released its newest creation, the WL285 Waste Master FlipScreen, specifically designed for waste and recycling applications. Its enormous capacity and specialised screens mean that it can be used across all council waste applications, from screening FOGO greenwaste and compost to concrete and metal. Wagga Wagga City Council was the first to purchase the brand new WL285 Waste Master to fit its existing 544J John Deere Loader. The Council put it to good use straight away, screening greenwaste at the local Gregadoo Waste Facility. Council operators were surprised at how quick and efficient the unit was at getting the oversized product separated from the rest. To prove the FlipScreen’s true portability, the Council relocated the Waste Master to the Wagga Wagga Sales Yards several kilometres away to screen stones out of manure, transforming the material from a waste product into a saleable commodity. The unit is now back at the Gregadoo Facility and is making quick work of taking oversized concrete out of crushed fines that will be reused by the council as road-base. The WL285 Waste Master features Flip Screen’s new direct drive system, and also boasts the Smart Valve, a revolutionary piece of technology that is FlipScreen’s own hydraulic solution to attachment failure due to incorrect pressures and flows.
Multi-million dollar licensing agreement Flip Screen Australia has just signed a licensing agreement with Japanese company, Ninomiya Industries Co. Ltd. Ninomiya studied and trialled two of the current
ABOVE: Flip Screen has just released its newest creation, the WL285 Waste Master FlipScreen, specifically designed for waste and recycling applications.
“Flip Screen started as a humble idea with a bit of mesh on the back of a bucket, some creative genius and a lot of persistence.”
machines, then reported back to FlipScreen requesting 20 changes that the company had identified as key design elements specific to the Japanese market. The EX85 was designed by Flip Screen engineers from these specifications and the new machines include features such as direct drive, a bolt on hitch and nonstick hopper liners, resulting in reduced weight and quieter operation for use in highly built up areas. The EX85 is the first of a new generation of direct drive FlipScreens that will join the existing range as a premium option for their customers. It has just been introduced into the Flip Screen range and following the success at the N-Expo Tokyo and Hillhead UK Trade shows, the EX85 is now also available in the European and Japanese markets.
LEFT: [r] Mr Toshio Nattaami, President of Ninomiya Industries Co. Ltd, signing an agreement with Mr Sam Turnbull, managing director of Flip Screen Australia. BELOW: FlipScreen can be used for a variety of council applications such as waste and recycling, roadbase, pipelines and other civil projects as well as landscaping and construction/ demolition purposes.
Flip Screen research and development In true Flip Screen fashion, new products are always in the pipeline and the next release is set to crush the competition. Tested on concrete and rock successfully, the newest innovation out of the Flip Screen factory is the Crusher Bucket, which the company hopes to release in the near future. Another fascinating piece of equipment that the engineers at Flip Screen have invented is the Introscopic Cylinder. This is a hydraulic cylinder that can internally create its own pressure, which means that you can put 300 bar down the hydraulic line and the cylinder uses this to increase the pressure fivefold and create 1,500 bar. This will be used where extreme pressures and force are required and for miniaturisation of high pressure hydraulic cylinders.
Flying FlipScreens Many of Flip Screen’s international customers are not only getting their FlipScreen imported from Australia, they are air freighting them to their destination. FlipScreens are flying alongside cargo such as Lamborghinis, Maseratis, and Rolls Royces. One dealer in Europe flies about 10 smaller units into the EU every year because it is quicker and the units can be put to work sooner than other forms of transport. A scrap metal company in Brazil bought a WL180 machine in July, a large FlipScreen unit weighing in at almost four tonnes, designed for 11-18 tonne
wheel loaders. It was so impressed by the FlipScreen’s productivity that the company immediately purchased two more. It has made the decision to transport the two units to Brazil via air simply due to the huge earning potential of the FlipScreen compared to weeks lost during sea freight. One American company reported that the FlipScreen was earning it around $4,000 per hour. When you’re making that kind of money per hour, you want those hours to start as soon as possible.
Company expansion Flip Screen is working with distributors in Japan, Europe and South America to continue the company’s massive expansion of its customer base through these areas, while also working with dealers in the US. To help drive this growth, the company has just relocated its Dallas office and warehouse to a new larger facility. Sam Turnbull is excited about the move and says that leaving behind the company’s existing warehouse in Carrollton and relocating to the new 13,440 square feet facility in Dallas will assist the growing manufacturing base of the business and the continuing expansion of Flip Screen in North America. One American dealer has requested a minimum of 300 units over the next four years and Mr Turnbull is due to visit the US to meet with mining companies and get the WL3000 project up and running. This gigantic FlipScreen can screen 30 cubic metres of coal at a time, which is more than 1,400 tonnes per hour. The company is positive that the hype will continue due to the ongoing need for portable and versatile screening attachments over the traditional fixed screening plants.
For more information visit: www.flipscreen.net or call: 02 6931 8002. Visit Flip Screen’s world-class manufacturing plant in Wagga Wagga at any time.
Australian Bulk Handling Review: November/December 2018 І 29
GRINDING TECHNOLOGIES
Questions and answers on grinding technology ABHR spoke to a panel of experts from Metso - Alan Boylston* (AB), Suzy Lynch-Watson* (SLW), Håkan Ståhlbröst* (HS) and André Vien* (AV) – about some of the trends and challenges facing the mining producers of today. The goal: to find out how new grinding equipment and technologies can impact the industry. Q: What are the main challenges facing mining producers today? AB: One main challenge we see for our mining clients in today’s markets is how to balance the increased production needed to meet a rising demands for metals, with the fact that ore grades around the world continue to fall. What this means is that to even maintain current levels of production, mines need to process more and more raw ore, which requires additional energy as they ramp up production. It also translates in many cases to higher investments in equipment and higher operating costs. In order to be profitable, mines have to really zero in on ways to improve operational efficiency. Q: What trends are you seeing in the industry to address these challenges? AB: The big trends are related to looking at the many options that can help to lower energy costs as
production demands increase. It becomes important to look at improvement opportunities across the entire process to find ways to drive down costs. On the equipment side, there is more openness to looking at new applications for older technology. For example, High Pressure Grinding Rolls (HPGR) have been around a long time in limestone, cement and kimberlite operations, but applications involving hard ores are relatively new. With their higher energy efficiency, HPGR’s are getting a second look as an alternative to more traditional grinding in certain applications. The Metso HRC™3000, launched in 2015, represents a significant technological leap for the mining industry with its simple yet robust design that maximises energy efficiency, availability and reliability. Process improvement is also what we are hearing more and more about from our customers. Mines are
“New and faster simulation tools also allow us to ensure that the mill feed contributes to increased grinding efficiency.”
LEFT: Metso is always looking to make improvements that will impact the grinding process and help clients meet their goals.
30 І Australian Bulk Handling Review: November/December 2018
looking at things like improving blasting practices at the mine face to reduce feed size to the primary crushers as well as optimising mill liners for longer service life and energy savings. We are also seeing the trend towards digitalisation with many mines using advanced process controls to make their operations more efficient and to reduce energy consumption. All these approaches are focused on improving operational efficiency and making better use of energy to drive down costs. HS: I would also add that there is a trend to replace small and medium-sized mills with fewer but significantly larger mills to handle the high capacities required. Large mills require fast and safe maintenance, something we will continue to improve. However, large mills also require large amounts of energy to operate, so I believe that the focus on efficiency will increase. Energy is expensive and in many areas becoming more so with time. Q: What technical improvements has Metso launched in terms of grinding technology? HS: Traditional horizontal mills are generally not particularly energy efficient. Only a very small part of the energy is transformed into efficient grinding, with the remaining energy channeled into liner and media wear, heat and noise. In terms of technology, there is not much that can be done with the mill itself except for the engine and drive, but it is often possible to control the process better. As an example, mills with variable speed controls allow you to run the mill as fast as needed and in combination with a control system that automatically adjusts speed and feed based on parameters such as mill weight and noise within the mill. You can ensure that the mill is always running in the most efficient manner which helps to decrease energy consumption. New and faster simulation tools also allow us to ensure that the mill feed contributes to increased grinding efficiency. Previously simulations took a long time, but now we simulate almost all designs for larger mills. If the grinding is as efficient as possible, you consume less energy per tonne. SLW: Metso is always looking to make improvements that will impact the grinding process and help clients meet their goals of increasing equipment availability and lowering operating costs. One recent advance in mill lining that has received a lot of attention is the Metso MegalinerTM made from polymet and steel. The liners can use less material
than previously since we use a ‘skip row’ design, where the liners now have only two-thirds of the number of lifters as before. Using this design, we can still achieve the same lift and charge trajectory but with less liner weight. The lower weight can make it possible to load more in the mill and together with an optimised design, you can produce more tonnes and in some cases, increase efficiency. Looking beyond products, we have also made technical improvements by combining our many services offers to find solutions that help clients achieve lower energy and higher production levels. This involves looking at our products and using our process, instrumentation and controls expertise to come up with the best combination of services to meet the clients’ objectives. For example, when our team is asked to assess why a particular grinding circuit is underperforming, we try to take a more holistic view. Questions such as, “are the drill and blast practices optimised?” and “is there a large variance in the characteristics of the ore coming into the plant?” are also important. Of course, the grinding mill itself needs to be assessed but the process steps before and after the mill all play a part in driving the overall performance of the circuit.
ABOVE: There is a trend to replace small and medium-sized mills with fewer but significantly larger mills.
Q: Do you see any trends in the way equipment is designed and used, especially as throughput tonnages continue to increase? SLW: One thing that we have seen is plants looking at different options in terms of equipment selection to keep energy costs in check as production demands continue to increase. For example, we are seeing interest in Metso Vertimill® stirred milling technology,
Australian Bulk Handling Review: November/December 2018 І 31
GRINDING TECHNOLOGIES
around the grinding media used in the mill, how the mill speed and liner angles are paired, relying too heavily on rules of thumb related to production, and finally a lack of communication between the mine and the plant.
“… a lack of communication between the mine and the plant can be classified as a poor grinding practice.”
RIGHT: The way to monitor for problems would be to try to get a better picture of exactly what is happening inside the mill.
particularly in cases where a plant needs extra milling capacity or wants a finer grind. In the past, plants would invest in a second ball mill to run in parallel with their current one to add the additional capacity, but this is not always an energy efficient way of tackling the problem. Recent research by Malcolm Powell and Sam Palandiandy at the Julius Kruttschnitt Mineral Research Centre showed that using a tertiary vertimill to increase circuit capacity can be 25 per cent more energy efficient compared with adding extra ball milling capacity in a secondary grinding service. The conclusion was that looking at the performance of a single mill or piece of equipment is not always the right approach. You really need to look at how all the different pieces of equipment in the circuit work together to find the most energy efficient combination. It comes down to finding the right approach to the right application. Q: What does Metso see in its field operations as poor grinding practices and how this can be overcome? AV: One key thing to remember is that even with the most modern and up-to-date equipment, performance in the field is still dependent on how the equipment is operated. Our global Process Optimization group has visited hundreds of concentrator plants, looking at the comminution circuits, assessing how things are set up and looking for improvements in terms of energy efficiency or throughput. Most of the process bottlenecks we run into are not caused by the machines themselves but rather have resulted from the way the comminution equipment has been configured or is operated. The four most common issues encountered revolve
32 І Australian Bulk Handling Review: November/December 2018
Q: Can you walk us through a few examples? AV: Well, looking at grinding media we run into situations where the media is too large for the expected grind. The result ends up being high wear rates to both the liners and the media and a very inefficient use of energy. You can also run into poor quality media that splits or else wears in a way that results in disk shaped media that does not roll as it should within the mill. This media consumes mill volume and power but the grinding is very inefficient due to the motion of the charge. All of these factors add up to inefficient use of energy. The solution to this would be to conduct ongoing calculations to ensure the optimal size of grinding media is used and to keep a close eye on media quality. In terms of incorrectly paired mill speeds with the liner angles, what you often have is media that becomes overthrown causing damage to the liners and to the media itself. The way to monitor for problems would be to try to get a better picture of exactly what is happening inside the mill. This can be done in several ways. One method would be to monitor the noise levels within the grinding mill using Acoustic technology such as Metso SmartEarTM OCS which measures steel on steel impacts within the mill. By measuring the noise levels within the mill, you can adjust the mill speed to compensate and
bring things back in line, resulting in more efficient grinding and energy usage. We also run into situations where a plant is relying too heavily on rules of thumb or general assumptions without going one step further. For example, we often think of increased power draw being tied to greater throughput. But what if the problem is not with the mills tumbling speed but there is a slurry pooling problem? In this case it is not a question of an issue with tumbling efficiency but rather with pumping efficiency. To correct this, converting a radial discharge to a curved discharge could be a solution, increasing throughput in the mill for the same energy due to the higher discharge capacity of the pulp discharge system. Finally, a lack of communication between the mine and the plant can be classified as a poor grinding practice. A plant needs to have good visibility on incoming feed materials, in particular the ratio between coarse and fine run of mine ore which can vary significantly. Without good visibility, the plant may not be able to react quickly enough to adjust its operating parameters and therefore lose efficiency and overall performance. HS: Sometimes it all comes down to not looking at the whole process. Many companies are just trying to accomplish one thing at a time, lowering the price or increasing equipment longevity instead of considering how to improve the efficiency of its entire grinding process and reduce the cost per processed tonne. It’s all about helping the customer to increase efficiency based on the conditions that exist. In some cases, investments may be required, such as a new liner handler, to maximise liner size/weight and reduce maintenance time. Changes in the process or equipment to solve problems or achieve set objectives may be required. There really is no one-size-fits-all solution and as a team we work on finding the right mix of equipment and services to help our clients meet their business goals. Over the years, our clients have come to expect results and that is what we try to deliver. * Alan Boylston is director, process engineering development, sales at Metso. * Suzy Lynch-Watson is global consulting and labs manager at Metso. * Håkan Ståhlbröst is global application support manager, mill linings at Metso. * André Vien P. Eng, Ph.D. is principal process engineer at Metso. For more information visit: www.metso.com
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І 33
IT AND SOFTWARE APPLICATIONS AGRIBUSINESS
Rabobank welcomes Drought Finance Taskforce Agribusiness banking specialist Rabobank has welcomed the establishment of the Federal Government’s newly-announced Drought Finance Taskforce. Rabobank Australia CEO Peter Knoblanche said the bank was fully supportive of the aims of the taskforce and welcomed the opportunity to be involved. “The opportunity to bring together the agricultural sector’s major financial providers with government and the National Farmers’ Federation is a very positive initiative, which will help facilitate a coordinated approach to supporting drought-affected farmers and rural and regional businesses,” he said. “Bringing together the knowledge and perspective of these key stakeholders involved in the agricultural sector will be a very positive development in providing constructive, practical outcomes for those impacted by the severe drought conditions in many parts of eastern Australia.” Mr Knoblanche said Rabobank had a range of measures in place to support its clients, who had been impacted by the current drought conditions. These include: ‘carry on’ finance to keep viable operations running; waiver of break costs on early redemption of Farm Management Deposits to allow access to needed funds; deferral of scheduled loan payments; waiver of fees on loan increases necessary for rebuilding operations; and waiver of fees for equipment finance variations. Mr Knoblanche said the bank’s clients in areas of Australia currently impacted by drought were, in the majority of circumstances, continuing to manage the dry conditions and remain in sustainable financial positions. “Where required, measures include individual agreements reached with viable clients to hold off action for agreed periods to allow them time to work through their financial difficulties and re-build their financial position when seasonal conditions improve,” he said. Mr Knoblanche confirmed the bank was not applying higher interest rates to loans in default due to drought (in droughtdeclared regions) or to natural disasters, such as floods, bushfires and cyclones.
34 І Australian Bulk Handling Review: November/December 2018
Shareholders support Nufarm capital raising program Fertiliser manufacturer Nufarm has successfully raised $238 million to help firm up its balance sheet and continue its growth plan as the ongoing drought cuts into its bottom line. NUFARM TOLD THE ASX ON 26 SEPTEMBER it had seen revenue growth in all regions except Australia during its most recent financial year, which for Nufarm ended on July 31. Australian sales were down 10 per cent year-onyear due to severe drought conditions through the autumn and winter cropping periods. Nufarm announced it would seek to raise up to $303 million via an entitlement offer, after experiencing the $15.1 million loss in FY18. “The autumn period was one of the driest on record across Australia, limiting pre-plant herbicide opportunities,” Nufarm said in its report. “Winter also proved to be very dry in the eastern and southern states. “Much of New South Wales and Queensland have been declared drought affected and production is expected to be down 30 per cent to 40 per cent on the prior year.” Managing director and chief executive Greg Hunt said the poor result and elevated levels of debt made a capital raising a “prudent measure”.
“It is important that Nufarm retains capacity to continue to grow its business and take advantage of new opportunities that add long term value.”
“A combination of severe drought conditions in Australia and later than normal selling seasons in other major markets resulted in higher levels of working capital and debt at the end of our 2018 financial year,” he said. “While we remain confident that this will unwind and return to targeted levels, it is appropriate that we take measures to de-risk the balance sheet in the short term.” Nufarm’s average net working capital to sales increased to 40.3 per cent in FY18, up from 36.8 per cent. Higher than normal inventories in Australia and later selling seasons in USA and Europe led to delayed collections, and higher year-end receivables, the company explained. Mr Hunt said the capital-raising, which covered more than two-thirds of the company’s target, was a sign shareholders “strongly supported” the program. “[The equity raising] helps ensure Nufarm remains in a strong position to manage short term balance sheet risk, and supports the continuation of the company’s growth strategy in light of recent market uncertainty,” Mr Hunt said on October 1. “There was strong demand for shortfall shares in the Institutional Shortfall Bookbuild from both existing shareholders and new investors, and we
are pleased that institutional shareholders who did not participate will receive a premium of A$0.50 for their renounced entitlements.” Nufarm will look to raise the rest of its target via the Retail Entitlement Offer stage, which opened in October. “It is important that Nufarm retains capacity to continue to grow its business and take advantage of new opportunities that add long term value,” Hunt continued. “Funds raised via this offer will ensure that’s the case.”
CONVEYOR COVERS
Conveyor covers – protecting people and the environment When reviewing and selecting the best conveyor belt covers to install, there are a few important factors to consider such as durability, weight and ease of access, says Kinder Australia. AUSTRALIAN BULK MATERIALS HANDLING
BELOW: Since 2015, Kinder Australia has had the exclusive Australian distribution of K-AllShelter®/ Capotex Belt Conveyor Covers.
operations are required to ensure the safety of personnel from moving parts and dust; and the protection of the environment. In many overseas countries, particularly Europe and Latin America legislation has been put in place that makes it mandatory for conveyor belts to be enclosed with protective covers. Occupational Health and Safety (OHS) hazards and accidents from incorrectly using conveyor belts include conveyed material falling during transportation, hitting and seriously injuring workers. There is also the potential risk of workers being dragged and/or entrapped within the transporting belt by clothing, hair and other loose elements. Conveyor belt covers can provide an effective protective barrier that responds to these requirements, according to Kinder Australia. Its K-AllShelter®/Capotex belt covers deliver a robust, aerodynamic and lightweight solution. “Covering up makes sense not only helping to minimise or eliminate serious costly belt mistracking problems which can arise when moisture seeps into the cracks and extending the wear life of the conveyor belt. But also, ensuring the safety and instances of injury/accidents to workers is of paramount importance,”says Neil Kinder, CEO of Kinder Australia. The environmental and OHS risks of unprotected belts requires careful consideration due to the buildup of airborne dust during the ongoing materials
handling conveying process. The risk to personal safety is very real, fine airborne dust particles create serious health risks when inhaled. Further safety considerations include the increased risk of slips, trips and falls in areas of poor access and visibility caused by dust emissions. There is also the risk to the environment, where dust can reach areas beyond the site boundaries. It can contaminate delicate ecosystems especially in wetlands and rivers, causing scrutiny from regulators and neighbouring communities. Today’s extractive industries constantly have their dust emission levels closely monitored and evaluated. Adherence to acceptable dust level regulatory standards set by industry bodies ensures continued site operations, productivity and profitability. The tightening of environmental regulations and site obligations will mean all conveyor belts should ideally be enclosed in the future, says Mr Kinder. K-AllShelter®/Capotex belt covers feature a patented lock/hinge system and can withstand the extremities of heat, wind, humidity and rain over long periods. The advantage of being hinged on both sides allows ongoing access from either side of the conveyor – conveyor maintenance is easy and hassle free. These conveyor belt covers are manufactured using a wide range of optional materials including galvanised steel; pre-lacquered steel; high performance steel; stainless steel; aluminium; and fibre reinforced polyester.
For more information visit: https://kinder.com.au/products/capotex-belt-conveyor-covers/
36 І Australian Bulk Handling Review: November/December 2018
CRUSHING
The Pulsar rock crusher STONE CRUSHERS WORK BEST WHEN THEY are full, referred to as “choke fed”. The weight of stone pushing down into the crusher increases the efficiency of the process, giving a more efficient use of the equipment and a more even stone size. The Pulsar Process Measurement non-contacting ultrasonic level control equipment is effective in these environments. It was recently used at a quarry to control the level of stone in part of the crushing process, where the Pulsar’s Level Ultra 3 level controller was coupled with a dB3 transducer. The system uses echo processing techniques to measure the level of stone in the crusher, and maintain it between 90 per cent and 70 per cent of the “full” level using a relay to switch a vibratory feeder.
A quarry is a very noisy environment, both acoustically and electrically. The Pulsar system is set up to undertake initial signal processing at the transducer head, which can be up to 500 metres away from the Ultra 3, so the signal between the transducer head and the controller is extremely resistant to electrical noise. Simple two core shielded cables can be used to connect the transducer with the Ultra 3. The Pulsar system is an ideal solution to the application. The non-contacting measurement means that it is maintenance-free, and the sophisticated echo processing software built into every Pulsar system means that a reliable signal is received regardless both of how the stone lies in the crusher and the level of dust in the air. The dB3 transducer is designed for accurate level measurement up to three metres range. Pulsar manufactures transducers that will measure up to 50 metres range, and the Ultra 3 unit will convert distance measurement to volume or weight.
LEFT: Ultra 3 provides reliable noncontacting ultrasonic level, volume, open channel flow measurement and pump control.
For more information visit: www.bintech.com.au
Designing, manufacturing and installing bulk solids storage and handling solutions world wide.
Kotzur Pty Ltd
60 Commercial Street, Walla Walla NSW 2659 Ph (02) 6029 4700 www.kotzur.com
Kotzur Bulk Solids Handling Pty Ltd formerly Downfields Engineering Pty Ltd
19-29 Enterprise Street, Wilsonton Industrial Estate. Australian BulkToowoomba Handling Review: November/December 2018 І 37 QLD 4350 Ph (07) 4634 4622 www.kotzur.com
BULK STORAGE
talk
Tales in bulk materials storage
I designed my first materials handling system for a greenfield project in Southern Africa in the mid-1980s. Since then, I have been involved in different aspects of many materials handling projects around the world. Here, I share with you some of my key insights into the engineering and operation of storage systems. STEVE DAVIS In his regular BULKtalk column, Steve Davis* of Rio Tinto considers the basics of bulk handling that sites often struggle with. In Sep/Oct 18 he shared his insights gained from more than 30 years in bulk materials handling. *Steve Davis is the principal advisor – bulk materials process at Rio Tinto, based in Perth. 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.
ABOVE RIGHT: Wood chip bin discharge. RIGHT: Example of linear stockpile capacity efficiency (1,000m long and 50m wide, 37 degree repose, 2.0 t/m3 bulk density).
MOST BULK MATERIALS HANDLING SYSTEMS include storage. The reason for having storage, and the type of storage, bin or stockpile, varies according to the process involved. Generally, the storage forms a “surge” or “buffer” between different parts of a process that improves utilisation and productivity. Storage also provides a steady state feed into processes for consistent operation, typically mine and crusher; crusher and plant; inter-plant process feed; plant and train; and train and ship. All storage has a significant cost to build and to operate, but many do not achieve the expected functionality, being value engineered too small or designed based on incorrect assumptions. Storage capacity is a recoverable volume, but process requirement is usually in tonnes. Definition of the recoverable volume and the density relationship define the tonnes available for the process.
Flow properties Material flow properties define storage capacities. Maximum and minimum (and possibly intermediate) bulk densities, angles of repose and rill (withdrawal, reclaim), ratholing and arching properties define the available live and dead volumes, and variability thereof, for all storage arrangements. I have seen many designs with undefined bulk material properties, and where properties are misused to define capacity: •T he use of maximum bulk density in design gives more tonnes for smaller (cheaper) storage size. Fifty percent bulk density variation is common in bulk materials, maximum bulk density is likely for only a small percentage of the total material and an average design value is better. Use of the highest density results in a storage design that holds less
38 | Australian Bulk Handling Review: November/December 2018
than the expected tonnes. •M any bulk materials are compressible, and 30 per cent increase in bulk density is common. The “compressed” density only occurs at the bottom of the storage, and not throughout. Use of the compressed bulk density will also result in a storage design that holds less than the expected tonnes. •R epose angle defines the total possible capacity, and also the base width and height. Repose angle
LEFT: Bin before hopper modification. RIGHT: Bin after hopper modification.
is variable, particularly for unprocessed materials. Design using a single angle can result in less capacity than expected. • Rill angle is always steeper than the repose angle. Gravity reclaim designs that ignore this can have significantly less live volume than expected from design. • Ratholing significantly reduces live volume; the rathole is still there when the stockpile is full. • Materials testing also defines storage reclaim outlet diameter or slot dimensions. The following phot of a woodchip bin clearly shows what happens when ignoring flow properties. Nothing flowed from this discharge into the pipe. Processing bulk materials, even if just size reduction, usually changes some of the flow properties. Use of the same densities and flow properties throughout the process can result in poor outcomes. Many mines have extensive resources and long operating lives. Ore bulk density and flow properties can change significantly as the resources are developed. In Australia, we are seeing these changes in both iron ore and bauxite mining operations. It is advisable to use current or predicted properties, and not historical or book properties. One project proposed a basis of design based on source book data. Material testing gave significantly lower densities, and poor flow properties. The proposed material handling design would have been a failure for many reasons.
Process consideration Most storage solutions are for balancing up and downstream flows. They have to operate in a nominal mid-range of the live capacity, the operating capacity. This allows for up and down stream process independence, and it is rare for the nominated live capacity to be available when needed. Designing a process assuming the live capacity is always available, will lead to disappointment.
For example, a crusher feeds a crushed ore surge stockpile before a plant. Rockbreaking may interrupt crushing for 15 minutes, and the plant draws down the crushed ore storage when this occurs. The plant operates best under steady state. There must be sufficient operating storage capacity to feed the plant until the crusher restarts. Usually, the crusher has overcapacity to refill the storage after rockbreaking. The plant may take 15 minutes to reset a trip. The crusher can continue operation until the storage is full. Crusher operates stop/start with no problem and plant restarts with a full storage. The stockpile size has total live capacity of 30 minutes nominal feed from the crusher, and operate normally at 60 per cent full. This allows for the either upset, but biased towards keeping the plant operating. The total live capacity is only available after a plant outage when the crusher continues to run. One study provided a “surge” storage bin having a total capacity of just 25 per cent of the feed rate (15 minutes), based on higher than average density, and assuming 100 per cent live capacity was always available for operation. These numbers justified the small size, which resulted in a capital cost saving to the project. When considered in detail, the nominal operating capacity was less than five minutes of plant feed, and irrelevant to process continuity. The design did not meet the key process parameters. The final design had a much larger stockpile based on realistic operating parameters. After a process plant, there is a storage for product prior to train loading. Trains arrive on a scheduled intermittent basis. Storage is sufficient to load a train or more, but also has sufficient capacity to allow the plant to continue operating between trains, and for some delays in scheduling. Functionality avoids delaying trains and maintains plant operation. These storages can be large and may operate relatively empty (20-30 per cent) normally,
Australian Bulk Handling Review: November/December 2018 | 39
BULK STORAGE
biased to continued plant operation, but with sufficient train loading reserve. One project design incorporated a very large bin for train storage. The live volume assumed the ultimate compressed density, with no recognition of other flow properties or train scheduling. When modelled using average density and flow properties (ratholing), the capacity was less than 10 per cent of that required to allow the process plant to operate continuously. The project changed to a larger ground stockpile, mechanically reclaimed to achieve almost 100 per cent live storage.
Design of gravity reclaimed storage Storage reclaim design in bins or gravityreclaimed stockpiles affects the live capacity: •S ize and shape of the storage, and the quantity and arrangement of outlets in the floor of a bin or stockpile, determine how the bulk material will flow and whether it will rathole or arch. Example: One large stockpile with poorly arranged and designed reclaim outlets had between three and five percent live capacity. A similar stockpile with wellarranged and designed reclaim outlets achieved 85 to 90 per cent live capacity. The second was more expensive to construct with much cheaper and easier operation; the second achieved the process feed requirement. Every aspect of a storage bin design has an impact on the material flow and live capacity. • Two large bauxite bins have conical single point discharges and no liners. Ratholing and arching at the outlet reduce capacity to about 15 per cent live and blockages result in regular manual intervention. Example: One bin had the cone replaced by a lined cone-slot transition into a long feeder outlet. Capacity in the modified bin increased to 90 per cent live, with the other bin being mothballed. Off-centre feed into storage, usually from poor consideration of trajectories, and off centre discharge, will reduce the live, and sometimes total, capacity. In bins, this can also give rise to structural issues from the resulting eccentric loads. • I have seen many designs where the feed conveyor RIGHT: Iron ore mine product storage before loading to train.
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discharge pulley centre line is on the storage centreline, resulting in eccentric bin loading and displaced stockpile position. • The configuration of the hopper interface between the discharge opening and a feeder or conveyor is also critical for achieving consistent and controllable reclaim rates and maximising live capacity. Poor configuration can result in erratic and low reclaim, reduced storage capacity, blockages, high wear and high power draw.
Flow regime and segregation Bin designs are funnel, mass or expanded flow. Gravity reclaim stockpiles are assumed expanded flow systems. These design bases assume cyclical filling and emptying the storage. This is often not the situation in an operating environment. The operating level in a bin or gravity reclaimed stockpile fluctuates around a nominal fill level as the up and downstream flows vary. This fluctuation results in a surface that is irregular rather than the cones shown in many design drawings. This level fluctuation can disrupt design flow regimes, particularly if part of the storage is static for some time and it compacts. Compaction may reduce live and operating capacity. Long-term storage in a dead area of the storage can change the chemical and physical properties of bulk materials. Regular draw down of the storage to almost empty can be considered, but fully emptying should be planned. Example: A large crushed ore bin was always run to empty, and was out of service every five weeks for re-lining and apron feeder repair. Changing the operating minimum bin level to two metres above empty extended life to nine months by protecting liners and feeder from regular direct impact. Bulk materials segregate when free discharged. Larger particles tend to rill to the outside of the storage, and finer particles are in the centre. Storage design should consider this effect if important to downstream process. For example, mechanical reclaim from a large
30% compaction density increase
Bulk Density (t/m3)
2800 2600 2400 2200 2000 1800 0
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Head (m) stockpile will load 100 tonne rail wagons with different size distributions, and funnel flow reclaim could result in size variation that can overwhelm a screen.
reduction. If this is not allowable, remnants will “sterilise” part of the stockpile until removed. Collected remnants need storage space until shipped out.
Number of materials stored - remnants
Blending and mixing
Large linear stockpiles are common in ports and rail loading. The total storage capacity reduces significantly for linear stockpiles holding different materials in discrete batches. A 1,000m long stack loses 30 per cent of total capacity if split into ten separate batches with a 10m gap. Remnants in the stockpile after reclaim can reduce effective storage capacity. If acceptable to stack over the top and combine, then there is no
True blending from storage on a ratio basis is quite feasible. Blending is different to the more usual practice of feeding and reclaiming storage to achieve a mix that will, to some extent, even out variability in the bulk material. The variability can be flow properties, mineral content or both. Blending or mixing needs impact size and complexity of storage. These should be in the design brief. ABOVE: Compaction of iron ore increases density (TUNRA report extract). LEFT: Poor design bin discharge – right outlet permanently blocked and 40 per cent capacity loss.
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FOOD AND POWDER HANDLING
Planting the seed for a thriving new industry
Since starting in 2016, a small idea has become a full scale production facility and Australian Primary Hemp is now one of the country’s largest producers of Australian grown hemp. The company’s Georgina Beasley speaks to ABHR. THE AUSTRALIAN PRIMARY HEMP JOURNEY began with four good mates, a passion for agriculture and an interest in developing a sustainable food source. Having all grown up together in the western district of Victoria, James Hood, Skye Patterson, Charlie Mann and Alexandra Mann, set out on a mission to find a sustainable, high protein source that could be grown and produced in Australia. After originally looking into crickets, they turned their focus towards hemp. At the time, hemp had not yet been legalised but with plenty of government lobbying happening and research showing it to be a promising new sustainable food source, they decided to found Australian Primary Hemp in August 2016. The legislation was changed in November last year, to recognise hemp as a food. “Since then, we have seen astronomical industry growth and also in our business,” said Ms Beasley. “I think this comes back to how versatile hemp is as a crop, it has over 25,000 different uses
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including being used to make healthy food products, clothing, plastic, paper, construction materials, biofuel and rope to name a few. “But most of all, people are excited about how sustainable hemp is and the positive impact it has on the environment. This has definitely influenced the success of the business,” she said. All of the original founders are still heavily involved in the company as directors. Skye Patterson is the company sales director and works in the Geelong facility with three other full time staff members and a handful of casual staff, who all come from farming backgrounds. Australian Primary Hemp offers customers a complete end-to-end hemp service, handling everything from seed selection, farming and processing to contract packaging, bulk and retail sales. “By controlling all points of contact we can guarantee the quality and freshness of our hemp products. It is incredibly important that we continue to support the local Australian community in
LEFT: All of Australian Primary Hemp’s products are made with one product only, 100 per cent Australian grown hemp.
everything we do,” said Ms Beasley. “For this reason, our products are made from Australian grown hemp seed only.” She said the collective agricultural experience of the founders has led to the company being at the forefront of the developing hemp industry in Australia, across areas such as health food products, hemp processing and an alternative, viable, sustainable farming solution.
From paddock to plate Australian Primary Hemp works with farmers around Australia to grow hemp as well as having its own farmer in the western district of Victoria. It is currently working with farmers in Victoria, New South Wales, Tasmania and South Australia. “We encourage all of our growers to farm sustainably where possible. Sustainable agriculture is the practice of growing food in a way that preserves and enhances the environment,” said Ms Beasley. “It provides good health for individuals and communities, economic opportunity and connects people to the land around them.” It is highly important to Australian Primary Hemp that it maintain freshness during transportation, as its products are heat and light sensitive. “Our packaging helps preserve the freshness and temperature of the hemp by having a foil lining on the inside of our packaging and a UV protection sleeve on our bottles,” said Ms Beasley. All freighted orders are transported with refrigeration. Any orders to Western Australia are express shipped, other domestic orders are always shipped early in the week on days that do not exceed 27 degrees. “Our team is always mindful of weather
conditions and don’t ship at the end of the week to avoid having the product sitting over the weekend,” said Ms Beasley. This year to date, Australian Primary Hemp has processed around 150 tonnes of Australian grown hemp to make its products. “With the high demand seen this year for Australian grown hemp, we are currently scaling our growing capacities dramatically for the 2018/2019 season, so Australian Primary Hemp can ensure a steady supply,” said Ms Beasley. Next year, the company aims to have close to 1,000 tonnes of hemp grain from its partner farmers to process.
The production process “Once we receive the hemp grain from the farm, it generally undergoes one of three processes before being distributed into either our retail or bulk sales lines,” said Ms Beasley. Before the hemp grain lands in the warehouse, the grain will be cleaned, dried and graded. Once it arrives in the Geelong-based facility, all grain is tested to ensure it is of processing quality. When it’s all cleared, the production processes begin. Process 1: De-hulling In order to produce Hemp Seeds, Australian Primary Hemp needs to de-hull the hemp grain. De-hulling is the process of separation, where machinery separates the hard outer shell (husk) of the hemp grain and the edible Hemp Seed (heart) inside. Any hemp grain that isn’t de-hulled is sent to be cold-pressed (Process 2).
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FOOD AND POWDER HANDLING
Process 2: Cold Pressing Australian Primary Hemp’s vibrant green Hemp Oil is produced when the hemp grain undergoes oil extraction through a cold pressing machine. What’s left over after extracting the hemp oil is what’s called ‘hemp cake’. This cake is nutrient rich and perfect for producing both protein and high fibre powders. While the oil is sent back to the ‘hemp-quarters’ to be packaged, the ‘hemp cake’ is sent on for further processing at a partner milling company (Process 3). Process 3: Milling The milling process uses different milling and sifting techniques to produce two different hemp powders. All products are then packaged in the Geelong-based facility, ready for dispatch. Australian Primary Hemp’s 680 square metre manufacturing facility is based in Newtown, Geelong and is where the day-to-day operations happen. Not only is it home to the company’s hemp specific de-huller, but it is also the location of its packaging and storage facility. The de-huller takes up roughly 100 square metres and is nearly three storeys high. This world-class machinery was the first of its kind and size to operate BELOW: Australian Primary Hemp’s Georgina Beasley.
What does Australian Primary Hemp make?
ABOVE: [clockwise] Hemp Seeds, Hemp Boost, Hemp Oil, Hemp Balance.
in Australia and can process up to three tonnes per hour at maxiumum capacity. The de-huller also includes separating sieves, aspirators and de-stoning equipment, along with a mix of chain conveyors, a bucket elevator, screw conveyors, and some gravity feeding and aspiration ducts. “Our de-huller is the core of our manufacturing plant, it really sets us aside from our competitors,” said Ms Beasley. “There is only a small handful of hemp manufacturing plants in Australia because the industry is so new.” In order to de-hull the seeds to a high quality, Australian Primary Hemp had to import specialised machinery that is not available here in Australia. “This is why our de-hulling plant is so important to us, as we have invested a lot of resources in importing and setting up a world class manufacturing facility that can produce high-quality hemp products to compete with those produced in Canada, Europe and Asia,” said Ms Beasley. Australian Primary Hemp’s packaging facility has been set up to package as many as 5,000 pouches per day, depending on the product, size and volume. “On a larger growth scale, the goal is to have an all-in-one facility where we can consolidate every aspect of all manufacturing process, including transport and distribution,” she said. “Hopefully, this will put us in good stead to break into the international market in a big way.”
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The company produces four core products; Hemp Seeds, Hemp Oil, Hemp Balance (natural protein and fibre, powder blend) and Hemp Boost (50 per cent protein powder), all of which are hypoallergenic, vegan, dairy free, GMO-free and do not contain any additives. All of Australian Primary Hemp’s products are made with one product only, 100 per cent Australan grown hemp. Its hulled Hemp Seeds contain 30 per cent protein, 10 per cent fibre and 42 per cent essential fatty acids, fuelling the body with the goodness it needs, all from one seed. They can be used in a number of different ways, in baking, raw treats, to make hemp milk, hemp tofu, dips such as hummus and pesto, sprinkled on salad, in smoothies and on cereal, it is incredibly versatile. The Hemp Oil is cold-pressed from the hemp seed and contains the perfect balance of the essential fatty acids omega 3, 6 and 9. Hemp Balance is a natural protein and fibre, powder blend, containing 30 per cent protein and 40 per cent fibre. Hemp Boost is a 50 per cent protein powder and contains the most magnesium out of all the products. This product is milled and sifted in different ways to achieve a higher protein content than the Hemp Balance.
Be featured in Australian Bulk Handling Review. Contact Luke Ronca for advertising opportunities luke.ronca@primecreative.com.au or 0402 718 081
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FOOD AND POWDER HANDLING
Using 3D level sensors to solve food storage challenges 3D scanners keep pushing the boundaries and addressing the concerns of increasingly complex food operations. Here, specialists from BinMaster outline some of the newest innovations. IN 2009, 3D SCANNER TECHNOLOGY STARTED a revolution in precise inventory management. Their evolution continues to address the unique needs of industry as the worlds of sensor hardware and software intersect with new solutions. 3DLevelScanners provide highly accurate level and volume measurement in challenging materials contained in bins, tanks, and silos. The only sensor to measure and map the material surface, it sends pulses in a 70-degree beam angle, taking multiple level measurements and accounting for uneven surface topography when calculating volume. Each sensor comes with 3DVision software that reports the lowest and highest points detected and the average level based upon a weighted average of all measurements in the bin. For the MV and the MVL models, a colourful graphical representation indicates where high and low spots exist in the silo.
“3D MultiVision software makes it easy to share real-time bin data across the entire organisation.”
Inventory management affects multiple departments across a food processing organisation. Plant personnel need adequate inventory for production, purchasing needs to know what to order and when, and finance needs accurate valuation for financial statements. To provide corporate-wide visibility, the optional 3D MultiVision software enables users to view data for multiple bins in a single window. And since it is
Windows-based, it can be configured for 24/7 access via an organisation’s Local Area Network (LAN). MultiVision software can be used with all versions of the non-contact, dust penetrating 3DLevelScanner including the RL, S, M, MV and MVL models. By clicking on a single bin, users can zoom in on detailed information for the bin including minimum, maximum, and average levels. For the MV and MVL models, they can also see the 3D visualisation of bin contents. The software allows multiple users at multiple locations to view bin level and volume data on a permissions basis. 3D MultiVision software makes it easy to share
ABOVE: This example shows how the user can view multiple silos on a single screen, getting an overview of inventory for their operation.
ABOVE: Upon selecting a single tank, the user can get specific details about minimum, maximum, and average volume and view the 3D visual.
View multiple silos on a single screen
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ABOVE: In this first example, it is evident from the 3D graphic that material is dispersed evenly and the cone is up. The average, minimum, and maximum levels are displayed along with the volume and mass. Also, volume as a percentage full and the maximum volume are displayed in the software. The acceptable zone for the centre of gravity is indicated in green and the centre of gravity of 0.05 along the bottom of the readings falls clearly in the acceptable zone.
ABOVE: Teflon-coasted transducers can reduce maintenance in handling powders and sticky granules.
real-time bin data across the entire organisation (or with vendors using VMI) to improve purchasing, logistics, operational decisions, and financial management. With user-friendly setup and intuitive operation, each user can customise their screen to view all bins or a group of bins and color-code bins by material type. Users can set high and low-level alerts to be notified when bins reach critical levels. Because the software is installed on the LAN, there are no third-party applications or data access fees.
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FOOD AND POWDER HANDLING
ABOVE: The second example indicates an alert status, displaying the vessel in red on the screen. The 3D visual indicates that as the vessel has been emptied, material has built up on one side of the vessel. The centre of gravity has fallen outside of the set parameters and is displayed in red as -1.03. A red centre of gravity alert is displayed at the top of the screen. Plant operations or maintenance can be alerted to aerate or clean the vessel before damage occurs.
Teflon-coated sensor for clingy materials For materials that want to cling to the sensor, a Teflon-coated transducer can be a great option. The Teflon coating resists buildup of dust, ensuring the scanner performs optimally in challenging materials such as powders or solids that generate excessive dust when the bin is filling or active. This special finish also extends the maintenance cycle by significantly reducing the need to clean the device after prolonged periods of use. Some common applications for the Tefloncoated transducer include meals, sugar, starches, brans, and other similar materials that are prone to cling to surfaces. It is especially appropriate for food processors in industries such as baking, pasta, and candy where non-contact technology is a requirement for food safety. Grain millers will also find measuring ground soybeans, wheat, rice, or corn less troublesome when using the Teflon-coated model of the 3DLevelScanner.
Detect and alert to centre of gravity danger Many powdered and solid substances used in food processing tend to clump, pile unevenly, and flow unpredictably from storage vessels. Not only does this make monitoring the volume of material inside the vessel challenging; uneven disbursement of material can also take its toll on the storage vessel itself. Over time, the walls of steel or concrete silos have
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been known to wear or fail causing cracking, denting, buckling, and bending. In the most severe cases, it can lead to catastrophic silo collapse. This has been seen in grain bins worldwide, where the walls of large storage vessels give way to the weight of grain that has built up on one side of the bin over time. For plant operations that want to detect uneven loading of silos that contributes to structural wear or failures, there is now a software option that uses 3DLevelScanners to identify the location of the centre of gravity, display it graphically, and alert when the centre of gravity falls outside of a predefined area. A 3DLevelScanner is mounted on the roof of the silo in an optimal location to view the material surface in the silo. Level measurements are used to determine the X, Y, and Z coordinates of the centre of gravity based upon the material topography. The coordinates are processed in 3DMultiVision software via a proprietary RS-485 communication protocol. Users define the alert parameters and accepted area into which the centre of gravity must fall. A 3D visual will indicate where the centre of gravity is located and show if the current centre of gravity falls in the acceptable area. Operations can use this unique solution to help reduce structural stress when loading or emptying a silo. It is a valuable preventive maintenance tool that can alert to the need for inspection or cleaning. Use over time can prolong silo integrity and create a safer environment by alerting to potential structural stress caused by uneven loading.
Measure volume in a wedge or pie-shaped silo Food processing operations routinely handle many ingredients, some of which can be stored in segmented silos. Tracking inventory by volume in these irregularly-shaped spaces can be tricky, especially for powders or granules that want to build up along the interior walls or the outer silo perimeter. Plant operations or purchasing personnel burdened with managing inventory in pie-shaped segments of silos now have a solution that provides very accurate volume data. The 3DLevelScanner measures and models the topography of material contained in these unusual pie-shaped wedges. This newest release of 3DVision software update then applies the measured distances to a 3D model of vessel dimensions and converts it to a highly accurate volume measurement. Other measurement sensors, such as non-contact radar, guided wave radar, or weight-and-cable style sensors measure only a single distance in these formidably-shaped segments. The location of the
LEFT: This illustration shows material piled unevenly in a silo segment and how the 3DLevelScanner measures multiple distances across the material surface to account for irregularities when calculating volume.
ABOVE: In this screen image, the topography of material is displayed and used to detect level per section.
filling or emptying points or lack of material flow may cause uneven piling of material, which could cause inventory estimates based upon a single measurement to be inaccurate. By comparison, the 3DLevelScanner maps the material surface accounting for variations or buildup then factors in the radius and height of the segment being measured, making the volume accuracy very precise. Using a system that provides accurate data about the amount and dollar value of material on hand can help reduce safety stocks, increase inventory turns, and pay for itself by freeing up cash that could be tied up in inventory. This can be especially true for high-dollar ingredients being used in many contemporary food products. Additionally, buildup on the outer perimeter of the silo segment or along on the interior walls of each segment can be detected, accounted for in inventory, and addressed by maintenance if needed. The same 3DLevel Scanner can be used for either segmented or round silos, making it a versatile choice over its long sensor life.
ABOVE: Several 3DLevelScanners are strategically mounted on the roof with each scanner measuring multiple points in a 70-degree beam angle.
Level monitoring in flat storage warehouses With grain production worldwide reaching record levels, there is a shortage of grain storage as valuable commodities await further processing. An intermediate step to protect grain is the use of large covered storage buildings where grain is piled using overhead conveyors or vehicles. However, due to irregular piling, it is extremely difficult to estimate the amount of grain in these temporary warehouses. Another revolutionary advancement not offered with any other inventory management system is a new software option that can measure the level of materials piled under structures. Multiple sensors measure and map levels across the material surface, while MultiVision software separates the piled material into virtual sections. Minimum, maximum, and average levels per section are reported for up to 99 unique sections. The data is aggregated to output a visual showing the topography of the entire storage building. This first-of-its-kind solution is used to estimate inventory and improve production efficiency. Identifying high and low sections allows for automating process control and managing the filling or extraction of materials. In proven installations, up to 20 x 3DLevelScanners have been mounted in the upper structure of the warehouse roof. The building is virtually divided into sections as small as 1.5 by 1.5 metres with 3D sensors continuously measuring changes across the surface and providing unique visual and data reporting of inventory in the massive structure. This cuttingedge technology is ideal for corn or other grains stored in covered warehouses. For more information visit: www.binmaster.com
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FOOD AND POWDER HANDLING
Advanced valve bag technology for flour packing Kirsten Meyer from HAVER & BOECKER Australia explains how advanced valve bag packing technology can deliver a competitive edge. PACKAGING FLOURY PRODUCTS WITH A large variety of grain sizes can be challenging for the milling industry. Australian mills and food manufacturers must adhere to strict regulations concerning dust emissions and food safety, yet remain competitive in a tough market. A market-leading valve bag packing system not only meets but also exceeds quality, hygiene, operator safety, maintenance, productivity and waste reduction standards. The key to engineering a revolutionary solution is to form close collaborations with the manufacturers themselves during the development process. The next-gen valve bag packing systems are fully automatic and flexible with the ability to pack into valve bags from 5kg to 50kg. The machine encloses the automatic valve-bag applicator, filling system, valve sealing unit, control system, operating unit and discharge belt inside one dust-tight cabinet. It can be equipped with one to four filling spouts and can fill up to 900 bags per hour. Dust and noise emissions are reduced considerably, improving health and safety standards for operational personnel. Plus, the machine’s design guarantees cleanliness during the entire filling process, automatically reducing maintenance costs. Cost and time-intensive assembly works onsite are avoided as all components can transported as one unit. This feature is particularly important when the packaging system has
to be integrated into existing industrial processes. Overall the transport and assembly of the turnkey unit is quick and safe, and only needs to be connected to the product and energy supply line.
Filling technology Depending on the product’s characteristics, bags can be filled with either the air or the impeller filling system. Special consideration is also given to the bag design and particularly its de-aeration capability. The pneumatic or air filling technology is highly suitable for the milling industry’s various bulk products and stringent requirements. The product enters the filling chamber via a pneumatically controlled butterfly valve. The continuous product flow from the filling chamber is ensured by the design of the integrated chamber bottom and top fluidisation air system, which provides an optimal product feed rate with a minimal air supply. During the filling, air is removed from the bag with the help of a filling nozzle with de-aeration channel and a cyclically operating ejector.
Sealing technology While sealing technology is now a standard feature in packaging plants across the world, innovative technology is taking it to the next level, delivering a quieter, cleaner and more profitable operation. The bag’s external valve is sealed directly after the filling process by ultrasound. A generator produces high-frequency vibrations and transfers LEFT: The BEHN+BATES INTEGRA FD for automatic valve bag filling.
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Applicator technology
them to the sonotrode that is made of massive titanium. Due to the vibrations, the plastic lamination of the bag valve is melted and welded in about 0.5 seconds. This unique development guarantees the seal even if the surface of the inlet bag valve is unclean. A compact unit design ensures noise produced by the ultrasound sealing process can be reduced effectively. Thanks to the valve bag sealing, the cleanliness of the filling installation is improved and with a cost-intensive spillage return system no longer necessary, the cost savings are considerable. Products are completely safe without any possibility of contamination. They are more easily opened and emptied saving time and potential contamination from strings.
A space-saving vertical bag magazine that is integrated in the cabinet ensures the empty bag feed. For higher storage capacities, a horizontal empty bag magazine that can hold 800 bags and more can be provided. The empty bags are singled from the empty bag magazine and the bag valve is opened. A mandrel is inserted into the valve. It spreads the valve and ensures an optimal forming for the subsequent bag application. The optimally prepared valve bag is applied in a linear motion onto the filling spout. A central aligning station ensures all bags are correctly applied onto the filling spout even if the tolerances between the bag valve and the filling tube are minimal. The integrated feeler on the filling spout recognises whether the empty bag is correctly applied, ensuring it only starts to fill when the bag is correctly positioned on the filling spout. By looking beyond conventional inline valve bag filling systems to the latest innovations being developed to solve the industry’s specific business challenges, milling manufacturers have peace of mind when it comes to the quality and safety of their products, and can enjoy greater operational efficiencies and improved bottom lines.
LEFT: The INTEGRA valve bag system is suited for filling loose, bulk materials from cement to building products, minerals, chemicals and food.
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FOOD AND POWDER HANDLING
Understanding the needs of industry Two specialists from HAVER & BOECKER speak with ABHR about current and future trends in the food and powder handling markets in Australia, namely Kirsten Meyer (after sales and service manager) and sales manager Martin Mersmann. HAVER & BOECKER Australia is a developer and manufacturer of processing and packing technology for minerals, chemicals, building materials and, via its BEHN + BATES brand, for the food industries. Its packing machines have been well received for packing baking ingredients such as flours and sugars. The company is similarly well positioned in the cement market, with around 60 per cent of the world’s supply being dispatched in bags packed using HAVER & BOECKER machines. Earlier this year the company released its ROTO-Packer technology for the cement industry. “We’ve had a good response in both Australia and New Zealand, recently installing two new ROTO-Packer packing lines with palletising and stretch hood equipment for cement producers,” said Mr Mersmann. “We commissioned a ROTO-Packer RVT with 14 filling modules, which can reach a capacity of up to 5,000 bags per hour.” Another recently installed machine can reach up to 1,500 bags per hour, out of four filling modules mounted on a body of a six spout machine. This gives the cement producer the option to extend the packer by two additional filling modules in the future. “Plus, our new cement packer comes with the unique spillage free and low maintenance dosing-unit ROTO-Lock, which can be retrofitted to most old packers, another highly sought after feature requested from buyers,” said Mr Mersmann. He said there is a trend towards ultrasonic sealed bags, which are already the standard in many other countries, to ensure a bag’s cleanliness and extend shelf life of the product. “Our SEAL system reduces spillage by inflating a rubber sleeve on a specially designed filling spout during the filling process. “After filling, the bag is carefully pulled off the spout and welded by using an ultrasound sealing device,” said Mr Mersmann. Spillage during transport is avoided, product contamination is prevented and weight accuracy increases without the need for overfilling the bag. In regard to the food and animal feed sector, Ms Meyer says it’s and exciting time for HAVER & BOECKER. “We have some great opportunities on the horizon. One area of growth we see for us is in hygienic filling. “We developed a revolutionary technology which fills tight PE bags, and which is also available with bags that have a
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strippable outer layer. As regulations tighten, this technology is taking hygiene standards to the next level and can provide customers with greater peace of mind,” said Ms Meyer. Another opportunity this innovation offers is safer machine execution, which involves minimising moving parts above the product to ensure nothing can fall into the bag or product, and that all the rubber parts of the machine are food safe. “We’re also well placed to assist manufacturers in meeting the increasing demand for exporting bagged milk powder and lupin or pulses to Asian markets,” she said. “We’re seeing an increasing industry trend to increase production rates and drive cost savings across production lines. “We’re meeting this demand with our high performance solutions which minimise downtime, and increase safety and hygiene to not only improve packing rates but to also increase the product’s shelf life, prevent pest contamination and reduce the amount of packaging material required to fill products,” said Ms Meyer. HAVER & BOECKER Australia has some new and innovative products in the pipeline, such as the BEHN + BATES Care-Line machine designed to meet the high hygienic filling standards of certain foods such as milk powder. “As mentioned before, BEHN + BATES follows the machine safe execution and we’re continuing to use ultrasonic sealing technology for valve bags to ensure extra-tight packaging to prevent product spillage and pest contamination,” said Ms Meyer. LEFT: Kirsten Meyer, after sales and service manager at HAVER & BOECKER Australia.
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FOOD AND POWDER HANDLING
Flexicon: drawing on a global wealth of experience Being the world’s largest manufacturer of its kind enables Flexicon to undertake the largest and most challenging bulk handling projects. Paula Wallace spoke to the company’s director of sales for Australia and South East Asia, Simon Hall. FLEXICON HAS PRODUCED EQUIPMENT and systems for more than 22,000 bulk equipment installations involving hundreds of bulk materials across all industries in which bulk materials are utilised. Every Flexicon engineer worldwide can reference these proven designs or can readily engineer new designs that deliver top efficiency. Simon Hall says this is one of the reasons why Flexicon is called upon to undertake some of the most challenging bulk handling projects. Another reason is that the company manufactures on four continents—North America, Europe, Australia and Africa—and can satisfy the needs of multinational corporations requiring standardisation, while meeting each county’s individual safety, electrical and cleanliness requirements. “Flexicon maintains a separate, fully-staffed Project Engineering Division specialising in the management of large-scale bulk handling projects,” said Mr Hall. This division offers dedicated Project Managers for a single point-of-contact; engineering teams specialising in large scale automated systems; and complete responsibility for the system overall, including new or existing upstream and downstream equipment of others. Flexicon has an enviable range of standard equipment, which all began following critical analysis by company engineers of the equipment on the market.
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“Flexicon engineers study the weak points of competitive designs, set specific performance and cost goals, and completely rethink traditional approaches,” said Mr Hall. “Our Research and Development Group focuses exclusively on the continual evolution of our product line, which enables them to gather information from many sources, both from within Flexicon as well as from our customer base as they work toward continually improving the value that we offer.” Today, Flexicon holds 36 patents around the globe, providing customers with equipment qualities not available elsewhere. Flexicon also offers customised solutions to customers. For example, Qube Bulk in West Perth worked with Flexicon to devise a bulk bag filling solution to productively and safely fill bulk bags with three abrasive mineral sands for a mining firm. As part of this solution, a skid-mounted mobile bulk bag filling station fills up to 80 bulk bags, or 160,000 kg, per eight hour shift — automatically, accurately and dust-free. For Qube, productivity is key for filling and loading bulk bags into shipping containers and transporting them to port on schedule. The 3.4 m high unit includes a 2.5 cu m capacity hopper, a 3 m long rigid tube screw conveyor, and a 2.8 m long offload roller conveyor. Another example comes from south-eastern Spain. There, Prosur manufactures powdered extracts from fruit and spices using seven Flexicon bulk bag dischargers, doubling productivity from 35 to 70 tonnes per day, in a factory expansion project. The company previously processed orders by transporting the powders by pallet truck and feeding the powders into the packaging machines. Today, on the top floor of the new factory, seven half-frame bulk bag dischargers feed 70 tonnes per day to the packaging machines on the floor below. At Once Again Nut Butter in the US, two Flexicon bulk bag dischargers and five Flexicon flexible screw conveyors doubled peanut butter production at the company’s newly dedicated peanut butter facility. The new line operates dust-free and improves operator safety. The company’s older facility for all nut and seed products now can operate peanut-free.
ABOVE: Simon Hall, director of sales – Australia, South East Asia, Flexicon.
“Flexicon engineers… completely rethink traditional approaches.”
FAR LEFT: Flexicon test laboratory for Flexible Screw Conveying Systems and upstream/ downstream bulk handling equipment.
In Australia, bulk solid handling opportunities cut across the same major industries (general industrial, chemical, food, packaging, etc.) as elsewhere, but the mining sector is a special case representing more than $245 billion in exports earnings and 600+ publicly traded companies. Needless to say, Flexicon’s mining business remains strong in Australia, but food and beverage processing applications have also taken off. “Food processors in particular are specifying custom engineered, integrated systems with fully automated controls to boost output and quality while minimising operator involvement,” said Mr Hall. “Even though Flexicon products are used across many different industries, a good number of our customers have similar needs and concerns as they encounter material handling challenges. “Although we tend to not release information on our specific research and development efforts, features that improve dust control, facilitate cleaning and improve safety are at the forefront of our efforts,” he said. Flexicon’s worldwide testing facilities simulate full-size customer equipment and systems, verify performance prior to fabrication, demonstrate newly constructed equipment for visiting customers, and
study the performance of new designs. “Customers are welcome to observe their test in person or by video before the equipment is built and/ or before it is shipped, ensuring it will perform as specified once installed,” said Mr Hall. For more information visit: www.flexicon.com
info@bbcp.com.au (02) 9618 9400 www.bbcp.com.au
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LEFT: Qube Bulk in West Perth worked with Flexicon to devise a bulk bag filling solution to productively and safely fill bulk bags with three abrasive mineral sands.
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FOOD AND POWDER HANDLING
New twin flexible screw conveyor from Flexicon New from Flexicon is a Twin BEV-CON™ Flexible Screw Conveyor system with a common hopper and mobile base constructed and finished to sanitary standards. LEFT: Twin BEV-CON™ Flexible Screw Conveyor system with common hopper and mobile base transfers difficult-toconvey materials and blends at multiple plant locations, and can be rolled to a wash-down station for sanitising.
READY TO PLUG-IN AND RUN, THE SELFcontained system can fill two vessels with the same material simultaneously. Mounted on a frame with locking castors for in-plant mobility, it can be utilised in multiple locations, and rolled to a wash-down booth. The hopper is equipped with dual discharge adapters, each of which charges a BEV-CON flexible screw engineered to move free- and non-free-flowing bulk materials that pack, cake, smear, fluidise, compress, or are otherwise problematic to convey. As material is conveyed, rotation of the screws causes them to self-centre in the polymer conveyor tubes, eliminating or minimising contact with the tube wall, preserving material integrity. The rolling action of material also prevents the separation of blended products comprised of disparate sizes, shapes and bulk densities. The screws are the only moving parts contacting material, and are driven beyond the point at which material is discharged, eliminating wear and contamination related to product contacting seals and bearings. Discharge housings of the conveyors, supported by dual booms cantilevered from the mobile base, allow discharge of material into processing equipment or
56 І Australian Bulk Handling Review: November/December 2018
storage vessels up to 3.5m above the plant floor. The hopper has a capacity of 550 litres, and is designed with a steep back wall and diametrically opposed side walls skewed to form a trapezoidal area, the divergent angles causing non-free-flowing material to topple into the conveyor charging adapters. The unit is constructed of 316 stainless steel, and features sanitary quick-release clean out caps, quick-disconnect discharge box access covers, wash-down motors, and a stainless control panel with stainless conduit and liquid-tight compression fittings that permit wash down during changeovers and/or when conveying of corrosive materials. HMI controls allow manual and automatic start/stop and speed adjustment. Flexicon also manufacture other types and sizes of flexible screw conveyors as well as tubular cable conveyors, pneumatic conveying systems, bulk bag dischargers, bulk bag conditioners, bulk bag fillers, bag dump stations, drum/box/container tippers, drum fillers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls. For more information visit: www.flexicon.com
PORT OPERATIONS
Preventing port crane failure through rope monitoring Greater awareness of condition monitoring of wire ropes using magnetic head technology is required to avoid the risk of catastrophic port crane failure. IN MAY LAST YEAR, A PORT SIDE CRANE IN Falmouth Docks failed without any warning leading to its jib crashing down to earth. Fortunately no significant injuries were incurred in the incident. While to date, no official cause has been published, the immediate prohibition notice described a failure to ensure that lifting equipment was maintained in an efficient working order. As this example highlights, the need for regular maintenance and inspection of lifting equipment at ports is critical says Denis Hogan, performance and special projects manager at the Lifting Equipment Engineers Association (LEEA). “Regular inspection on the structure of a port crane, its sheaves, the jib and the slew mechanism are just some of the areas of focus for maintenance programs carried out by port operators,” said Mr Hogan. “But wire ropes should also be a key part of the program, yet too often this element is overlooked.” There are around 80 members of LEEA in Australia and New Zealand; and Ashley Thacker from Ranger is the Australian director of the association. “Magnetic Rope Testing (MRT) is a great method to inspect and maintain ropes but it needs to be coupled with the visual examination and experience of the inspector,” he told ABHR. “As the data needs to be interpreted and the inspector needs to understand the working conditions and ancillary components it works with to understand how the rope will work in the intended operation.” Mr Thacker believes more industries will adopt MRT now that IS04309 has now been updated – and includes MRT as the preferred method of inspection – and the new document from International Marine Contractors Association has extensively stated MRT as the only true method to inspect wire rope. “This should be at least a 12 month minimum inspection with quarterly visual examinations.” This allows operators to predict the point
where the wire rope actually needs to be changed allowing planned preventive maintenance, leading to maximising uptime. MRT technology for the non-destructive examination of wire rope has been around since the mid-1950s. It involves running a wire rope through a magnetic head that allows an inspection right into the centre of the rope, giving clear visibility of any broken wires, voids and corrosion. “The MRT service has been offered in Australia for the last 20 years but mainly within the mining sector and the technology was quite basic when the first machines we made and pricing was exorbitant,” said Mr Thacker. “These days as the technology has advanced and machine prices have come down slightly it has opened this service up to other markets.” Ranger has just completed some extensive training and purchased its first machine with the aim of offering reasonably priced services. “Especially the multistrand rotation resistant ropes where they literally wear from the inside out making inspection near impossible,” said Mr Thacker. The benefit of MRT is that when the rope gets to the point of rejection criteria, managers can plan in the change without fear of rope failure, maximising uptime in busy ports. LEEA says when it comes to the provision of lifting equipment maintenance and repair services it is always prudent for ports to seek out the ‘gold standard’. In addition to offering expertise on MRT and condition monitoring of wire ropes, “LEEA members are structured to provide specialised repair and maintenance as well as the inspection function, as separate parts of a one stop shop,” said Mr Hogan. This allows ports to further mitigate risk of crane failure and to improve the management of their lifting equipment uptime, allowing them to handle growing volumes safely.
ABOVE: Denis Hogan, performance and special projects manager at LEEA.
Australian Bulk Handling Review: November/December 2018 І 57
FOOD AND POWDER HANDLING
Improved design for diverter handling abrasives After installing a diverter valve, Vortex Global Limited was called upon later to make design revisions and modifications in order to supply the end user with a more robust piece of equipment that could perform in a particularly harsh environment. Durability issues
IN MARCH 2015, A FABRICATION COMPANY RIGHT: CLOCKWISE Figure 1: The materials handled are heavy-duty, abrasive raw material lumps. Figure 2: Replaceable rubber “wiper” seal atop each of the recessed areas. Figure 3: Materials had created significant holes in the diverter body after eight months of operation. Figure 4: Ceramictiled steel plate fabricated and bolted into the diverter body to serve as a replaceable abrasion-resistant liner.
contacted Vortex Global Limited with a client’s process need. The project was for an international building and construction materials group. The end user sought a solution for diverting cement, clinker, limestone and dried slag from a conveyor into three chutes, to be routed toward various silos. In response, Vortex supplied a Seal Tite Diverter. The main features of the valve were its threeway diverting design and “A-style” flapper blades to address blade shaft wear and prevent material “ski jumping” against the outlet chutes. The blades actuate into recessed areas (Figure 2) to address abrasion to the blade from the material flow stream. The Seal Tite Diverter had inlet and outlets size of 450mm (square); the centre outlet chute was a straightthrough channel; outermost chutes were offset 45 degrees from centre; and the body, blade and materials contact areas were constructed from 400 Brinell hardness number (BHN) abrasion-resistant steel.
58 І Australian Bulk Handling Review: November/December 2018
After four months of operation, the end user’s maintenance team identified a few durability concerns. Most notably, material packing between the diverter body and the leading edge of the flapper blades caused actuation issues. The materials being handled were heavy-duty, abrasive raw material lumps. Because of these characteristics, holes were worn into the diverter body. This promoted material leakage, which resulted in product loss and hazardous emissions into the plant atmosphere. Also because of the abrasiveness of handled materials, wear between the seals and material contact areas promoted material migration past the flapper blades and into the closed outlet chutes. This created concerns for contamination. The end user’s maintenance team made several modifications to address concerns they found in the field as outlined below. A replaceable rubber “wiper” seal atop each of the recessed areas (Figure 2). When either blade is in the vertical position, the wiper seal clears materials away from the leading edge of the blade and forces their discharge into the process line below. Doing so prevents material packing between the diverter body and the blades.
The maintenance technicians found that as the mechanical conveyor above fed materials into the diverter, the flow stream repeatedly impacted upon a particular material contact area near the blade shaft. This created significant holes in the diverter body after eight months of operation (Figure 3). To address this issue, a ceramic-tiled steel plate was fabricated and bolted into the diverter body to serve as a replaceable abrasion-resistant liner (Figure 4). The Vortex Seal Tite Diverter features a removable access panel at the front of the valve; but because the abrasion-resistant liner was necessary at the back of the valve, the end
user desired a second interior access panel – which they could not achieve themselves. So that the flapper blades could actuate against the added thickness of the ceramic liner, the end user also fabricated new flapper blades with adjusted tolerances. The revised tolerances created new opportunity for material leakage and contamination to the closed outlet chutes. A rubber compound was used to provide the best possible seal across the blades, under these modifications. Beyond the flapper blades, wear similar to that aforementioned was observed in all three outlet chutes after three months of operation. In an attempt to address this issue, ceramic tiles were adhered to the side walls and the bottom face of the chutes (Figure 5). However, the material impact was too great for the ceramic tiles to defend. Significant holes in the outlet chutes were observed after 12 months of operation (Figure 6). As a maintenance requirement to prevent materials from conveying beyond the outlet chutes during upset condition or downstream maintenance, threaded sockets were attached at each of the three outlet chutes to accommodate the insertion of two steel bars. Once the steel bars are secured, a metal plate is
FAR LEFT: Figure 5: Ceramic tiles were adhered to the side walls and the bottom face of the chutes. LEFT: Figure 6: Significant holes in the outlet chutes were observed after 12 months of operation.
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Australian Bulk Handling Review: November/December 2018 І 59
FOOD AND POWDER HANDLING
inserted to cover over the outlet chute (Figure 7). Though these modifications added to the diverter’s overall durability – still, the end user desired greater reliability, prolonged lifecycle, and reduced maintenance cost.
Collaborative design In June 2018, the end user’s maintenance team contacted Vortex to report its field study findings. With that, Vortex collaborated with the end user to learn more about its findings and the application at
hand. Then, Vortex worked alongside its in-house team of engineers to make design revisions and further modifications, in order to supply the end user with a new, more robust diverter valve. Revisions to the design included: •A replaceable rubber “wiper” seal atop each of the recessed areas, in order to clear materials away from the leading edge of the flapper blades (as identified by the end user). • ( Figure 8): Replaceable abrasion-resistant liners throughout (thickness: 10mm). Liners throughout the diverter’s central housing constructed from Blanchard-ground chromium carbide. Liners throughout the diverter’s inlet/outlet chutes constructed from 400 BHN abrasion-resistant steel (for added durability, as desired by the end user). • ( Figure 9): Designed with a second removable access panel, for easy interior access at the front and back of the valve (as requested by the end user). •O utlet covers to prevent material leakage during maintenance (as identified by the end user). The new, more robust diverter valve was supplied in August 2018. “This was a great example of two engineering groups working together to come up with a solution,” explained Laurence Millington, managing director at Vortex Global Limited. “Our internal staff and the engineering groups consulted each other over a period of time to work through the issues with the original diverter. “From those findings, Vortex developed a truly engineered solution for this very tricky application. This field study shows great teamwork and the importance of listening to end user needs, so that their process requirements are truly met for the long-term,” he said. “In short: ‘If at first you don’t succeed, continue trying and follow through with the client.’” This open line of communication has led to many design improvements and new product developments – and allows Vortex’s client-focused design philosophy to take shape.
For more information visit: www.vortexglobal.com
60 І Australian Bulk Handling Review: November/December 2018
LEFT: Figure 7: Once the steel bars are secured, a metal plate is inserted to cover over the outlet chute. BOTTOM LEFT: Figure 8: Replaceable abrasion-resistant liners throughout (thickness: 10mm).
BELOW: Figure 9: Designed with a second removable access panel, for easy interior access at the front and back of the valve; and outlet covers to prevent material leakage during maintenance.
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Australian Bulk Handling Review: January/February 2019 І 63
MINING INNOVATION
Meet Escondida’s giant robotic arm Head of commercial innovation for Minerals Americas at BHP, Susan Lasecki, writes about an example of open innovation which has a dramatic impact on safety and productivity at the company’s copper operations in Chile. OUR GLOBAL OPERATIONS NEED BILLIONS OF dollars of goods and services every year to support the extraction of products for our customers – safely, productively and sustainably. When our supply teams buy these good and services they create partnerships with global suppliers and local businesses in our communities. And these partnerships extend way beyond the standard buyer/seller relationship. One of the greatest contributions we bring to the places where we operate is to engage our suppliers in helping solve our challenges, stimulating innovation and growing businesses to create shared value for local economies. Take for example changing screens in our trommels. Trommels are used in the processing of the minerals we mine to sort them into different sizes. It is an important part of the process of grading the minerals. Trommel screens have to be heavy and robust to sort tonnes and tonnes of this raw mineral. Replacing them at the end of their life was difficult, sometimes dangerous and time consuming work – until now. The Trommel Maintenance Robot has completely transformed the way we complete this task at our Escondida mine in Chile. It’s just one of the unique technology solutions delivered through our Supply Innovation program. Developed collaboratively by FLSmidth and local Chilean supplier MIRS, the robotic arm has benefits for safety and productivity. Workers are removed from potentially hazardous situations when changing the trommel screens and it also reduces the time to change each screen. BHP’s Supply Innovation program develops operational solutions to productivity, safety, health
62 І Australian Bulk Handling Review: November/December 2018
and environmental challenges with suppliers. It brings us together with local suppliers in the search for unique bottom up transformation. However, the lessons learned through this project, like so many others in the Supply Innovation Program, are much broader. It reveals the enormous opportunity to improve our performance and deliver greater value by drawing in others to the quest for increased competitiveness.
Diversity of thought drives better value Large companies like ours don’t necessarily have all the answers to the challenges of our production processes. We understand our operations and processes but when it came to finding a technical solution for our trommel maintenance we needed to look to outside of our business. Working with
ABOVE: BHP’s Escondida mine in Northern Chile. Image: BHP. BELOW: The Trommel Maintenance Robot has completely transformed the way BHP changes screens in its trommels. Image: BHP.
collaborative suppliers meant we got some of the best minds to share their expertise. Over the past 20 years, the technological innovation ecosystem in Chile has evolved to integrate universities, research and development centres, highly qualified and motivated local entrepreneurs, government and funding. The links between participants in this ecosystem have attracted increasingly diverse players, amplifying the opportunity for continuous improvement and value creation. This would not have been possible by BHP operating alone in Chile.
Engagement with suppliers creates shared value One of the greatest contributions we can bring to places where we operate is to enable local suppliers to benefit from the knowledge and globalised approach we have access to. Programs such as Supply Innovation engages our suppliers in our challenges, opening up global development and learning opportunities for them and creating shared value for local economies. The technological and operational challenges of mining companies fuel the ecosystem and provide compelling opportunities for local suppliers and economies. When companies like ours open the door to these innovation ecosystems, it stimulates development that address the needs of companies in our industry around the world.
We see the Supply Innovation Program as a way to use our business challenges as a platform to spark innovation and create shared value for BHP and the communities and countries where we operate. At the same time we aim to create a base of knowledge and social capital for the future of Chile and the world. We believe Chile is capable of transforming its geological capital into knowledge capital. We want to support this and contribute to building an ecosystem of innovation that will enable countries to thrive through mining and start to build a future for when mining is no longer there.
FACT FILE: Escondida (Chile) BHP owns 57.5% of, and operates, the Escondida mine which is a leading producer of copper. Escondida, located in the Atacama Desert in northern Chile, is a copper porphyry deposit that also produces gold and silver. Its two opencut pits currently feed two concentrator plants which use grinding and flotation technologies to produce copper concentrate, as well as two leaching operations (oxide and sulphide).
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Broadened thinking contributes value globally The Trommel Maintenance Robot project also demonstrates that local suppliers can produce world-class technology solutions. This not only has application in mining operations throughout the world; it may also help to address challenges in other industries. Projects like this are neither accidents nor isolated cases. They are the fruit of systematic work initiated by us in Chile more than a decade ago. We have evolved and extended this program into a partnership with Codelco, Antofagasta Minerals and the Chilean government. We use an open platform known as Expande to connect unique mining challenges with suppliers, mining companies, government agencies, universities and sources of funding. Continued success demands a consistent and long-term view. By continuing to more closely unite and align all of the parts to support entrepreneurs, we are increasingly growing an ecosystem in Chile of innovation, collaboration and economic development. This has helped fuel economic growth in Chile while also supporting development of companies as exporters of goods and services linked to the mining sector.
MINERAL SANDS
CEMENT TECHNOLOGIES PTY LTD
10 Peekarra Street, Regency Park SA 5010, Australia Phone: +61 8 8118 6466 Email: sales@flowforce.com.au www.flowforce.com.au
Australian Bulk Handling Review: November/December 2018 І 63
MINING INNOVATION
Unearthing value from under our feet BHP’s chief financial officer, Peter Beaven, writes how developing the company’s ‘latent capacity’ is paying off. OUR LATENT CAPACITY PROJECTS ARE ABOUT unlocking untapped production with minimum risk, which is why they tend to compete so well in BHP’s fight for funding. Our Caval Ridge Southern Circuit in Queensland’s Bowen Basin is a great example of one of these projects on the ground. ‘Latent capacity’ has become part of BHP’s vernacular for good reason. In a nutshell, it refers to all the production not yet realised within our existing operations. While this might not sound like a big deal, latent capacity projects are important because they often provide a simple way to increase production at lower capital cost than larger development projects. They also come with a reduced risk profile, and anything we can do to reduce risk is worth its weight in gold...or copper, or coal, or iron ore. These initiatives often piggy-back off the larger, growth investments we’ve made in the past which increases our certainty around: What is there; How to get to it; What it will cost and; When we can do it. The Caval Ridge Southern Circuit (CRSC) project in Central Queensland’s Bowen Basin is a good example of a latent capacity project that is starting to take shape. The project links the Peak Downs mine to the Coal Handling Preparation Plant (CHPP) at the nearby Caval Ridge mine and in doing so, takes advantage of unused capacity. Rod Walsh, who leads the commissioning activities for this project thinks it makes perfect sense because of the way the plant was set-up in the first place. “The coal handling plant was built with the latest technology so it runs really efficiently. We just needed a smart way to feed it more coal. “When we looked at options there was nowhere else we could get that much extra production for such a low capital outlay,” he said. “The solution was pretty straight forward – to build a new conveyor to tie in to the plant, with the right sized fleet and stockpile yards to service it. “The beauty is, we’re doing all this without taking any big risks as we’ve been able to draw on existing knowledge around coal and other BHP assets in designing the conveyor system and then building it.
64 І Australian Bulk Handling Review: November/December 2018
“The level of detailed planning we did early on, and the great interaction between site resources and the project team, means that things are running smoothly and safely.” To secure the investment funding required, the team needed to pit it against other projects at BHP, through what we call the Capital Allocation Framework (CAF). The CAF considers the risk and return of a wide variety of initiatives, including returns to shareholders, to guide our decisions in the future. This might conjure up an image of thousands of lines of data running through a super computer and spitting out the perfect answer. But really, it is about helping us understand trade-offs between risk and return, so we get the most out of every dollar we earn, and maximise shareholder value. In this prize-fight, latent capacity options are often the heavy weight contender. Over the last two years we have progressed five of these options and our businesses have benefited from the cash flow they have delivered. From Western Australia Iron Ore, to Escondida, to Queensland Coal these projects set us up for a bright future. As competition for capital becomes increasingly fierce, only the most attractive options will be considered for funding. As the chief financial officer, I like this competitive tension because it is good for BHP and it is good for our shareholders. I look forward to seeing what our teams around the world can do next to strengthen our project pipeline and raise the bar even higher in the future.
ABOVE: ‘Latent capacity’ projects provide a simple way to increase production at lower capital cost than larger development projects. Image: BHP
DATA ANALYSIS
Data analysis has a new name REMA TIP TOP has been revolutionising asset management through data and emerging technologies with its asset management approach. Now REMAlytik takes that a step further. COLLECTING DATA ON ASSET PERFORMANCE is one thing; being able to implement data-driven improvements that reduce maintenance costs and improve conveyor system availability is another altogether. That is what REMA TIP TOP does with CARMA. Now, with greater investment in technology and innovation it is launching REMAlytik, a platform that will provide its customers with live asset and maintenance performance data. CARMA is REMA TIP TOP’s Complete Asset Reliability Management Approach that underpins the way the business partners with its customers. Since 2015, the CARMA approach has been implemented at 25 operations and delivered more than 200 improvement cases that save mine operators an estimated $10 million each year. REMAlytik is a next generation analytical tool that strengthens CARMA. Asset performance data is captured through inspections and condition monitoring, while maintenance expenditure, safety statistics, downtime and throughput tonnages are also automatically ingested into REMAlytik where the Analysis and Innovation (A&I) team goes to work. According to product manager – technologies, Luke Sassé, this is one of the key differentiators for REMAlytik. “As well as data scientists and analysts, our A&I team consists of engineers and conveyor maintenance and operational experts,” he says. “This gives us the ability to drill down into the
performance of individual components in the conveyor system and provide our customers with meaningful reports.” REMAlytik improves on this process by using emerging technologies and innovations such as the Internet of Things (IoT), to provide customers with portal access to see live performance data of their components in addition to analysed reports and solutions. They’ll also be able to see aggregated industry performance benchmarks from the REMA TIP TOP data warehouse. “We have a massive volume of system performance data identifying the trends across our customers’ sites,” said Mr Sassé. “We utilise this data to set benchmarks and industry standards, helping our customers exceed their targets.” “For example, we use the data we’re collecting to identify trends where individual components are experiencing a problem. “Then using this data and more than 80 years conveyor knowledge we implement a solution and prove its effectiveness. We can then use this experience and our benchmarking tools to deliver these benefits to other REMA customers.” Mr Sassé says anyone can collect performance data on conveyor components, but only REMA TIP TOP brings together other key operational data, industry standards and benchmarks, and truly analyses the data to produce cost-saving, safety improvement and availability initiatives.
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Manage Large-ScaLe BuLk HandLing ProjectS with control and efficiency unique to Flexicon
Project Managers Dedicated To Your Success
Engineering Teams Ensure Smooth Integration
Effectiveness Only a Major Manufacturer Can Provide
• The Lead Flexicon Project Manager supervising your system offers you a single point-of-contact through every phase of development, streamlining your communications
• Engineering teams on four continents relieve your staff of overloading
• As one of the world’s largest manufacturers of bulk handling systems, Flexicon can provide the engineering, manufacturing, outsourcing, integration, programming and validation of your project—eliminating the risk of coordinating multiple suppliers
• Strict adherence to your unique standards, documentation requirements and timelines
• Over 20,000 bulk handling installations worldwide provide the breadth and depth of experience essential for seamless integration with your upstream and downstream processes
• Commitment to the successful performance and cost effectiveness of your project by serving as your dedicated advocate
• Ability to work with the engineering firm managing your entire project, or directly with your team
Flexicon’s Project Engineering Division can assume singlesource responsibility for engineering, integrating, automating and supporting your large-scale bulk handling project— and guarantee its performance
• Greater efficiency and control than available through diversified engineering firms, dedicated equipment makers or in-house engineering departments with limited time and/or bulk handling experience
AUSTRALIA sales@flexicon.com.au 1 300 FLEXICON
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