Bulk Handling Review Jul - Aug 2018 by Prime Creative Media

www.bulkhandlingreview.com Volume 22 No 4 | July/August 2017

 Iron ore projects: $7bn Koodaideri & South Flank  Pneumatic conveying misconceptions  $14.3bn S11D dissected  Grain handling  German Creek train load-out automation

REMA TIP TOP Conveyor Solutions Australia

CONTENTS

www.bulkhandling.com.au

EDITOR Charles Macdonald Tel: 02 9994 8086 Email: charles.macdonald@mohimedia.com HEAD OF SALES Patrick Roberts Level 14, 309 Kent St, Sydney, NSW 2000 Tel: +61 450 928 798 Email: patrick.roberts@mohimedia.com PEER REVIEW Ronda McCallum Tel: +61 2 9994 8086 Email: ronda.mccallum@mohimedia.com PRODUCTION MANAGER/GRAPHIC DESIGNER Magazines byDesign - Linda Gunek Tel: +61 2 8883 5890 Email: production@bydesigngraphics.com.au FOR SPONSORSHIP & EXHIBITION OPPORTUNITIES Patrick Roberts Tel: +61 450 928 798 Email: patrick.roberts@mohimedia.com PLEASE SEND ADVERTISING MATERIAL TO Ronda McCallum Email: ronda.mccallum@mohimedia.com Tel: +61 2 9994 8086 PUBLISHING DIRECTOR Michael Mohi Email: michael.mohi@mohimedia.com

24 contents

JULY/AUGUST 2017

6 Yancoal trumps Glencore for Rio’s Hunter jewels

WEIGHING & LEVEL MEASUREMENT

8 Dos Santos supplying high angle conveyor to fertiliser company

44 MRA & Rockwell automate train load-out at German Creek mine

10 Industrial users clobbered by power prices; ABB claims world record for motor efficiency

46 Position Partners on loader scale differentiators

12 Ex-Tunra boss goes to WearX; new MD at Rockwell Automation

49 Flexicon’s automated system improves re-bagging of granular sugar

14 Rio and BHP to spend $7bn on Koodaideri and South Flank mines

52 ConvaTech and Rema Tip Top merger creates conveyor maintenance giant

18 Relocatable conveyor trial for FMG

GRAIN HANDLING

20 Jenike & Johansen sponsors awards for top bulk solids students

54 Rabobank sees limited upside for wheat prices

22 Cut To Size Plastics on plastic vs metal drive trains 23 Sandvik modular carbide cast liners aid mine’s chute maintenance

55 Glencore tilts at Bunge, gets cold shoulder 56 Prescient decision on rail fleet pays off for CBH 58 GrainCorp sitting pretty as profits swell

24 Kockums Bulk Systems on pneumatic conveying misconceptions

59 Intermalt opens new facility in Vietnam

27 Enerpac pump for underground jacking system

60 Kinder Australia FRAS-rated polyurethane for grain handling

28 US engineer specifies HammerTek Smart Elbow AUSTRALIAN BULK HANDLING REVIEW (ABHR) is published 7 times a year by Mohi Media Pty Ltd ACN: 611591210 ABN: 436111591210 PO Box 455 Rozelle, NSW 2039

48 ABB’s “revolutionary” level measurer

31 Martin/ESS railcar vibrator 32 Thank you Japan! BHP and Rio celebrate Japan’s role in nurturing bulk industries 34 Vale’s US$14.3bn S11D mining complex ramps up 39 Rabobank cautiously optimistic on dairy sector 43 Larger Haver & Boecker Hydro-Clean test facility; JL Lennard merges packaging machinery business with Tech-Pack

60 Seaco spruiks palletwide bulker for grain handling

62 66 67 68 69 70 71 73

Boral’s Linwood quarry opts for Metso crushers ARTC upgrades track to Broadbent facility Nord gears and drives for Austrian mill expansion Eng Access website links professional engineers and clients Razerlink mobile conveyor fits multiple applications 7km Flyingbelt transports 1,500tphr of limestone in Brazil Second Doppelmayr RopeCon for Swiss landfill site Schaeffler on preventing bearing contamination

ISSN 1444-6308 Circulaton: 5,263 (audit period ending September 2015) Member Circulation Audit Bureau (Australia)

Copyright © 2017 Mohi Media Pty Ltd. All rights reserved. Reproduction of the editorial or pictorial content by any manner without written permission of the publisher is prohibited. While contributed articles to ABHR are welcome, return postage must accompany all manuscripts, drawings and photographs if they are to be returned and no responsibility can be assumed for unsolicited materials. All rights in letters submitted will be treated as unconditionally assigned for the publication. All products listed in this magazine are subject to manufacturer’s change without notice and the publisher assumes no responsibility for such changes. The publisher’s advertising terms and conditions are set out in the current Advertising Rate Card, which is available to read before placing any advertisements.

ABOUT THE COVER No teething troubles at Wiluna Gold www.bulkhandlingreview.com

When a new girth gear was urgently required at the Wiluna Gold Mine, the operation’s new owner opted for a segmented model from SEW-Eurodrive.

Volume 22 No 4 | July/August 2017



Iron ore projects: $7bn Koodaideri & South Flank



Pneumatic conveying misconceptions



$14.3bn S11D dissected



Grain handling



German Creek train load-out automation

The non-traditional design sees the SEW-Eurodrive girth gear formed from several identical segments, as opposed to the two-part fabrication of most conventional designs. The SEW-Eurodrive girth gear was easier to transport to site. It is also stronger, lighter and less costly to buy and operate. Installation of the new girth gear went so smoothly that the mining company commented “The guys on site were gobsmacked at how easily it went together.” For the full story, see page 40.

sew abhr 8-9.2o17 frtcvr girth ring.indd 1

18/07/2017 12:15 PM

Australian Bulk Handling Review: July/August 2017

EDITORIAL

$7bn iron ore twins promise better times for suppliers In the mining space, Australia’s bulk handling suppliers have been starved of major greenfield projects. Times have been tough. Two big new greenfields iron ore projects from BHP Billiton By Charles Macdonald and Rio Tinto hint at better times Editor – ABHR to come. In June, BHP said it would spend $244m on accommodation to kick-start development of its $4bn South Flank project, replacement for the aging 80mtpa Yandi mine. South Flank is expected to be rubber stamped by BHP’s board in mid-2018 with first ore due in 2021. The project’s economics are attractive, leveraging, as it does, BHP’s existing Mining Area C hub. Meanwhile Rio Tinto is completing feasibility study work on its Koodaideri development, which will cost around $3bn and include a 40mtpa dry crushing and screening plant. For more details see page 14.

Giant Brazilian mine ramps up In Brazil, BHP and Rio’s arch competitor in the iron ore trade, Vale, is ramping up its 90mtpa S11D iron ore complex. Despite its boring name (the deposit sits on block D of the S11 orebody, on the south range of Carajás), S11D is a monster mining complex costing US$14.3bn and employing a suite of advanced technologies. The operation is truckless, using a network of mobile excavators and crushers interconnected by 68kms of conveyor belts. Had the operation opted for trucks it would be using 100 of 240t capacity. S11D’s Australian connection is engineer David Morrison, previously of SKM (now Jacobs) and now employed at low profile firm Bechtel. Morrison and SKM did the feasibility study work on the viability of truckless operation at S11D. See page 34.

Pneumatic conveying misconceptions There is a lot of mis-information and woolly thinking in the market on the finer details of pneumatic conveying. In this issue two vastly experienced engineers, Ivan Price and Francois Steyn of Kockums Bulk Systems, set the record straight on what does, and doesn’t work. See page 24.

Identifying registered engineers Queensland stands alone as the only state requiring engineers to be registered in order to provide engineering services or products. While this bolsters standards and safety it can be hard for clients to find engineers, and vice versa, with lots of frustrating cold calling taking place. While existing freelancing and hire sites like hipages and Upwork can help, to a degree, they are not specifically designed for this task. This is where a new site, Eng Access, comes in. It has been assembled from the ground up by two tech-savvy Queensland engineers passionate about the internet. For the full story, see page 68.

Australian Bulk Handling Review: July/August 2017

NEWS

Yancoal trumps Glencore for Rio’s Hunter jewels

A scene from Rio Tinto subsidiary Coal & Allied’s Hunter Valley assets.

In a long drawn out bidding war, the Australian arm of China’s fourth largest coal producer has seen off Swiss commodities trader Glencore in a contest for Rio Tinto’s Hunter valley thermal coal assets, some of the best quality steaming coal mines in the country.

alued by analysts at US$2bn, Yancoal, majority-owned by the Chinese state controlled Yankuang, eventually paid US$2.69bn for Rio Tinto’s wholly owned Hunter Valley coal miner, Coal & Allied Industries. The bid trumped Glencore’s last offer of US$2.675bn and followed a protracted bidding duel between the two companies. Rio Tinto chief executive J-S Jacques said “The revised offer from Yancoal of $2.69 billion offers compelling value to our shareholders for our Australian thermal coal assets. This sale process has been in progress for a long period of time and we believe it is in the best interests of our shareholders to take the greater certainty of Yancoal’s strong proposal.” With its own Hunter Valley mines abutting those of Coal & Allied, Glencore was felt by many to be the ‘natural’ owner of Rio’s business. Under common ownership, a combination of Rio’s and Glencore’s mines would have generated strong synergies, cost cutting opportunities and brownfield expansion possibilities. However, Rio was seen as favouring Yancoal for a number of reasons, chief amongst which was being seen to keep in with ‘China Inc’, the biggest customer for its mineral commodities. In addition, Chinese company Chinalco is a major shareholder in Rio, and the Chinese government is closely involved with Rio’s Oyu Tolgoi copper project in Mongolia. Yancoal will have to launch a large capital raising to finance the Coal & Allied deal, which will put pressure on troubled commodities trading house, Noble Group, a 13.2% shareholder in Yancoal. Industry watchers believe that in time to come Yancoal and Glencore could well do a deal or deals that recognise the logic of more closely combining certain of their Hunter Valley mines and infrastructure. 6

Australian Bulk Handling Review: July/August 2017

Rio’s Hunter assets are the Mount Thorley, Warkworth and Hunter Valley Operations. Glencore’s major NSW assets are Bulga, Mount Owen, Ulan, Ravensworth and Mangoola. Yancoal Australia produces around 15.5 million tonnes of saleable (equity basis) thermal and metallurgical coal per annum. It operates four sites and manages five others across New South Wales, Queensland and Western Australia, employing around 2,000 people. Yancoal’s New South Wales region includes the mines of Moolarben and Stratford Duralie, with the Queensland region comprising Yarrabee and the Middlemount Joint Venture. Yancoal also manages the Cameby Downs and Premier coal mines in Queensland and Western Australia respectively, and the Ashton, Austar and Donaldson mines in NSW.

Mining at Glencore’s Mount Owen complex.

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HIGH ANGLE CONVEYING Yara’s production site has been located at Sluiskil for the past 80 years and now encompasses more than a dozen plants with the largest ammonia and nitrate fertilizer capacity in Europe. New investment sees the prilling unit replaced by a new urea granulator also designed for production of urea with sulphur.

Dos Santos International to supply high angle conveyor for Yara plant High angle conveying specialist Dos Santos International has been awarded a contract to provide its DSI Sandwich belt high angle conveyor to Bedeschi S.p.A. for Yara’s Sluiskil project in the Netherlands.

ertiliser company Yara International is spending US$263 million on an expansion of its venerable Sluiskil production site in the Netherlands. The investment will increase granulation capacity enabling increased production of granular urea with sulphur, and nitrates. In 2011, Yara completed the construction of a new world scale urea solution plant in Sluiskil which partly feeds an old prilling unit producing 400,000 tons of urea annually. With the new spend, the prilling unit will be replaced by a new urea granulator also designed for production of urea with sulphur, a product that is sold with a premium to regular urea. The new granulator will have an annual capacity of 660,000 tons of urea with sulphur. In parallel with increasing urea production, Sluiskil will reduce UAN production by around 230,000 tons per annum, freeing up nitric acid capacity enabling 130,000 tons per annum of additional CAN production. “In Europe and gradually also in other regions of the world, agricultural soils are lacking sulphur, which is an essential plant nutrient. With this investment we are able to serve a growing demand, helping farmers improve both yield and crop quality while contributing to improved nitrogen efficiency,” said Torgeir Kvidal, president and chief executive Officer of Yara International ASA. The new plant will be based on technology developed by Yara. Construction started in 2015, with completion expected later in 2017. The DSI Sandwich high angle conveyor will transfer urea and amidas prills at a rate of 600 t/h at a 40° angle. The material will be transferred from the tripped dock conveyor and elevated to the shiploader boom conveyor. The sandwich conveyor discharge is centred on the bridge rotation axis of the boom, allowing the boom to rotate freely. DSI was awarded supply of the sandwich conveyor by Bedeschi,

Australian Bulk Handling Review: July/August 2017

which was awarded the contract for the supply of the ship loader for the plant in January 2017. DSI says its sandwich belt high angle conveyors take on many forms and offer many advantages. Each DSI Sandwich Conveyor uses two standard, smooth-surfaced conveyor belts, face-to-face, to gently but firmly contain the product being carried. DSI said: “This not only makes steep angles possible. It also offers a spillage free, environmentally sound operation because the material remains sealed between the carrying and cover belts. The use of all conventional conveyor parts ensures high availability and low maintenance costs, as well as interchangeability of components and fast delivery of replacement parts. A DSI sandwich conveyor is capable of higher conveying speeds and greater capacity than other high angle conveying methods. The availability of wide belts and hardware makes capacities greater than 10,000 t/h easily achieved with a DSI Sandwich conveyor. High angles of 90° are typical, and lifts of 300m are easily accomplished.” Dos Santos International specialises in sandwich belt high angle conveyors. The business was founded and is led by the inventor of the system, Joseph Dos Santos. The DSI Sandwich belt high angle conveyor will elevate urea and amidas prills at a rate of 600 t/h at a 40 degree angle.

Superior

Engineering

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NEWS

Industrial users clobbered with power price rises Schneider Electric, Wilson Transformer and similar industrial companies are coming to terms with surges in their price bills of anything from 50% to 80%.

chneider Electric’s Clipsal manufacturing plant in the north of Adelaide has suffered from a rise of over 50% in its electricity prices over the last year. According to The Australian Financial Review (AFR) Schneider is looking at another 20% increase in prices when its longterm contract expires at year’s end. Schneider Electric’s vice-president of energy and sustainability services, Brian Morris said “It’s another challenge, another cost pressure. It’s another burden on business in an already challenging environment.” The AFR also says that Wilson Transformer in Victoria has seen an 83% surge in its power bill this year. Rises in industrial users’ prices come off the back of surging wholesale prices.

According to figures by analysis firm Global Roam, prices in the June quarter, compared to the same period in 2016, were up 63% in Victoria, 43% in South Australia, 22% in NSW, and 15% in Queensland. That equates to wholesale prices in the second quarter of 2017 of $104.92 in Victoria − a level described as ‘gut wrenching’ for energy users in Victoria by Global Roam − $115.93 in South Australia, $93.62 in NSW, and $85.83 in Queensland. The surge in prices can be put down to a suite of factors: the closure of the 1600 megawatts Hazelwood brown coal power station in Victoria; an increase in intermittent renewable energy, much of it without back-up storage; allegations of ‘gaming’ of the system, particularly by Queensland generators; and poor winds for South Australian wind farms.

ABB nears 100% efficiency with synchronous motor Industrial giant ABB is claiming a world record for a synchronous motor driving compressors at an air separation plant. The firm says the quarter point lift in efficiency will save the plant US$500,000 over the motor’s lifetime.

ests carried out on a 44 megawatt 6-pole synchronous ABB motor shortly before delivery showed an efficiency 0.25 percent greater than the 98.8 percent stipulated in the contract, resulting in the world record for electric motor efficiency. According to ABB, this efficiency improvement could save approximately $500,000 in electrical energy costs over the course of a 20-year lifetime for each motor. “With electricity costs being, by far, the largest component in the total cost of ownership of such a motor, savings like these have a significant impact on profits,” said Sami Atiya, president of ABB’s robotics and motion division. “In addition to extremely high efficiency, synchronous motors are renowned for their proven quality and reliability. Their robust design ensures reliability through cool operation temperatures and low vibration. We are strongly committed to developing technology that improves efficiency and productivity.” ABB says it achieved world record efficiency by optimising the motor’s electrical and mechanical features. The average efficiency for this type of synchronous motor is between 98.2

Australian Bulk Handling Review: July/August 2017

and 98.8 percent. If the motor is in continuous operation, the 0.25 percent efficiency improvement saves 1000 MWh energy per year which is equivalent to annual electricity consumption of 240 Western households. The world’s demand for energy today is nearly twice what it was 30 years ago. By 2030, it may have risen by over 50 percent again, according to estimates by the International Energy Agency. To cope with this not only are new energy resources necessary but the more efficient use of energy already available is critical. The energy saving potential in industry is enormous just in motor-driven applications alone. Variable speed drives and high efficient motors can help lower energy use typically by 20 to 50 percent, by reducing power consumption and losses. Motor efficiency is the ratio of mechanical power output divided by electric power input. The world record results were obtained during tests carried out with a customer that will be installing ABB synchronous motors to drive compressors at an air separation plant that produces industrial gases. The synchronous motor is a special type of alternating current (AC) motor,

ABB’s record breaking motor.

being some 5 x 4 x 4 metres in size for an output power of 44 MW. Typical uses of synchronous motors are for driving fans, pumps, rolling mills, mine hoists, and compressors in such industries as bulk handling, air separation, oil and gas, chemical, marine, metals, mining, water, and pulp and paper. Contact: www.abb.com

WHICH OF THE TOP 4 ELBOW PROBLEMS DO YOU NEED TO SOLVE IN YOUR PNEUMATIC CONVEYING SYSTEM?

PROBLEM

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.

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 against the outside radius of conventional 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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FF-0707

+61 (7) 3360 8580 • sales@HammerTek.com.au www.HammerTek.com.au

NEWS

Ex-Tunra boss to lead research push at Wearx Wear products specialist Wearx has appointed Dr Tobias Krull as its innovations and technology manager.

n his new role, Tobias will focus on growing Wearx’s internal technical and research and testing divisions. Tobias comes to Wearx from Tunra Bulk Solids where, as general manager, he was actively involved in engineering and research projects for mining and engineering companies in Australia and overseas. Tunra specialises in flow property testing and consults to major mining and bulk handling companies. The organisation taps the expertise of researchers and academics at Newcastle University and was established by Australia’s foremost bulk solids guru – Emeritus Professor Alan Roberts. Tobias received a Dipl – Ing (ME Equivalent) from the Technical University of Braunschweig, Germany in 2000, and a Master of Business Administration, and an Engineering Doctorate

specialising in bulk solids handling, in 2005. Gary Newman, chief executive of Wearx, commenting on Dr Krull’s arrival said “Wearx is privileged to have Tobias joining us, bringing his skill set, leadership, and an in-depth understanding of bulk material handling engineering, enabling us to reach the next level in transfer solutions. “Tobias brings a wealth of knowledge and experience in materials handling for the mining industry, which will play a key role in further cementing Wearx’s status as a market leader in wear solutions for forward thinking mining companies.” Wearx provides a range of wear protection solutions for mining operations. These include wear liners, rubber and ceramic lining, skirting, chute and bulk handling equipment protection, design and engineering, and site services and project management.

Industrial internet expert takes the reins at Rockwell Scott Wooldridge, formerly of Citect, Schneider Electric and Energy Action, has been appointed managing director for Australia and New Zealand by Rockwell Automation.

n his role, Scott will oversee sales and busiScott Wooldridge. ness operations in Australia and New Zealand and be responsible for Rockwell’s growth and performance. “I’m looking forward to working closely with our key distributors, system integrators, end users and OEMs to make sure they continue to be well supported with power, automation and data management solutions and services,” said Wooldridge. Wooldridge has an engineering and sales background in the automation and energy industries both within Australia and the US. He commenced his career in project engineering and management prior to working for Citect as vice president of professional services in Chicago, then vice president of sales in Georgia. He returned to Australia as managing director for Citect. Following Schneider Electric’s acquisition of Citect, Wooldridge moved to the role of vice president, industry business for Schneider Electric. Most recently, he was chief executive officer of the ASX-listed company, Energy Action. 12

Australian Bulk Handling Review: July/August 2017

With extensive experience in the Internet of Things (IoT) and big data space, Wooldridge says is looking forward to leveraging his domain knowledge to help customers address challenges they are facing. “Connectivity is expected everywhere now − the need to securely align information technology with operational technology to share data transparently, while retaining data integrity, is critical to support improved business productivity outcomes across the organisation. My key focus is to help customers understand the business outcomes connected ecosystems deliver, instead of focusing on individual components,” he said. In describing why he was attracted to Rockwell Automation, Wooldridge emphasised the company’s dedication to industrial automation and information. “A key strength of Rockwell Automation is that it is the largest company dedicated to industrial automation, it lives and breathes automation,” he said.

ContiTech is your conveyor solutions provider Choosing the best conveyor belt for your operation is vital for maximising productivity and minimising cost. There is only one rubber manufacturer founded in Germany in 1871 which today has combined sales of $8 billion. Only one that has over 41,000 employees in 150 locations in 31 countries. Only one who provides market-leading Technical and Onsite 14658 A4

Services for all makes and types of conveying systems. And only one who has more repeat business customers than any of its competitors. Make ContiTech Australia Pty Ltd www.contitech.net.au +61 3 9721 0600 Melbourne VIC +61 8 6240 3502 Perth WA +61 8 8 91860500 Karratha WA +61 7 48419800 Mackay QLD +61 2 8839 9600 Parramatta, NSW +61 2 4966 3493 Beresfield NSW

sense? Then talk to ContiTech before you make your next conveyor decision. And ensure it will be one of the best youâ&#x20AC;&#x2122;ll ever make.

OVERHEAD GREENFIELDS IRON ORE MINES

BHP and Rio Tinto are on the cusp of major billion dollar investments in new iron ore projects in the Pilbara.

Rio and BHP to spend $7bn on Koodaideri and South Flank For bulk handling suppliers starved of greenfield projects, Rio Tinto’s Koodaideri and BHP’s South Flank promise welcome respite, with around $7bn expected to be sunk into the two new iron ore projects.

t’s the iron law of the mining business: depleting assets must be replaced. And so it is in the Pilbara where BHP Billiton, Rio Tinto and FMG must establish new mines to replace the millions of tonnes of ore scooped up by them from the Pilbara each year. BHP is releasing early funds, earmarked for construction of mining camps, to get the ball rolling on its US$3bn South Flank project, replacement for the aging Yandi. Rio Tinto is completing the project feasibility study for its US$2.2bn Koodaideri project, while, nearer term, extra tonnes will soon flow from Silvergrass, and extra projects at West Angeles and Yandicoogina. ‘Third Force’ Fortescue Metals Group is spending millions in studies as it mulls a replacement for Firetail.

$184m for South Flank accommodation In late June, BHP confirmed spending of US$184m (A$244m) in initial funding for the South Flank sustaining mine project. 14

Australian Bulk Handling Review: July/August 2017

BHP president operations, minerals Australia, Mike Henry, said the funding would generate several hundred construction jobs and provide exciting opportunities for Western Australian suppliers. The South Flank project, which will leverage and expand the existing Mining Area C hub, is BHP’s preferred option to replace production from the 80 Mtpa Yandi mine when it reaches the end of its economic life in the early-to-mid 2020s. The project is expected to be submitted for BHP board approval in the middle of the 2018 calendar year, with first ore targeted in the 2021 calendar year and ramp-up timed to coincide with the ramp-down of Yandi. Full development of South Flank would generate several thousand jobs during construction. Mr Henry said the capital efficient South Flank project was a compelling option to replace Yandi production and offered attractive returns. Its high-grade lump and fines ore and a strip

GREENFIELDS IRON ORE MINES

“The capital efficiency of South Flank is underpinned by the planned use of existing infrastructure at Mining Area C,” BHP president operations, minerals Australia, Mike Henry ratio in line with the company’s Pilbara average would establish it as a highly-competitive operation. The initial funding will be used primarily for the expansion of accommodation facilities to support current and future workforce requirements. “As well as supporting our current operational requirements, this work will advance potential first ore from South Flank, while we further optimise the full development and progress external and internal approvals. As we have said previously, a continuing stable investment environment in Western Australia is required to underpin ongoing investment in the business, including this project,” Mr Henry said. The capital cost for South Flank is expected to be in the range of US$30 to US$40 per tonne, with expenditure fitting within BHP’s previously indicated average sustaining capital expenditure of US$4 per tonne over the next five years. “The capital efficiency of South Flank is underpinned by the planned use of existing infrastructure at the Mining Area C operation, which would, if approved, become one of the largest standalone iron ore processing centres in the world, within reach of several billion tonnes of high-grade ore,” Mr Henry said.

FAG SmartQB Condition Monitoring made easy. With the FAG SmartQB, rotating equipment such as motors, gearboxes, pumps, fans, compressors and vibrating screens can now be diagnosed for mechanical and electrical faults and reported via a touch panel in clear plain text. Industries that will benefit of this intuitive surveillance system: • Bulk Handling • Steel • Cement • Paper • Sugar

Rio completing studies on Koodaideri In April BHP’s greatest rival, Rio Tinto, approved an investment of $30.9 million to complete the project feasibility study for the development of its Koodaideri iron ore deposit in Western Australia. The study will examine the Koodaideri option as Rio Tinto’s next potential major mining development in the Pilbara, and is intended to replace existing production. Rio has already completed pre-feasibility work on Koodaideri which posits a US$2.2bn development with construction starting in 2019. The project will likely involve a 40mtpa capacity dry crushing and screening plant, non-process infrastructure, product stockyards, rail loop and load-out and a 170 kilometre rail link to the main line.

www.fag-smartcheck.com/smartqb Schaeffler Australia Pty Ltd +61 8977 1000 www.schaeffler.com.au

GREENFIELDS IRON ORE MINES

Rio Tinto iron ore chief executive Chris Salisbury said of the feasibility study spend “We are pleased to be investing a further $30.9 million in Western Australia, which will be spent with local businesses and suppliers as well as firms outside the state. “The Koodaideri development will require an expected 1,600 construction jobs and a further 600 operational staff if approved. “We remain firmly focused on our value over volume strategy and maximising returns through enhanced productivity. We are examining the Koodaideri project as an option to help us maintain our low cost competitive position and assist in maintaining the Pilbara Blend product quality.” The feasibility study will focus on obtaining necessary consent and permits, increasing Rio’s understanding of the orebody and technical elements, and providing the data necessary to validate the project. The final decision on the progression of the Koodaideri iron ore development will be made following the completion of the feasibility study and subsequent review by the Rio Tinto investment committee and board.

Silvergrass close to completion A more immediate prospect for Rio Tinto is completion of the $338 million brownfields expansion of its Silvergrass project which will add an extra 10mtpa of iron ore production capacity by the second half of 2017 at a competitive capital intensity of US$29/t. Silvergrass is a satellite deposit located adjacent to Rio Tinto’s Nammuldi mine and is part of the Greater Nammuldi precinct, located approximately 70 kilometres north-west of Tom Price. The 10mt of extra capacity at Silvergrass comes on top of 10mt of incremental capacity at Nammuldi brought online in 2015 and 2016. The latest investment in Silvergrass will lower mine operating costs by replacing road haulage with a more efficient conveyor system that links the Silvergrass operations to Rio’s existing processing plant at Nammuldi.

“The Koodaideri development will require an expected 1,600 construction jobs and a further 600 operational staff,” Rio Tinto iron ore chief executive, Chris Salisbury

Australian Bulk Handling Review: July/August 2017

“Silvergrass……is one of the most value-accretive projects across the mining industry,” Rio Tinto chief executive, Jean-Sébastien Jacques. Rio Tinto chief executive Jean-Sébastien Jacques said “We are committed to disciplined capital allocation and the approval of the final phase of the Silvergrass development, which is one of the most value-accretive projects across the mining industry, delivers high-quality, low-cost growth that will underpin future returns to shareholders. “The additional low-phosphorus tonnes that Silvergrass delivers will sustain the long-term viability of our Pilbara blend, ensuring continued premium pricing, whilst also lowering our operating costs through infrastructure improvements.” In April 2017, Rio said that the Silvergrass work and developments at its West Angeles and Yandicoogina mines are expected to support more than 1,000 construction jobs in Western Australia. Construction of Rio Tinto’s sixteenth iron ore mine in the Pilbara, Silvergrass, has been ramping up since the beginning of 2017 and has provided about 500 jobs during construction. Development of a new deposit at West Angeles mine is now nearing completion, with an estimated peak workforce of 120 people. Mine development projects to sustain production at Yandicoogina mine are forecast to involve a further 470 jobs during construction. Rio Tinto iron ore chief executive Chris Salisbury said “Rio Tinto continues to invest in its Pilbara iron ore business, which is helping to sustain local businesses and jobs. “To date, we have awarded more than $180m in construction contracts to develop our Silvergrass mine. This includes a $40 million contract to Western Australian company Decmil and $120 million contract to Perth headquartered company RCR Resources,” Mr Salisbury said. “Decmil was awarded a contract to design, construct and commission buildings, services and support facilities at the existing Nammuldi central mine and at the new Silvergrass mine. “Other Western Australian suppliers are benefiting from Decmil’s local purchasing of major items such as structural steel, modular buildings, gantry cranes and waste water treatment plant.

GREENFIELDS IRON ORE OVERHEAD MINES

“RCR Resources has engaged more than 40 Western Australian suppliers and contractors to support the fabrication of a new primary crushing plant, and construction of nine kilometres of overland conveyors and associated power distribution.” Pilbara Traditional Owners haven’t missed out on opportunities. “This is demonstrated by the awarding of a $3 million contract to a local indigenous contractor, Eastern Guruma, to complete earthworks, light vehicle road construction, overland conveyor overpass construction, and associated drainage for the Silvergrass mine,” said Mr Salisbury.

FMG mulls its options Fortescue needs to find a replacement for Firetail, beginning production around 2021. According to the Australian Financial Review, two possibilities are the Eliwana deposit at its Western Hub or the Nyidinghu Hub. The replacement cost of Firetail is put at between US$1 billion and US$1.5 billion. Fortescue will spend US$40m in financial year 2017 on development work for the Firetail replacement, with consideration going into approvals and licences.

An EarthTechnica GY54-74 at an iron ore operation in Australia.

Sharing the spoils of Silvergrass RCR, Decmil and Minprovise are three companies sharing in the spoils from Rio Tinto’s Silvergrass project.

iversified engineering and infrastructure company, RCR Tomlinson was awarded a contract by Rio to deliver a primary crusher and overland conveyor system for Silvergrass. The contract is valued over $120 million. The project scope of work includes the engineering, procurement and construction of a new primary crusher, 9km of overland conveyor and associated 33kV power line. Construction began in late 2016. RCR managing director & CEO, Dr Paul Dalgleish said “This contract award demonstrates that RCR is certainly leading the iron ore processing industry and is a result of our innovative approach to cost competitive solutions. This win, when added to recent successful projects and new contract awards, firmly places RCR as a market leader in the engineering, procurement and construction of mineral processing plants in the mining and minerals sector. “Our design was innovative and provides Rio Tinto with a solution that uses capital efficiently. We look forward to delivering this important turnkey project for Rio Tinto”.

Accommodation specialist Decmil Australia secured a circa $40m contract with Rio for the design, construction and commissioning of new facilities at the existing Nammuldi central mine services and at the Silvergrass mine services area. The scope also includes modifications and extensions to existing facilities at the Nammuldi central mine services. The project is due to be completed in late 2017. Western Australian-owned engineering services company Minprovise is supplying the primary crusher for Silvergrass. The GY54-74 primary gyratory crusher will form part of the processing plant supplied by RCR Tomlinson. The GY54-74 primary gyratory crusher assembly will be manufactured by Japan’s EarthTechnica, a subsidiary of Kawasaki Heavy Industries. Assembly, engineering support and project management of the crusher and related ancillary items will heavily utilise Australian local content and expertise. Minprovise managing director Graham Townsend stated, “we are grateful to again be given the opportunity to contribute to another Western Australian mining project. We look forward to repaying RCR and

Rio Tinto for their support by delivering a world class product within a significantly reduced timeframe (compared to other recent gyratory crusher installations).” Minprovise is EarthTechnica’s Australasian partner and a leading supplier of crushing equipment, service and support. The GY54-74 primary gyratory crusher being supplied to Silvergrass is the same model supplied to Rio Tinto’s recently completed Western Turner mine and, says Townsend, is part of the next generation range of crushers offering improved throughput, greater reliability and reduced maintenance. More than 110 Earth Technica crushers have been supplied into Australia including three of the last four primary gyratory crushers into Rio Tinto Iron Ore operations. Minprovise offers full support ranging from installation, maintenance and on-site repairs to spare parts and offsite repairs and refurbishment. “EarthTechnica crushers offer considerable advantages over industry peers,” said Townsend. “As part of the Kawasaki group they share the same passion for innovation with the backing of one of the world’s leading industrial engineering companies.” Australian Bulk Handling Review: July/August 2017

NEWS Fortescue is investigating a relocatable conveyor system. Pictured is an in-pit crushing and conveying system from P&H (now a brand of Komatsu).

Relocatable conveyor trial highlights FMG's productivity drive Fortescue Metals Group has announced three major productivity and efficiency initiatives for its Pilbara iron ore operations, including an innovative relocatable conveyor trial at its Cloudbreak mine.

n late June, FMG updated the market on its continued investments in “safety, productivity and efficiency.” The miner outlined three initiatives. “As part of Fortescue’s assessment of options for the Firetail replacement project,” the release said, “the company is investing in an innovative relocatable conveyor trial at the Cloudbreak mine.” Another initiative is the expansion of autonomous haulage technology at FMG’s Solomon Hub. “Fortescue has successfully deployed CAT autonomous haulage technology at the Solomon Hub since 2012 with 15 AHS trucks now operating, achieving a 20% improvement in productivity. Up to twelve 793F trucks will be converted to AHS to further improve productivity across the site.” The third initiative outlined by FMG was the further rollout of more AHS vehicles at the Chichester Hub. “The implementation plan for the rollout of AHS at the Chichester Hub from FY18 is now underway,” Fortescue said, “including commencement of commercial negotiations with suppliers 18

Australian Bulk Handling Review: July/August 2017

as well as upgrade of the IT network at both the Cloudbreak and Christmas Creek mines.” Approximately 100 haul trucks will be converted to AHS at Chichester, with an expected productivity return on par with that achieved at Solomon. Fortescue may be Australia’s lowest cash cost iron ore producer. The company needs to be as its 58% ore, low in impurities, is priced at a significant discount to 65% and 62% ores from Vale and arch competitors Rio Tinto and BHP Billiton. While Fortescue has suggested that it receives around 85% to 90% of index prices, commentary in The Australian Financial Review has suggested that, on occasion, the discount blows out leaving it with only 76% of the index. Truckless operation, using in-pit crushing and conveying technology, is a very competitive method of mining but only for massive, highly contiguous ore bodies. The most notable recent application of the technology is at Vale’s new S11D mine in Brazil, where systems from Sandvik will eventually move 90mtpa of ore and 135mtpa of material in total.

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14619 A4

OVERHEAD EDUCATION AND TRAINING

Top bulk solids students recognised Specialist materials handling engineering firm Jenike & Johansen has sponsored a number of student awards at the University of Newcastle and Curtin University. It also recorded the students’ impressions of bulk solids science and practice.

Zoe Scott, winner of the Jenike and Johanson Prize for High Achievement in Bulk Solids Science, receiving her award from the head of University of Newcastle’s School of Mechanical Engineering, Professor Mark Jones.

Ryan Stiff, winner of the prize for Excellence in Bulk Solids Science, receiving his award from the head of University of Newcastle’s School of Mechanical Engineering, Professor Mark Jones.

Australian Bulk Handling Review: July/August 2017

rant Wellwood, general manager, Jenike & Johanson told ABHR that the firm sponsored the awards in a bid to promote the science of bulk solids. The initial term of the sponsorship is three years. “There is concern within Jenike & Johanson and elsewhere that unless we can attract the brightest and best to our industry, the achievements in our industry over the last 50 years or so may cease to keep coming,” he explained. “As you know there are lots of sexy options out there for students these days and while I think this is one of them it lacks the coverage and profile of its competitors. “These awards are intended to celebrate undergraduates who show an interest (in the field) and via the interview questions try and get students at decision points to at least consider this pathway.” Ryan Stiff and Zoe Scott won Jenike and Johanson prizes for high achievement in bulk solids science at the University of Newcastle. The awards were presented at the Mechanical Engineering and Mechatronics Dinner. In the west, the firm awarded Dirk Oskar Garland the Jenike and Johanson prize for the highest grade in the bulk materials component of the Metallurgical Processes and Materials Handling (PRRE2002) course at Curtin University’s Western Australian School of Mines, Kalgoorlie Campus. J&J put some questions to its three winners in a bid to enumerate their experiences of and attitudes to bulk solids handling. ABHR presents the questions and answers with Zoe Scott, Ryan Stiff, and Dirk Oskar Garland. Q - What was it about bulk solids that attracted you to it and motivated you to apply yourself so passionately? A – (Zoe Scott) - The incredible volume of material that is handled daily, locally and in the rest of Australia, made me want to find out more about the way it is transported and the engineering behind those methods. Materials handling is such a large industry that’s rarely spoken about and I just had to know more about it. Q - What aspect of bulk solids science did you find the most interesting during your studies? A – (ZS) - I most enjoyed studying overland conveyors and learning about

EDUCATION AND TRAINING

all the different contributing factors to calculating belt tensions. It was interesting to see the amount of science that goes into the designing of a conveyor and how dependant their design is on the material and flow characteristics. Q - What was the most surprising thing you learnt about the behaviour of bulk solids? A – (ZS) - I had no idea that different materials had a different angle of repose, or that that angle even had a name! I’d not thought about it much before. It seems so simple and obvious now, but learning about it for the first time was really interesting. Q - Things are changing and while there will always be a need for the basic science, the way it is applied may change. How do you think things might go in the future? A – (ZS) - As systems become more and more automated and companies demand longer systems with a larger throughput, new ways of handling materials will need to be developed. Also, the types of things we will be dealing with will change as renewable energy replaces coal fired power stations. Q - What aspect of bulk solids science did you find the most interesting during your studies? A - (Ryan Stiff) I found it to be a very interesting course because of its difference to the course I have completed. Rather than looking at a single component or multiple interacting components it was all about the interaction of millions of individual particles and all the ways they could interact with each other and the environment they are in. Q - What was the most surprising thing you learnt about the behaviour of bulk solids? A – (RS) - It was not as linear as I thought it would be. Coming into the course I believed it would be as simple as just

adding more conveyor belt, adding a chute to change height or just increasing the pipe length but it is more complex than that. Every system has to be designed for its own purpose and no system can be just copied from another without important alterations to be made. Q - Things are changing and while there will always be a need for the basic science, the way it is applied may change. How do you think things might go in the future? A – (RS) - I think in the future there will be more systems developed that reduce the need to perform large batches of calculations. There are already programs that allow simulations of bulk solid material transportation and as the industry further develops these programs will become more sophisticated and have faster processing times. For engineers, it will be smarter designing and optimizing existing designs that will continue to become important, rather than having to spend time on calculations for simpler designs. Q - What was it about bulk solids that attracted you to it and to apply yourself so passionately? A - Dirk Oskar Garland - The fundamentals of bulk solids science are reasonably simple and approaches to solving problems are quite systematic, which is something that I can appreciate. I think what really drew me in was how easy it was to see the real world applications of the theory. Q - What aspect of bulk solids science did you find the most interesting during your studies? A – (DOG) - My studies have included a ‘materials handling’ unit that focussed on bins and hoppers and the behaviour of bulk solids. I found the interactions between individual particles and the effects of moisture on these interactions to be quite

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EDUCATION AND TRAINING

interesting, especially since it then has follow on effects on systems like bins and hoppers. Q - What was the most surprising thing you learnt about the behaviour of bulk solids? A – (DOG) - The thing I found most surprising was the fact that many mining operators dealing with bulk solids did not regularly check and improve their systems. I would have thought this to be common practice, as everybody is aiming for maximum productivity and efficiency, which is certainly something that should be applied to such an important part of an operation. Q - Things are changing in mining and while there will always be a need for the basic science, the way it is applied may change. How do you think things might go in the future? A – (DOG) - I can see that the major focus of science in the mining industry is heavily shifting towards the automation of operations. Technology is increasingly becoming a major component of the industry with the introduction of systems like the Internet of Things (IoT) and − even on a small scale − using drones for

Dirk Garland, winner of the Jenike and Johanson Prize for the highest grade in the bulk materials component of PRRE2002, receiving his award from Professor John Cordery, Provost and Senior Deputy Vice-Chancellor at Curtin University. Photo courtesy - GFP Graduations [https://grads.gfp.com.au/].

surveying and monitoring purposes. I think improvements or changes in processing technologies will have a large effect on bulk materials science and will perhaps introduce new types of materials, with new challenges to face. Jenike & Johanson is a leading

engineering firm in the field of powder and bulk solids handling, processing, and storage technology. The company claims that over the past 55 years, it has tested 10,000 unique powders and bulk solids and worked on more than 7,500 projects.

ENGINEERED PLASTICS

In favour of plastic vs metal drive trains A plastics supplier says that plastic drive train components offer benefits often unrealised in Australasia, including design flexibility, reduced noise, and the ability to operate without lubrication.

ther pluses include lower cost and weight, higher efficiency, and chemical resistance, says Mr Pat Flood, NSW manager of the national and international engineered plastics specialist, Cut To Size Plastics. “Traditionally Australasian industry has been wedded to metal drive train engineering, which is suitable for a proportion of particular application needs. But the more our industries evolve, the greater the need to think carefully about the smartest use of materials for ‘Clever Country’ industries and design solutions. This is particularly true for rapidly evolving hygiene-conscious sectors such as food and beverage, chemical, recycling, water and waste water management, robotics and medical engineering.” Cut to Size says its durable alternatives to metal, with major design advantages in particular applications, include Wearlon nylon ranges and Wearace acetal engineering plastics. Gears and drive train components made from them can

Australian Bulk Handling Review: July/August 2017

be moulded and precision machined into shapes difficult to machine in metal. Other functional elements, such as springs and pawls, can be incorporated into them, thereby consolidating parts and trimming the cost, weight, and complexity of geared speed reducers. “The use of plastics in drivetrain engineering has come a long way over the last 20 years,” said Mr Flood. “From previously being considered only suitable for light, low-power and non-critical applications, engineering plastics today have moved out into areas such as bevel gears, metric gears and worm gears. Now cams, lugs, ribs, webs, shafts and holes are moulded into plastic gears in one integral design in a single operation, opening the door to significantly lower production costs in areas as diverse as conveyor and feeder drives, through to materials handling, packaging and robotics. Contact: Mr Pat Flood, email - pat@cuttosize.com.au

(Left to right) Wearace nylons and Wearlon acetyl ranges each have major strengths in particular applications (pictures courtesy of Licharz GmbH, Germany).

CHUTE MAINTENANCE

Carbide casts aid with chute maintenance

In cooperation, Sandvik and Prime Solutions found a way to let mine personnel carry out chute maintenance in a safer environment. Photo: Prime Solutions.

Modular carbide cast liners have been used by Sandvik and its engineering partner to shift chute maintenance at a mine from the cramped mine site to a more pleasant workshop environment.

common challenge in almost all mines is abrasion in the chutes used to transport rock both from the crushing stage to the long belt conveyors and between the conveyors. Frequent maintenance stops are common, due to the extreme wear of the equipment. For one large mine in northern Sweden with a production rate of some 8,000 tons of rock per hour, every hour of standstill costs the company about US$ 112,000. Keeping the mine running is critical. A first reduction of unplanned stops was accomplished in 2009, when Sandvik implemented its HX900 Cast In Carbide in the mine chutes. Sandvik HX900 Cast In Carbide is a wear material combining the wear resistance of cemented carbide with the shock resistance, malleability and forming capability of nodular iron. “Sandvik’s HX900 composite lasts 15 to 20 times longer than any other material on the market,” says Oskar Larsson, product manager wear protection & screening media at Sandvik Mining and Rock Technology. “It’s absolutely unparalleled.” However, the new carbide casts could not solve the safety problems. The risk of falling rocks combined with dust, cold and high noise levels made maintenance work in the chutes unattractive and insecure. In 2012, Håkan Zaar of Prime Solutions was invited to the mine to discuss the working conditions. His first idea was based on a previous solution he had created for a steel company. “My idea wasn’t restricted by conventional mining boundaries, which was a bit surprising for the customer at first,” Zaar says. The customer accepted his initial idea, and Zaar contacted Oskar Larsson at Sandvik to discuss a solution. “We wanted to get the maintenance work out from the chute itself,” Zaar says. “It wasn’t designed for such work, so neither safety nor the work environment were optimal. In addition, the crushers had to be stopped for each maintenance session, which was very costly.” Since HX900 allows for longer time in operation, maintenance can be planned when crushers or conveyors are standing still for other reasons. In addition, the work could be moved from the mine to a separate workshop onsite. “We’ve created a solution that no one else can provide, thanks to Sandvik’s unique material knowledge and Prime Solutions’ system engineering competence,” explained Zaar. “The chute can be replaced during regular maintenance. It saves valuable production time, reduces stress and increases both safety and the work environment.” According to Sandvik, both mine management and employees are satisfied. The company estimates that some 300

hours of interruptions can be avoided yearly, thanks to the new solution. “The heavy and demanding job of maintaining chutes inside the dark and dusty mine has been replaced with a job that employees gladly sign up for,” says Larsson. Larsson is optimistic that the modular system will be of interest to other mine operators around the world. “We’ve created a solution that no one else can provide, thanks to Sandvik’s unique material knowledge and Prime Solutions’ system engineering competence,” he says. “It’s a perfect match.”

Australian Bulk Handling Review: July/August 2017

PNEUMATIC CONVEYING

Pneumatic conveying misconceptions are not commonly transferred longer distances than 150 or 200 metres.

2. Increasing the distance for conveying by 30 or 40 metres should be OK (IP & FS) Probably we have all heard of a powder like flyash being blown over a kilometre, so it can’t be too hard, as it is a fluid during conveying? And fluids handle well, don’t they? − consider water − and how easy it is to transfer long distances through a pipeline. Well, a good explanation is seen in Figure 1 for conveying cement. Increasing the convey distance from 40 m to 120 m actually halves the rate of transfer of cement in dense phase mode. And every extra bend in the pipe(L to R) Ivan Price and Francois Steyn, chairman and chief executive, respectively, of Kockums Bulk Systems. line provides significant resistance, which is equivalent to adding an extra four metres of pipe length. There is a lot more resistance in a pipeKockums Bulk Systems has many decades of line handling an aerated powder product than handling a fluid experience in pneumatic conveying installations. such as water.

Below, the company’s chairman Ivan Price and chief executive Francois Steyn provide some do’s and don’ts and dispel some commonly held, but erroneous, assumptions.

1. Any bulk product may be efficiently conveyed

3. Tubes are better than pipe for conveying (IP & FS) Well certainly they are lighter for assembly, cheaper than pipe, and more suited to attachment by clamps, for cleaning purposes. But there are two problems: Firstly, the noise generated with granules passing through. Secondly, if a product is abrasive it will quickly wear through a thin wall. Generally, for cement and abrasive chemical products, schedule 40 pipework is used to overcome these two obstacles. And sometimes schedule 80 is used in bends.

(Ivan Price and Francois Steyn) In fact products vary enormously in their conveying characteristics. A general rule is that the finer the product, the more efficiently it will handle. Efficiency is defined by power usage related to mass flow rate, in tonne per hour. 4. Lean phase will solve all applications. Who Products having particle sizes below about 150 micron genneeds dense phase? erally are quite efficient as they fluidise (are mixed with air) for Lean phase is very common in the food industry where non-abraease of handling, as a fluid. Cement powder is around 45 micron, sive products and relatively low flow rates are utilised. and is a good reference product because it fluidises easily, and Dense phase consideration is very important with abrasive the closest thing to a world-wide standard for handling. products and high throughput systems. Flyash is finer than cement, and will generally perform better Some test work has been published, advising that wear on than cement. bends is proportional to the 4th or even the 5th power of the Flyash from quality black coal is used extensively in concrete making, replacing some of the cement. When it has been classified, producing a finer product, the handling improves further. The coarser ash from the classifier needs more energy for transport. How far down the micron scale can we go? We will generally see efficiency improvement using a good quality fluidising technique until we approach 5 micron size, when aeration becomes quite difficult. What about coarse products? As we proceed up in micron sizing, we find handling dry sand is still quite practical. It simply takes significantly more power to convey than cement, as it does not fluidise. It is pumped along in slug flow mode. And conveying sugar and plastic granules is common, but requires higher energy levels. So the higher power requirements for coarse products mean they Figure 1: Graph shows how increasing the conveying distance will affect the rate of transfer. 24

Australian Bulk Handling Review: July/August 2017

PNEUMATIC CONVEYING

velocity. That means wear increases dramatically with increasing velocity. There is a wide range of pipeline velocities encountered, depending upon the product and the means of conveying. Lean phase uses considerably higher velocities than dense phase, so the wear becomes very significant with an abrasive powder handled in lean phase. The velocity in lean phase with cement is around 28 metres/ sec (5,500ft/min) when the product is fully entrained in the air flow, whereas dense phase velocity is regularly significantly less than half that of lean phase. Lean phase operating pressures are usually ½ to 1 bar, whereas dense phase may use significantly higher pressures and may go up to 5 bar in certain circumstances.

5. Keeping a consistent pipe diameter is important for the flow (IP & FR) Yes, and no! It is vital to keep a consistent smooth line of flow along the inside of the pipe or tube. Joins need to butt together smoothly. However, with dense phase at higher pressures, as the air expands approaching the end of the pipeline, the velocity of the fluid increases significantly. The pressure is progressively lost to the end of the pipe, which is close to atmospheric pressure. For this reason, it is common to expand the pipe diameter to reduce the arrival velocity into the silo or hopper. If fact in power stations handling flyash, velocities generally must not exceed 10 metres/second. This is to challenge the wear factor, for long pipeline life. To do this in an application of ours, it was necessary to expand the pipeline by a pipe size at about two thirds the distance, and expand again as the pipeline rose up into the silo. The 200 mm line expanded to 250 mm and finally to 300 mm.

6. More airflow will give a faster rate of conveying (IP & FS) Why not speed up the compressor to get more air flow, to achieve a better product flow? Yes, it is done; but will not achieve the desired result, generally giving a detrimental outcome.

It’s not airflow increase, but pressure increase that gives higher throughput. In fact, a reasonable guide is that doubling the pressure of conveying will double the flow rate (by raising the material/air ratio). A good example is at a plasterboard manufacturer. A lean phase system was being used, but the throughput rate needed to be upgraded. By changing to dense phase the tonnes per hour of plaster product passing was doubled in the exact same pipeline. In this instance the pipeline had been installed using pipe and flanges, so was able to handle the higher pressure. A similar result was achieved in the past with plastic granules, when significantly higher throughput was achieved using the same nest of pipework by upgrading to dense phase operation.

7. Vacuum transfer is cleaner, safer and therefore more efficient (IP & FS) It’s all a matter of how you define efficiency. Indeed, vacuum transfer has advantages, particularly for handling unpleasant products. We heard once of a new plant handling carbon black by a pressure conveying system. When it blew a hose during commissioning, one can only imagine the cost of cleaning the factory. It would not have happened if the transfer was by vacuum. Vacuum requires a very good quality air filtration system to protect the vacuum generator from dust. In the past, wet vacuum pumps commonly solved this situation, but the cost of cleaning the effluent from the water seal has diminished its viability. But vacuum has a more severe restriction, and this relates to usable pressure differential. Practically, vacuum is limited to 1 bar operation, and in reality ½ commonly, to ¾ bar with advanced machines, is all that may be utilised. So, it is suited to low mass transfer rates and relatively short distances for practical applications. There are always special cases, and we supplied systems to Hong Kong for transferring cement from barges to Lantau Island when the new Chek Lap Kok airport was built. Our vacuum system drew cement from the holds of the barges at 200 tonnes per hour in a 200 mm line. Many dust filtration systems are basically very lean phase vacuum transfer systems.

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PNEUMATIC CONVEYING

8. You dare not handle products that are hydroscopic, explosive or products that react with air (IP & FS) Under normal circumstances, this is a reasonable statement. But it is a matter of suitable engineering parameters. Many of these situations, like conveying coal dust, may be conveyed safely using an alternate gas such as nitrogen that is quite inert. Hydroscopic materials may require dried air. This can be supplied by air dryers associated with compressors. Although it is common practice worldwide, in the past there have been questions about using a road tanker compressor to convey cement into a silo. Normal air has a relative humidity factor, so a tanker compressor will draw in some moisture in the air during the conveying application. Some of this moisture will pass into the cement. A tanker compressor could deposit moisture at the rate of 1 part View of sample shelves of a wide range of products that have been tested at Kockums Bulk Systems. The firm has to 10,000 by mass on a wet day at maximum experience of, literally, hundreds of powders, grain and granules. humidity, which is quite insignificant. It is a means of bringing a raw material into a clean room in a What is the purpose of pneumatic conveying? plant from an external silo, or bulk bag discharge station. The convenience of pneumatic conveying is the simplicity of It is a significant means of achieving automation and minmoving a product from one location to another, generally around imising human interaction like lifting sacks with all their asa plant, with a simple pipeline network. sociated skeletal injuries. An 80 mm or so pipe may go easily between f loors and around obstacles.

NEWS

BHP stalwart takes the reins at Pacific National BHP-lifer Dean Dalla Valle has taken over as CEO at coal haulier Pacific National.

Dean Dalla Valle.

Australian Bulk Handling Review: July/August 2017

ean spent 40-years at BHP, rising from apprentice electrician to executive suite heavy hitter. Most recently Dean was chief commercial officer of BHP Billiton with responsibility for marketing and distribution of commodities, the global health safety and environment program, technology and the highly complex Samarco recovery project in Brazil. Prior to this, Dean was president of BHP Billiton’s international coal business. “With his depth of background in the successful management of large, capital intensive businesses, his knowledge of supply chain dynamics and his extensive hands-on operational knowledge and experience, Dean is an excellent fit for Pacific National,” said executive chairman Russell Smith. “As CEO, Dean will be extremely well placed to lead Pacific National as we continue to deliver on the company’s plans to strengthen and grow the business, leveraging the expected expansion in the national freight task over coming years.” Dean commenced work at Pacific National in mid July 2017. To ensure a smooth transition current Pacific National CEO David Irwin is maintaining an advisory role with the company, supporting the board and Dean. Industry analysts said that Dean left BHP after two other company executives – Peter Beaven and Mike Henry – were promoted into roles that made them more likely successors to chief executive Andrew Mackenzie on the latter’s ultimate departure from the company.

NEW PRODUCT

CME’s underground jacking system uses Enerpac hydraulic lifting equipment to change heavy vehicle tyres in tight spaces while underground.

Jacking system targets problematic UG flat tyres CME Boilermaking aims to solve underground mining’s flat tyre challenges with Enerpac’s powerful 100t lifting combination.

hanging a flat tyre on heavy machinery is one of underground mining’s most hazardous and time-consuming maintenance tasks, often taking up to 12 hours to complete in confined spaces with sloping surfaces. This issue was such a problem that some manufacturers began selling underground machinery with in-built jacks, but this posed a significant extra cost to the end-user. Leading Australian engineering and fabrication specialists CME Boilermaking has designed an efficient solution that allows manual jacking of the vehicle for safe and reliable lifting and maintenance. CME’s underground jacking system comprises an Enerpac XC-Series cordless hydraulic pump, connected to an RAR-Series lightweight aluminium cylinder, which can handle loads up to 100 tonnes. These are integrated into CME’s custom-fabricated lifting plinths and pedestals, which are designed to optimise stability and safety. “The lightweight cylinder and battery pump are crucial elements in our underground jacking system. With sloped or rough surfaces and limited space, once a huge mining vehicle has reversed down the track, no other vehicles can access it to perform maintenance tasks,” explained Peter Camarri, managing director, CME Boilermaking. CME Boilermaking has extensive experience in design, engineering and fabrication for industries such as bulk handling, cranes and lifting, mining, food and beverage, agriculture and steel. “There’s also no power source down there, so air or electrical options are ruled out. The Enerpac battery pump is the perfect solution. The battery power means that it can operate underground, and not having cords adds to the safety of the operators,” said Camarri. “Once a mining vehicle gets a flat tyre, the chassis is essentially on the ground, which means that many conventional lifting devices

Flat tyres on heavy off-road vehicles are difficult enough on the surface, but when they occur underground a whole new set of challenges arise.

are not an option. The entire lifting system had to be under 25kg so that it was as light as possible to manually carry to the vehicle. “My engineering team worked closely with Enerpac to come up with a solution to this perennial problem for underground miners.” Enerpac WA territory manager David Capper says that CME are onto a real winner with the underground lifting jacks. “Changing heavy vehicle tyres underground has caused the industry a lot of pain. CME’s innovative solution will save many hours and lots of frustration in the underground mining industry,” he said. The technology is in the final stages of an on-site trial, and CME expects it to be ready in the second half of 2017. Engineered as a long-lasting pump that can be used in hardto-access areas, XC-Series cordless pumps are constructed of lightweight materials, equipped with a one-half horsepower motor and feature 28-volt, Lithium-Ion battery technology. With its bladder reservoir, Enerpac says its cordless pumps eliminate venting and offer leak-free operation in any orientation. Australian Bulk Handling Review: July/August 2017

PNEUMATIC CONVEYING

US engineer specifies vortex chamber elbow A Texas-based specialist designer of bulk handling plants has moved away from long-sweep elbows in favour of HammerTek’s Smart Elbow deflector elbow citing reduced wear, dust, and offload times.

obert Ober & Associates is a specialty design/build firm in Texas that serves an international client base for bulk material handling projects that range from A$32,500 retrofit contracts to A$32.5-million turnkey plant projects. The company’s early focus on pneumatic material handling for concrete plants has grown to include a wide range of material handling, weigh batching, and powder blending systems in mining, grain, fertiliser, food, fly ash, plastics, pharmaceuticals and other industries. About 60% of that focus is on new plant designs and 40% on plant retrofits. The company began specifying Smart Elbow deflection elbows from HammerTek, a Flexicon Company, in 2001 to reduce elbow wear and related downtime, but now also relies on them to cut offload times, reduce degradation/dust, improve safety and reduce the space needed for conventional sweep elbow installations.

15 years of use without a documented failure Since initially specifying the Smart Elbow deflection elbow (also called a “vortex chamber elbow” or “non-impact elbow”) for wear resistance in concrete plant designs, company founder Bob Ober and his associates have expanded the elbow’s use to conveying of materials from fine, soft powders to larger, more abrasive particles such as silica sand in size ranges from 200 mesh (74 μ) to 20 mesh (840 μ). “I do not know of a single vortex-chamber elbow being taken out of service, among all that we have put in service over these past 15 years,” Ober says. “They have become an integral part of the fabric of our design any time we are dealing with dilutephase material transport.” In fact, he says his company specifies the elbows as an alternative whenever a client’s design calls for long-sweep elbows. The policy evolved after receiving ongoing client complaints about prior uses of long-sweep elbows requiring excessive maintenance downtime for patching or replacing worn-through ells, or clogging of hygroscopic materials. Ober’s company has evolved its own installation procedures based on the historic longevity of the deflection elbow’s wear resistance in its clients’ plant applications. “We will frequently hot-dip the flanged piping and paint the elbows with a zinc-metal cold galvanising compound, because once they go up they’re going to stay there for more than a decade,” Ober explains.

Vortex chamber reduces elbow wear, material degradation, installation space A unique characteristic of the HammerTek Smart Elbow design is a nearly spherical vortex chamber designed into the curve of the elbow. Key parameters allow the chamber to capture a portion of the airflow traveling through the line and cause it to double back into the material stream, creating a deflection zone 28

Australian Bulk Handling Review: July/August 2017

The tight-radius Smart Elbow deflection elbow provides a controlled flow, which is especially advantageous when conveying dusty materials such as cement or fly ash.

At this concrete production plant, the compact dimensions of the tight-radius Smart Elbow design minimise space requirements compared to long-sweep elbows.

that minimises both elbow wear and product degradation. The deflection zone also causes material to exit the elbow more uniformly across the airstream than in conventional sweep elbows in which material skids along the outside radius of the elbow and the downstream conveying line. The airstream sweeps the vortex chamber clean after the material feed is shut off. The tight-radius Smart Elbow design requires roughly onehalf to one-tenth the space needed to accommodate long-sweep elbows of equivalent diameter. This enables Ober’s company to reduce space requirements in new installations and reclaim space in retrofit applications.

PNEUMATIC CONVEYING

The teardrop-shaped vortex chamber designed into the curve of the Smart Elbow creates a deflection zone that minimises elbow wear and product degradation without compromising material flow.

Minimal degradation aids dust control Although Ober initially specified the deflection elbow to reduce wear and downtime, he has also found it to reduce degradation and dust by preventing material impact. “Based on my years of bulk material handling experience, I also appreciated their ability to improve dust control,” he recalls. By incorporating the Smart Elbow units into his plant designs, Ober says he was able to achieve the dust control he

wanted while resolving the issues of wear and of bulk materials plugging pipelines. He has found that Smart Elbow installations promote the material flow change from dilute-phase to what he describes as “slugging-phase” flow that deposits materials into storage silos with less aeration and less dust. “Using these short-radius vortex chamber elbows provides a more controlled flow,” he says, “and for dusty cement and fly ash applications, that’s an important consideration.”

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PNEUMATIC CONVEYING

These Smart Elbow deflection elbows reduce aeration of dry cement powder moving through the pneumatic lines, decreasing dust collection demands.

Bulk materials offload times reduced by 50% Because about 80% of Robert Ober & Associates’ dilute-phase pneumatic transport installations involve offloading of bulk materials from trucks or railcars into storage silos, transfer times are an important measure of design efficiency. The company optimises the parameters of conveying systems on an individual basis by applying the performance characteristics of the Smart Elbow design to decrease aeration and increase density, thereby reducing the time a transport driver must wait for materials to settle as the silo fills up. Ober notes that some bulk transport drivers were initially reluctant to hook into his plant designs, for fear that the pneumatic transport lines with short-radius elbows would plug up with material. “Some of those drivers were not just skeptical, they downright refused to connect without a call to the dispatcher or to us,” he relates. “The first thing we would tell them was to lower the offloading pressure from 0.83 or 0.69 bar down to 0.41 bar,” he explains. “At that lower pressure, they could get as much product through a 127mm pipeline with a properly specified Smart Elbow system design as they could at 0.83 bar. They could get it done faster than with a sweep ell, and the product going into the silo was 30

Australian Bulk Handling Review: July/August 2017

The Smart Elbow design features a spherical chamber that protrudes partially beyond the desired 90º or 45º pathway, which causes a ball of material suspended in air to rotate, gently deflecting incoming material around the bend without impacting the elbow wall or generating heat − despite the short-radius design.

denser, which was a huge consideration.” Ober estimates that offload times improve by up to 50% – ranging from 20 to 30 minutes with the deflection elbow design vs. 40 to 60 minutes with long-radius sweep elbows.

Environmental stewardship and safety concerns relieved Long-wear characteristics and less dust being generated within the system also improve environmental and safety performance, according to Ober. “By severely reducing the likelihood of elbow wear-through, we minimise the risk of creating a polluting situation where bulk powder can escape from the system and increase employee exposure,” he says. “By generating less dust within the system, the Smart Elbow vortex chamber design also reduces the likelihood of filter media in silo-top dust collectors clogging and causing a safety valve to release material into the atmosphere,” he explains. Lower demand on filter media additionally minimises the risk of a safety valve malfunction that could result in an over-pressurised dust collector being launched from its mounting. Contact: sales@hammertek.com.au

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RAIL CAR UNLOADING

Powerful railcar vibrators deliver high force, low weight A global leader in industrial vibration technology has introduced a portable vibrator that activates the free flow of bulk materials from closed-top hopper railcars.

The IMP3 is designed to withstand punishing conditions. Set on the hopper slope of the railcar, the unit dislodges adhered and compacted material.

ith one of the highest force to weight ratios available in the marketplace, Martin says its IMP3 Impacting Railcar Vibrator delivers the power required to evacuate compacted bulk materials such as fertilizers, bentonite clay, Portland cement, grain and other agricultural products. The company says that high quality standards for the design deliver superior equipment reliability and long service life, allowing the competitively priced units to improve workplace safety with very little maintenance and a low cost of ownership. “When a railcar is being emptied, the process needs to be fast, efficient and thorough, because extra time spent unloading, manually cleaning or sending cars back with material in them can translate into lost profits or increased costs,” explained Marty Yepsen, business development manager for railcar products at Martin Engineering in the USA. “The higher the force to weight ratio, the more force is delivered to the material, increasing the efficiency of the vibrator.” The IMP3 was purpose-built for unloading dry powdered bulk materials. If vibrators fail, workers may need to resort to unsafe practices to get material flowing again, such as hammering on the cars

or attempting to unclog them from the bottom of the hopper. To avoid these expensive and potentially hazardous scenarios, the IMP3 produces 3,000 vibrations per minute (VPM) and 1542 kgs of force, which has been compared to a sledgehammer blow 50 times per second. The rapid impacts generate a vibratory wave through the metal hopper of the railcar, loosening adhered material to promote fast and even flow.

The IMP3 requires an air supply of 80 psi and 25 cubic feet per minute (0.012 MPS). When operated using a filtered, regulated and lubricated air supply, Martin says the unit requires virtually no maintenance. Made in the USA and priced to replace heavier and less reliable competing designs that can be difficult to handle, the IMP3 has already built a following among its users. “Visiting the facilities that have started using these units, operators tell me they’re impressed by the ease of use and the low maintenance,” Yepsen concluded. “This is one of those products that has a profound impact on logistical efficiency, workplace safety and overall cost of operation.” Martin Engineering manufactures flow aids and conveyor products around the world for a wide variety of bulk material applications. The company manufactures around the world and and under exclusive license with ESS Australia. 1) https://www.osha.gov/SLTC/etools/electricalcontractors/materials/heavy.html

The weight factor Lifting heavy items is one of the leading causes of injury in the workplace. In 2001, the US Bureau of Labor Statistics reported that over 36 percent of injuries involving missed workdays were the result of shoulder and back injuries. Overexertion and cumulative trauma were the biggest factors in these injuries.1 The IMP3 replaces a traditional cast iron housing with an aluminum body coupled with a wedge bracket, and it features an integrated handle for easy gripping and moving. The low weight means that more of the energy is transferred from the unit to the hopper. “Weight and ease of use are important, because transferring the vibrator can be a repetitive motion that produces fatigue and eventual injury,” Yepsen said. “This lightweight unit is designed specifically for constant handling in less-thanideal environments.”

Unit is designed to be light weight with an easy grip handle, reducing the strain of mounting/ dismounting .

Australian Bulk Handling Review: July/August 2017

NEWS

Thank you Japan!

Japanese steel mills kick-started Australia’s iron ore and coking coal industries in the 1960s, signing long term off-take agreements that underwrote pits, equipment and infrastructure.

BHP and Rio Tinto have celebrated milestones which reveal Japan’s pivotal roll in birthing Australia’s bulk commodity industries.

io has just celebrated the shipment of its five billionth tonne of iron ore from the Pilbara to, fittingly, a Japanese customer as was the case with its first tonne. BHP had a big party in early June to celebrate 50 years of partnership with Japan, with the country’s major trading houses jump-starting exports of coking coal from the Bowen Basin and iron ore from the Pilbara in 1967. Rio’s record-breaking shipment was sent to Nippon Steel & Sumitomo Metal Corporation in Japan on the bulk carrier MV Onozuru Maru in April and was celebrated at a ceremony in Tokyo in mid-May. Rio Tinto Iron Ore chief executive Chris Salisbury said “Shipping five billion tonnes is a remarkable accomplishment and it is fitting that it was delivered to Japan, our first customer and valued long-term partner.” Rio Tinto’s first shipment of iron ore was 52,000 tonnes from Mount Tom Price. On 22 August 1966, it set sail on the MV Houn Maru from Dampier bound for Yawata Iron and Steel (now part of Nippon Steel & Sumitomo Metal Corporation).

The development……underwritten by the Japanese steel mills in the 1960s through long-term off-take contracts. The development of that mine and the necessary infrastructure to transport the ore had been underwritten by the Japanese steel mills in the 1960s through long-term off-take contracts that were revolutionary at the time. “The five billion tonne milestone would not have been achieved without the pioneers who developed the Pilbara more than 50 years 32

Australian Bulk Handling Review: July/August 2017

ago and the hard work and dedication of the 11,000 Rio Tinto Iron Ore employees running the business today,” said Salisbury. BHP celebrated its 50 year bash in June at an event with representatives from the Japanese, Australian and British governments, customers, joint venture partners and employees at the Australian Embassy in Tokyo. BHP CEO Andrew Mackenzie was joined by Australian Ambassador to Japan, Hon. Richard Court AC and joint venture partners Mitsubishi Development, ITOCHU Corporation, JFE and Mitsui & Co., Ltd to mark the milestone. Mackenzie acknowledged the importance of long-term business relationships and two-way trade between BHP and Japan in building economic growth.

NEWS

“In 1967 BHP and Japan became partners when Japanese steel mills signed long term contracts….” Andrew Mackenzie, chief executive of BHP Billiton. “Both BHP and Australia owe much to Japan for the development of the resources industry. Just as it was 50 years ago, Japan remains a critical market for BHP and the industry as a whole, and I am delighted to celebrate this important milestone. “In 1967 BHP and Japan became partners when Japanese steel mills signed

long term contracts for coking coal from our Blackwater mine in Queensland. It was also the year that we entered into partnership with Mitsui and ITOCHU in the Western Australian Mount Whaleback iron ore project. “As trading companies they were a crucial link into Japanese markets. As Japan’s economy grew the iron ore and coal we exported came back to Australia as high quality manufactured products such as motor vehicles and Komatsu trucks and the rolling stock and rail equipment our industry relies on. “A few years later Mitsubishi and JFE partnered in our iron ore and copper assets in Australia and Chile turning a trading relationship into a business partnership.” Today BHP supplies iron ore, coal, copper, nickel, uranium, LPG and LNG to Japan. “These commodities produced by BHP and our joint venture partners have helped Japan become one of the world’s largest economies,” Mr Mackenzie said. “Together we have helped to create jobs and stimulate investment around the world. Our partnership with Japan is closer and stronger than ever. We look forward to partnering with Japan for decades to come.”

Japan nurtures Pilbara production The 1960s was a golden era for Japan. As the country rebuilt its warravaged economy, annual growth was just shy of 10% per annum, a rate only matched by China in more recent times.

ot surprisingly, the discovery of more and more iron ore deposits in Western Australia soon piqued the interest of Japan’s government and major trading companies. Hamersley Iron, formed by Conzinc Rio Tinto of Australia and Kaiser Steel Corporation of California in 1962, was in the forefront of binding Australia and Japan closer together. The company led a mission to Japan in November 1962, working closely with Japanese companies Marubeni-Iida and Mitsubishi Shoji. Japan, in turn, staged its own mission in 1964, inspecting reserves in the Pilbara. Hamersley signed a 16-year deal with Japanese steel mills in 1964, to supply 65.5mt from 1966. Funding came from US banks and the Federal and Western Australian governments, with Japan

supplying machinery and technology. Mt Goldsworthy Mining signed another 16-year deal in 1965, this time for 16.5mt of ore. The BHP-operated Mt Newman Mining developed the Mt Whaleback mine. As a discussion paper from the University of Western Australia’s business faculty (by MAB Siddique) spells out, Japan’s steel output almost doubled between 1966 and 1970, rising from just under 48mt to 93mt. In that period, its demand for iron ore grew at around 19% per annum. In turn, Western Australia’s iron ore production, worth only $1m in 1960 had reached $446m in 1973. In 1973, Japan purchased 84% of Western Australia’s iron ore exports, which supplied around 45% of Japan’s requirements.

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IRON ORE

US$14.3bn state-of-the-art Brazilian mining complex ramps up Vale’s 90mtpa S11D iron ore mine, rail and port project despatched its first shipment in January 2017. The sophisticated operation is a technical tour-de-force, employing truckless operation, dry processing and a network of overland conveyors.

ormally dubbed the “Eliezer Batista S11D Complex”, Vale says the project is the largest in it, and the world mining industry’s, history. Vale produced 349mt of iron ore in 2016. Aided by S11D it expects to lift output to between 360mt and 380mt in 2017. The first shipment from S11D of 26,500t left on January 17th with the ore set to be blended with output from other Vale operations at overseas distribution centres. Vale’s then CEO, Murilo Ferreira described S11D as one of the company’s “most daring projects”, incorporating,

as it does, enormous scale and a suite of new technologies. First production in January 2017 was the culmination of a 16-year journey that began in 2001 with the first technical and economic feasibility studies. The mine’s lifespan is expected to be 30 years. Out of the US$14.3 billion invested in the project, US$ 6.4 billion went to the mine and plant, with US$ 7.9 billion for a 101km-long rail spur, expansions of the Carajás Railroad and a new terminal in São Luís (MA). Vale expects S11D to slash its production costs, saying that the C1 cash cost

of ore delivered to port for S11D will be US$7.7/t, 41% less than its current average cost. The high quality of the ore extracted from the new mine will provide flexibility for the company to blend it at ports in China and distribution centres in Malaysia and Oman, with ore from Vale’s other mines. The project was named after its location: it is on block D of the S11 body, on the South Range of Carajás. On the north range, since 1985, Vale has operated the Carajás Mine, located in Parauapebas, a neighboring

SKM’s important role in S11D

Aerial view of the mine.

Truckless operation.

Australian Bulk Handling Review: July/August 2017

While SKM has been subsumed into acquisitive US engineering firm Jacobs, it’s worth remembering that the firm played an important role in S11D’s development. SKM and its mining systems manager David Morrison (now at Bechtel in Brisbane) established a truckless mining centre of excellence. This unit, through cost-benefit analysis, advised clients on the economic, social and environmental consequences of truckless mining for particular projects. The firm also delivered truckless EPCM projects. For Vale, SKM did a feasibility study on the general technical and economic viability of truckless mining systems at S11D. On-going work with Vale prompted SKM to establish a Brazilian offshoot with an office in Belo Horizonte. The rationale behind the truckless mining studies was that, in essence, no two mines are alike. The most applicable mining method must be determined on a case-by-case basis. Trucks are best suited to short hauls and selective mining/dumping. As haulage distances increase and production ramps up, conveyors and mobile mining/dumping machines start to come into their own.

IRON ORE

municipality of Canaã dos Carajás. For geological purposes, S11D is only one block of the ore body, which was divided in four: A, B, C, and D. S11’s mineral potential is 10 billion tons of iron ore, and blocks C and D together have reserves of 4.24 billion metric tons. The first geological surveys in the region occurred in the 1970s. S11D comprises a mine and an iron ore processing plant, with three production lines − each with a processing capacity of 30 million tons/year. The ore is extracted from an open pit mine and transported to the plant via a longdistance belt conveyor (TCLD). The plant, product and buffer stockyards, the waste and canga (iron ore with higher impurity grades) piles, and the train manoeuvring and loading area are located in a pasture land, outside the Carajás National Forest. Carajás National Forest has 412,000 hectares and, even after the implementation of S11D, only about 4% will have seen interference from mining activities since Vale began operations in the region 30 years ago. At the peak of construction works, the project absorbed a workforce of more

Process plant and stockyards.

than 40,000 workers. Once the ramp-up is completed, about 2,700 employees will be working directly at the plant and mine with 10,000 indirect jobs created.

Technology and systems Significantly, Vale adopted a truckless system for S11D, the set-up comprising

mobile excavators and crushers interconnected by conveyor belt. In a truckless system, the shovels dump the ore in fully mobile crushers, which feed a system of mobile and fixed conveyors installed inside of the mine, and long distance conveyors connecting the mine to the plant and waste piles. The total

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Australian Bulk Handling Review: July/August 2017

IRON ORE

Process plant and stockyards.

length of the truckless conveyor belts operating in the mine and plant is 68 km. The system replaces traditional off highway trucks (OHT) used in mining. If S11D had been structured as a conventional operation, 100 off highway trucks with a 240t capacity would be required. Without trucks, Vale will reduce fuel consumption by 70%. With less mining equipment, there will be a significant reduction in waste generation, such as tyres, oil filters and lubricants. Truckless technology is commonly used in coal mining, where ore layers are continual and homogeneous. The characteristics of S11Dâ&#x20AC;&#x2122;s mineral body enabled the application of this mining configuration, since it is an elongated, relatively homogenous mineral body, 9.5 km long by 1.5 km wide, and 300 metres deep. Located 400 metres above the processing plant level, S11D mine will be divided into four mining systems operating simultaneously, each with one shovel and one fully mobile crushing plant. After being crushed, the mined material will be transported through in-pit conveyor belts to a transfer station, where the iron ore, canga and waste will be redirected to one of the three long distance conveyors: iron ore to the processing plant and canga and waste to stockpiles. The ore is transported through the Long-Distance Conveyor Belt Conveyor (TCLD), which is more than nine kilometres long, while the canga and waste are transported through two parallel overland conveyors, each measuring five kilometres. Despite the high phosphorus content, considered a contaminant in the iron and steel process, canga has a high iron content so it will be stocked at a different pile and may be used as product in the future. Another technological driver of S11D project is the use of dry processing of the ore, with equipment developed by Vale in partnership with manufacturers, specially tailored to process the natural high moisture ore of CarajĂĄs. Dry processing is already in use in some plants in CarajĂĄs and will enable a 93% reduction in water consumption. Another benefit of dry processing is that there is no need for a tailings dam, due to the high quality of the ore and to the dry processing. The ultrafine fraction of high grade iron ore, which would end up in the dam, will be part of the final product. A final technological driver was the modularisation of the processing plant, similar to methods in the oil industry to build maritime platforms. The buildings of the processing plant were divided in modules during project development and engineering. Then the modules, 109 in total, weighing from 80 to 1.3 thousand tons, were assembled at a construction site more than 40 km away from the place where the plant is now working. 36

Australian Bulk Handling Review: July/August 2017

Before being put together, welded and bolted as if they were large Lego pieces, to form the plant buildings, the modules were transported through a road specially prepared and paved to support the weight and dimensions of the modules. The transportation of the 109 modules was completed in August 2015 and their assembly at the mine was done in October of the same year. Thanks to the truckless system, together with the dry ore processing, Vale expects to see a reduction of at least 50%

IRON ORE

Process plant and stockyards.

in its greenhouse gas emissions, which means about 130 thousand tons of CO2 less per year in the environment. Also, according to Vale, 18,000 MWh/year of electricity is going to be saved.

Logistics After being processed, S11D’s iron ore will be carried by railway to the Ponta da Madeira Maritime Terminal (TMPM) in São Luís. To enable transportation, it was

necessary to build a whole set of logistics accounting for 55% of total project cost. Logistical solutions comprised construction of a 101km-long railroad branch; the expansion of the Carajás Railroad (EFC); and the expansion of TMPM. Most of the 101km railway goes through pasture areas, with only three within forest. One tunnel and two railway bridges were built to minimise environmental disturbance, along with 32 wildlife crossings. The rail branch connects to the existing Carajás Railroad in Parauapebas, Southeast Pará. Considered one of the most efficient railroads in the world, EFC is 892 kilometres long. As part of the EFC expansion, 570 kilometres of new railway lines were built alongside the existing lines, interconnecting 48 crossing yards. In addition, 220 kilometres of railroad tracks on 55 crossing yards were remodelled to allow trains to transit at designed speed. Previously, 56 trains could circulate at the same time in the Carajás Railroad, including ore trains, general cargo and passenger trains. The system’s iron ore trains are some of the largest in the world in regular operation, with 330 cars at 3.3

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Australian Bulk Handling Review: July/August 2017

IRON ORE

Conveyor systems.

kilometres long, carrying 33,000 tons of iron ore. With the duplication of the railroad, circulation increased to 69 simultaneous trains, sufficient to accommodate S11D and Vale’s other Carajás Mining Complex expansions.

Port S11D’s logistics included expansion works at the Ponta da Madeira Maritime Terminal lifting nominal capacity to 230 million tonnes per year. The TMPM works included onshore and offshore expansions, in addition to the expansion of the railroad branch, located within the port. In the offshore area, the project included the construction of a new berth on Pier IV, the north berth, plus a ship loader, replicating the same design already existing in the south berth. According to Vale, the advantage of Pier IV in relation to other Brazilian ports is the capacity to receive large-size ships such as Valemax, the largest ore carriers in the world, with a capacity of 400,000 tons, 362 metres long and 65 metres wide. Since it is in open sea − that is, with no seawalls or jetties − the pier required extra safety precautions from Vale, since the construction was performed over the sea. Its mooring system is unique in the world for ships with a capacity of 400,000 tons. It is comprised of onshore lines that aid the mooring of the ships to the berths. For a Valemax, 16 onshore lines and 20 ship lines are used, for a total of 36 lines. The system enables giant vessels to operate without restrictions at the pier. The onshore works comprised the expansion of the port’s dry area, where four new ore stockyards were built, with a capacity for 600,000 tons each. They were in addition to nine existing stockyards. The new yards have two rotary car dumpers, one stacker, two reclaimers and two stacker-reclaimers. Finally, the works at Ponta da Madeira also included the expansion of the railroad branch to include a Locomotive Inspection and Filling Station (Pial) and a rail car workshop, which includes a wheel exchange centre and a wheel maintenance centre. According to Vale, both use brand new technologies, 38

Australian Bulk Handling Review: July/August 2017

which are able to exponentially increase the productivity cycle in these routine operations. Today, almost 15,000 wagons are used to transport iron ore over the EFC and, in 2020, when S11D is in full production, there will be 19,000. The increase in the number of wagons in circulation will make the part replacement process an even more complex task. Vale believes this is when the new wagons workshop and the new locomotive filling station will come to the fore. The process works as follows: the 330-car trains coming from Carajás, in southeast Pará, are broken down into 110-car blocks to facilitate unloading. While the ore is removed, the locomotives move on to being reviewed at the Locomotive Inspection and Filling Station, with a capacity to service up to 12 locomotives at once. According to Vale, this station resembles a F-1 pitstop, since it is completely integrated with the railroad circuit. Before, the locomotive would have to leave the circuit and be brought into a workshop to be supplied and submitted to corrective and preventive maintenance. Now, in addition to a greater integration of processes, the main benefit is a reduction in the preparation time of the locomotives for a new trip. After being unloaded, the cars are pulled by the locomotives already revised and loaded to the wheel exchange centre. The axle comprises the wheels, the bearings and the shaft and enables the movement of the car over the tracks. At the wheel maintenance centre, any axles that require maintenance are removed and replaced by others in good order. The centre has a capacity to service up to 2,000 cars a day. Under the new method, which lasts up to 15 minutes, there is no longer need to separate the car with the damaged axle from the block, as was done before. The exchange made with the integrated block reduces maintenance downtime. Any axles requiring maintenance are sent to the wheel maintenance centre. At this other large workshop in the complex, state-of-the-art equipment is used to perform the necessary repairs, leaving the axle suitable for new trips. Once the locomotive is supplied and revised, and the axles are replaced, it is time to assemble the train to go back to Carajás.

NEWS

Cautious optimism for dairy sector in report A report from Rabobank suggests an improved 2017/18 outlook will see a rise in the forecast farmgate milk price range.

ustralia’s dairy farmers can look forward to an improved 2017/18 season ahead, with a partial recovery Rabobank senior dairy analyst Michael Harvey. in forecast farmgate milk price for southern export regions to AUD 5.40-5.80/kg MS, according to Rabobank in its newly-released Global Dairy Quarterly report. Favourable input prices and better seasonal conditions will support a partial recovery in milk production, the agribusiness banking specialist says. In its Q2 report, Rabobank says this farmgate milk price is slightly higher than the previous forecast and supported by a better-than-expected butter fat price. Rabobank senior dairy analyst Michael Harvey said opening prices announced by southern Australian dairy processors are in line with Rabobank’s expectations. “Fundamental to this outlook, we expect global markets to remain well balanced through the 2017/18 Australian season,” he said. “And while global pricing has reached the peak of the cycle, markets are set to remain well balanced for the next 12 months.” The report says – after a very challenging past 18 months with the sector beset by low prices, poor seasonal conditions in key areas and milk supply decline – trading and seasonal conditions look mostly favourable for Australia’s dairy farmers, with the 2017/18 season approaching.

Supply growth Rabobank expects to see a recovery of approximately three per cent in Australian milk supply in the coming season. While this represents a “decent” level of supply growth, Mr Harvey says, it goes only part way towards replacing the supply lost last season. “Since the start of the 2016/17 season, Australia’s national milk supply has fallen by more than 660 million litres (or eight per cent) compared with the same period the previous season,” he said. “Not surprisingly, more than 80 per cent of that decline has come from Victoria and 50 per cent from northern Victoria alone.” Mr Harvey said the rate of decline in milk supply had started to slow in most key dairying regions in Australia. “Rabobank’s expectations are for a modest supply recovery in the 2017/18 season,” he said. “The cost of key inputs remains affordable, but more importantly climate conditions look likely to set a much better season from a home-grown feed perspective. Early indications are rainfall has been mostly favourable in many dairying regions which goes a long way to helping set up an improved season.” Mr Harvey said confidence levels were improving among dairy farmers, but from a very low base. Also, the capacity to recover production remains constrained by lower herd size and the ability and willingness to invest heavily on-farm.

Exports The report says Australia’s exportable milk surplus had significantly contracted over the past 12 months. In the period from July 2016 to April 2017, dairy export volumes from Australia fell 2.1 per cent. “Trade in skim milk powder and butter has been hit hardest due to reduced production and product shortages in the local market,” Mr Harvey said. “As the season winds down and the focus shifts to the new selling season, inventories are low in Australia.” Mr Harvey said milk volume was an issue confronting most dairy processors. “The national trend has seen milk being prioritised over cheese, skim milk powder/butter and liquid streams,” he said. The report says there will be an easing off in the decline in Australian milk supplies eventually returning to growth later in the year. This will help in delivering higher milk volumes for export markets going forward. “A healthy rate of volume growth in Australian domestic consumption will partially offset any supply increases in the first instance,” it says. “Dairy consumption is growing in excess of two per cent across major dairy categories, including cheese, butter and milk.”

Globally Looking globally, the report says the dairy market continues to move back towards modest year-on-year milk supply growth in the major export regions. In line with Rabobank’s previous forecast though, growth has been slower than expected by many, Mr Harvey said. New Zealand, the world’s largest dairy exporter, has started its new season with expectations of healthy year-on-year production growth, due to higher milk prices and compared with the weak level of production last season. While China – after disappointing import growth for the year to April – is expected to be a more substantial buyer on global markets in the second half of 2017 which will help keep the global market balanced. “These global factors should continue to keep prices relatively range-bound through the forecast period,” Mr Harvey said. “While demand growth for dairy in developed markets will remain strong, reducing export surpluses and countering more sporadic demand growth in developing markets.”

Watch factors There are several watch factors, however, for the remainder of the year which may impact this forecast price outlook, Rabobank says. These include the level of supply response in New Zealand and the fate of current EU skim milk powder stockpiles, as well as moves to substitute expensive dairy fats with cheaper vegetable alternatives among industrial and bakery end users. “The other factor to watch is anticipated Chinese buying in the second half of the year and whether it does not materialise,” Mr Harvey said.

Australian Bulk Handling Review: July/August 2017

COVER STORY SEW-Eurodrive’s segmented girth gears easily fit into containers for shipping and transport to the mine site.

No teething troubles at Wiluna Gold When a new girth gear was urgently required at the Wiluna Gold Mine, the operation’s new owners opted for a segmented girth gear from SEW-Eurodrive. As this was a non-traditional girth gear design, reputations were on the line. However, with the backing of its global operation, SEW-Eurodrive says its local team delivered in spades.

hen refurbishing a closed-down mine, it is impossible to know exactly what to expect, no matter how carefully the exercise has been planned. That is just the nature of the business. Sometimes the refurbishment includes a mission-critical production item, and that means quick action is required. After two teeth on a 4.5-metre diameter girth gear had snapped off during the last phase of operation in 2013, prior to the refurbishment, that was the situation facing Stewart McCallion, project manager – Matilda Gold at Blackham Resources, at Wiluna Gold Mine, in outback Western Australia. “It takes a lot of pressure to break a tooth off a girth gear. You can imagine the noise,” says McCallion. Fixed in place at the larger of the mine’s two mills, the girth gear is a heavy-duty piece of machinery that rotates the ball mill shell. This slowly rotating shell is filled with steel balls that grind the ore down to a fine powder with particles only 75 microns in diameter. There was much to be done to replace the girth gear in the short time available between obtaining investment approval and commissioning the plant in readiness for the planned production

Australian Bulk Handling Review: July/August 2017

schedule. McCallion and his colleagues would need to align procurement, fabrication and installation of the new gear and pinion with all the other refurbishment and construction deliverables.

Mammoth task The mine has a long history, dating back to 1897 with the discovery of a 13-kilogram gold nugget – the largest found in Australia to that point. It has undergone numerous transformations in the years since, as successive owners have introduced more modern technology and techniques to deal with its complicated ore bodies. The complication is that in addition to oxidised ores, the area is rich in sulphide ores, which require an extra step in the process to recover the gold. The girth gear that failed was just one part of the tired infrastructure that McCallion and his team encountered when Blackham Resources took over the mine in early 2014. Bringing the mine back to life after its three-year hiatus in care and maintenance was a huge task. The company invested heavily in all aspects of the mine, from the crushing and grinding circuits and leaching tanks to the mine’s village.

COVER STORY

“No matter how much you do at the beginning to estimate the amount of work needed in a refurbishment program like this, it’s almost impossible to make an accurate assessment. Stripping things apart to find out what’s really required is almost half the job,” says McCallion. In addition to the as yet undiscovered but nonetheless expected tasks, McCallion’s team also undertook a number of planned activities such as building a new power station and a new tailings dam. A major challenge for his team was to align the timing of the girth gear replacement with all the other elements of the mill’s refurbishment. These included concrete and structural repairs, replacement of the trunnion bearings, refurbishment of the mill motor and gearbox, removal and replacement of the mill liner, and also refurbishment of the mill’s electrical systems and instrumentation.

Racing to replace McCallion says the mine aims for 95% availability. It operates around the clock, except for scheduled maintenance shutdowns. With the ball mill out of action, the daily cost of lost production would be significant, so the race was on to find a replacement girth gear that could be installed before the mine’s planned reopening date. Nathan Langham, technical sales representative – industrial gears with SEW-Eurodrive, was aware that his company was better known in Australia for its gear motors and heavy industrial gearboxes rather than equipment like girth gears. However, he was also well aware of SEW-Eurodrive’s reputation for successfully installing hundreds of girth-gear sets around the world over the last decade.

Fixed in place at the larger of the mine’s two mills, the girth gear is a heavy-duty piece of machinery that rotates the ball mill shell.

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Australian Bulk Handling Review: July/August 2017

COVER STORY

The installation of the new girth gear went precisely as planned. “The guys on site were gobsmacked at how easily it went together,” says McCallion.

Langham says he expected an initially sceptical response when he first approached Blackham Resources with a solution for its problem. By their nature, girth gears for retrofitting are often designed and produced individually according to careful measurements so that they fit in place when delivered. This meant close cooperation with an overseas manufacturing plant would be necessary at all stages of the project as the gears were neither assembled nor stocked locally. On top of this, the SEW–Eurodrive design was radically different from others used in Australia to date. It was a lot to ask of a new customer.

Segmented at girth Perhaps the most unusual aspect of the SEW-Eurodrive solution was the construction of the girth gear. According to Langham, most conventional girth gears are fabricated in two parts. In contrast, the girth gears from his company are formed from several identical segments. He says that although this approach is still regarded as unconventional in Australia, it has a number of clear advantages. “Transporting these girth gears to site is much easier,” he says. “Unlike the traditional parts, these smaller segments easily fit into containers for transport to Australia. Similarly, transport to the mine itself is just as easy.” The segments are constructed from Austempered Ductile Iron (ADI), which has a higher tensile strength than the 42

Australian Bulk Handling Review: July/August 2017

usually employed materials. Because of this, the girth gears from SEW-Eurodrive are thinner. Less material means less initial cost. It also means that less lubrication is required when the mill is running, so operating costs are reduced as well. “Production times are faster, delivery times are shorter and, with the right dimensioning, load and lubrication, an ADI girth gear is virtually wear-free,” says Langham. “Other advantages of the segmented design are that each part can be easily checked before installation and fewer spares are required.”

Laser precision The major challenge for the engineering team was to design a girth gear that would precisely match the existing mounting arrangements of the mill. Rather than relying on archival documents or approximate manual measurements, the SEW-Eurodrive engineers chose to bring in an external contractor to take three-dimensional scans of the mill, using highly accurate laser technology. This allowed the international team of designers from SEW-Eurodrive to customise the new girth gear to fine tolerances. “Each hole for mounting needs to be accurate within microns,” says McCallion. “Despite the assurances from SEW-Eurodrive that their quality system was the same regardless of which plant in the world the equipment is designed and manufactured at, our contractors on site were very concerned about putting a

The new girth gear was customised to fine tolerances.

multi-segment gear together on site and getting it to fit.” When the time came to put this to the test, the results were pleasing. So much so that representatives from SEWEurodrive’s project engineering team who had travelled from Perth specifically to witness the girth gear being mounted missed out on seeing it. McCallion says that, normally, girth gears need a little ‘coaxing’ to align. However, at Wiluna, the segments were assembled and mounted so quickly that it was all over before they arrived. “It went in amazingly well,” says McCallion. “The guys on site were gobsmacked at how easily it went together. Because of the nature of a large mine refurbishment project like ours, things don’t always go smoothly, and we have our challenges. The installation of the new girth gear was probably the one thing that came to fruition precisely as planned – including on schedule and within budget. I now recommend them and would use them again.” With Australia’s first segmented girth gear installed successfully, SEW-Eurodrive says two more have been ordered for mines in Western Australia and more are expected. “It is clear that this alternative girth gear design is now gaining acceptance in Australia,” concluded Langham. Contacts: Wayne Martin, WA state manager, email – wayne.martin@sew-eurodrive.com.au

NEW PRODUCT

Larger Hydro-Clean test facility Australian mineral processing operations now have the opportunity to test out a newer, higher capacity version of Haver & Boecker’s Hydro-Clean washing technology with the arrival of a test facility at the company’s premises in Malaga, WA.

he Hydro-Clean 350 test unit, a new pilot scale version of the washing system developed by the mineral processing technology firm, will allow companies to test their products at the test facility’s Malaga home or hire it to trial onsite. The system is suitable for a variety of materials including iron ore, bauxite, uranium ore, gold ore, magnesite, mineral sands and aggregates. Haver & Boecker Australia operations manager Jan Averhaus said: ‘The Hydro-Clean technology provides a number of advantages over conventional maintenance-intensive washers such as scrubber drums and other tumbling or sheer forcesbased systems. “Its efficient design uses minimum water and energy to blast away sticky, stubborn grime that even the toughest washers can’t budge while gently handling precious metals and stones. It means cleaner, more valuable product and reduced operating costs.” The test unit offers a capacity of up to 20 tonnes per hour allowing Haver & Boecker’s customers to test a greater quantity of product and get a better understanding of the system’s capabilities and return on investment. Equipped with measuring equipment such as flowmeters and pressure

The Hydro-Clean test unit has capacity of up to 20 tonnes per hour against the 320 tonnes per hour of the commercial model.

meters, water consumption can be logged for different material properties. A full scale Hydro-Clean unit offers a throughput rate of up to 320 tonnes per hour.

PACKAGING

NZ packaging businesses merge Packaging leader J.L. Lennard has merged its New Zealand packaging machinery business with Tech-Pack in a bid to create a stronger competitor in The Shaky Isles.

company representing world-leading brands in packaging machinery, J.L. Lennard, has merged its packaging machinery division in New Zealand with Tech-Pack (NZ), a well-established supplier of filling and packaging machinery. The new business – J.L Lennard Packaging, a division of the Australasian network of J.L. Lennard Limited – will extend the long-held customer service philosophies of both companies, specializing in the efficient execution of contracts ranging from the supply of single machines through to the design, supply and installation of complete packaging lines on a turnkey basis. Leadership of the new business will continue under Mr Phil Lea, says the managing director of J.L. Lennard Ltd, Mr David Boekemann. “Phil has spent over 30 years in the packaging industry in NZ, with particular expertise in the plastics and materials area and

with a strong background and understanding of machinery to assist our customers with their requirements,” he says. Customers will also gain the full backing of the Australasian network of J.L. Lennard, which is one of Australia’s leading suppliers of packaging machinery and food service equipment through offices in five states. J.L. Lennard is one of Australasia’s oldest companies and an established leader in its field known for its tradition of strong, open relationships in dealings with customers, suppliers and staff. J.L. Lennard Packaging will represent some of the world’s leading names in packaging machinery including: Rovema, Multipond, Fawema, Stephan, Hunter Filling Systems, Thermo Scientific, and Strapack. “Offering access to a very broad and complementary range of brands available from one supplier, J.L. Lennard Packaging will be at the edge of innovation. Our

J.L. Lennard distributes and supports multiple packaging brands, including Rovema, Multipond, Fawema, Stephan, Hunter Filling Systems, Thermo Scientific, and Strapack.

ranges of advanced, cost-efficient and environmentally sustainable packaging solutions are backed nationally by our strong Australasian service and support network,” said Mr Boekemann. Contact: www.jllennard.co.nz

Australian Bulk Handling Review: July/August 2017

WEIGHING & LEVEL MEASUREMENT TECHNOLOGY The automated system is adaptable to chute or clam shell loading systems.

MRA pioneers train load out automation technology Electrical and control system specialist MRA says that its automation of the train load out process has improved capacity, profitability and safety at Anglo American’s German Creek mine.

he reliability and efficiency of the train load out process at coal mines can be a ‘make or break’ when it comes to meeting production timelines and profitability. Anglo American is the world’s third largest exporter of metallurgical coal. The company uses the latest technology to run its operations in the best possible way and strives for continuous improvement at existing assets. Train loading stations are often considered a bottleneck, as these facilities are typically operated manually resulting in variable performance, wagon over or under loading and poor reliability. As a result, companies are often faced with heavy fines and in some cases substantial costs to obtain additional trains to meet required throughput. MRA Electrical & Automation Engineering (MRA) was initially involved in the first automation of a train load out (TLO) in Australia more than fifteen years ago. As such, the company has a detailed understanding of the systems required. At that time there were some limitations in the technology that resulted in shortcomings in early systems. These limitations culminated in issues with accuracy and environmental conditions. To address this, MRA says it conducted extensive research and development, using the latest technologies to overcome these shortfalls and develop an efficient and reliable automated TLO solution. When Anglo American tasked MRA with automating its TLO process at the German Creek coal mines, the result exceeded expectations. MRA says it provided an intelligent and intuitive system that not only improved efficiency and reliability but also delivered a state-of-the-art solution with an unrivalled return on investment.

Clever control technology Initially MRA investigated primarily vision-based systems, but these were subject to accuracy issues as a result of changing 44

Australian Bulk Handling Review: July/August 2017

environmental and weather factors such as sun, rain and fog. As laser and sensing technologies advanced, they provided a more reliable alternative that is not as vulnerable to weather and environmental factors. According to Stephen Mount, general manager at MRA, “We built the robust automated TLO system on the fundamentals of train speed and position to improve the accuracy of the process. The raw data is filtered and moved into our system to perform the correct analysis to overcome any issues with environmental conditions.” There are three major components to the system, the first being the sensors in the field, the laser scanners and RFID tag reader; the second is the PC-based server that performs all the filtering and analysis of data prior to communicating to the third component of the system, the PLC. “The system architecture of this TLO demonstrates the power of the ControlLogix platform for data processing and integration as well as control,” said Geoff Irvine, mining industry manager, Rockwell Automation. The Allen-Bradley ControlLogix PLC is programmed to provide centralised control for the entire TLO process. The MRA system has been engineered to integrate with the controller via Ethernet/IP communications using point to point networking via a Stratix switch. “We incorporate as much functionality as possible inside the Logix controller which delivers unmatched fault-finding capabilities and advanced integration between the PC and controller,” explained Peter McPherson, engineering manager at MRA. “Laser sensors detect information about the wagon location that is communicated to the Logix controller. Also, information about coal profiling is concurrently fed back to the controller which is programmed to analyse this information and provide advanced feedback control of the TLO process in real time,” he said.

WEIGHING & LEVEL MEASUREMENT TECHNOLOGY

The automated TLO is monitored from the central control room

Automated loading Prior to the automation of the TLO process, operators were only able to load wagons based on the available tools at their disposal. However, significant advancements in automation technology have enabled operators to consistently load train wagons with uniform and symmetric profiles to meet coal height and bogie loading requirements “There are substantial penalties involved if a train is not loaded correctly with the right profile over the bogies. Overloading results in significant penalties but there is also an issue with under-loading that needs to be considered. By underloading, each wagon is losing capacity, which directly impacts on efficiency and profitability, but it also entails a safety issue and risk of derailment. Reducing weight variations in order to optimise the amount of coal loaded per train is the ultimate goal in automating the TLO,” explained Mount. Considering variables such as operator fatigue, time of day and environmental conditions presented challenges for MRA in developing the automated TLO system. To address this, MRA’s solution used predictive modelling and advanced filtering methods to compensate for aberrations in raw data. It also allows for environmental compensation through scanning methods and adaptive software. The Logix controller provides the platform for feedback control and real time output of data through Ethernet/IP communications. This use of smart technology with self-diagnostics and alarming provides an intelligent and intuitive system that removes the guesswork for operators. By automating the TLO, the operator performs a supervisory role either from the TLO or a central control room during loading to monitor the system. According to Anthony Manousso, Capcoal control system coordinator, Anglo American, “When you automate a process, you have to consider all the variables in the design and commissioning phase. We did that and the way the system is running now, the operators can sit in the control room and

Automation technology enables operators to consistently load train wagons.

monitor the process. The operator interface is easy to use so training requirements are minimal.”

Remote commissioning reduces downtime When it comes to a TLO, time is money and therefore any amount of time that the system is down has direct impact on profitability. One of the features of MRA’s TLO system is that the outage time for installation is minimal. “It took less than a day’s downtime to go from the existing system at German Creek to the new automated TLO. The bulk of our commissioning is done remotely by accessing the PLC online to make any required changes, which saves significant costs with no need to go to site,” said McPherson. “Once the scanners are installed prior to the cutover we record live data from the site and undertake detailed simulation prior to installation to make sure it’s working as per the specification. This reduces not only the commissioning time but also the need to delay trains post installation,” he added.

Impressive return on investment Having been in operation for approximately three years now, German Creek has recorded real time results indicating a return on investment of less than four months for the TLO automation system. Prior to the upgrade, the subjected TLO was consistently achieving average payloads in the order of 9,100 to 9,300 tonnes per train. Post upgrade, the subjected TLO is now averaging 10,000 tonnes per train. “With this monthly average increase of approximately 700 tonnes per train, based on 40 trains per month, this equates to a significant efficiency gain,” said Mount. Automating the TLO also provides significant benefits in terms of improved safety by reducing the risk of derailment from under loading, which can also have detrimental environmental effects resulting from spillage. In addition, automation of the TLO process removes operators from potentially hazardous situations and fatigue issues can also be avoided. “The coding that MRA developed within the ControlLogix

MRA says automating the TLO process delivers improved capacity, profitability and safety at Anglo American’s German Creek mine.

Australian Bulk Handling Review: July/August 2017

WEIGHING & LEVEL MEASUREMENT TECHNOLOGY Post upgrade, the TLO is now averaging 10,000 tonnes per train.

PLC is extremely efficient and reliable. We are now using it for 98 percent of loading with only 2 percent being loaded manually as a result of external factors. This TLO system is an integral part of our pit to port operation − the end goal is to make sure our trains are fully loaded,” explained Anthony Manousso. The TLO is an integral part of the pit to port operation.

Loader scale differentiators

Not all loader scales are created equal, says Martin Nix of Position Partners.

ABHR spoke to Martin Nix, chief executive of Position Partners, about some of the features to look for in loader scales.

dding loader scales to a loader is a productivity enhancer. By ensuring each load is right the first time, every time, loader scales can dramatically reduce trips to the stockpile, so saving on fuel, and reducing machine and tyre wear. But Martin Nix, boss of Position Partners − a company that is a specialist in positioning and machine control solutions − has some firm views on desirable features in loader scales. “A dynamic weighing capability is important,” said Martin. “To really save time and get accurate results, look for a system that can keep up with the machine. It sounds simple, but in order to get reliable repeatability and accuracy you need scales that can weigh continuously, when the machine is either moving or stationary. Most systems on the market do not do this! “Inclinometers and accelerometers, in engineer speak, translate to a system that can stay accurate in rough terrain, at speed and cater to slopes up to +/- 10 degrees.” Another desirable feature identified by Martin is oil temperature compensation. “Loaders are doing the machine equivalent of interval training all day, every day,” he said. “Heavy lifting, cardio to

Australian Bulk Handling Review: July/August 2017

and from the stockpile and times where it’s idling lead to fluctuations in oil temperature, which can lead to fluctuations in weight accuracy unless you have a system that can compensate for it.” The ability to add ‘Trade Approved’ functionality to loader scales means operators can transact from the weight data on the system. Meanwhile, the ability to transform a loader scale indicator into a reversing camera screen increases safety and reduces clutter in the cab. Finally, Martin is a firm believer in the flexibility of an open source platform. “Companies need to make sure that the system they invest in can handle everything they need, including support for a wide range of buckets, forks or other attachments, the ability to work with wheeled, telescopic or tractor style machines and, importantly, the option to interface directly with their ERP system,” concluded Martin.

Contact: www.positionpartners.com.au

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THE EVOB IS DESIGNED FOR BASIC APPLICATIONS

• Controls up to 12 lifting points

• Cylinder stroke control

• Network up to 4 systems

• Controls up to 8 lifting points

• Center of Gravity option

• Uses Z-Class pump technology

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WEIGHING & LEVEL MEASUREMENT TECHNOLOGY

ABB launches “revolutionary” level measurer ABB is vigorously promoting its LLT100 laser level transmitter, a non-contact device that can measure the level of any solid or liquid in industrial applications.

BB says the LLT100 revolutionises the level measurement industry, replacing open-path radar and other level transmitters. “This new product changes the way level measurement is performed. It is measurement made easy,” stated the company. The LLT100 measures the level of any material, solid or liquid, independently of its properties or conditions. ABB said: “With its narrow laser beam, the LLT100 can avoid obstructions, can be installed near vessel walls, or in tanks with mixing blades, grids or obstructions. “The LLT100 measures continuously and provides rapid surface change

LLT100 laser level transmitter.

tracking. In addition, the advanced signal processing delivers reliable measurements in the presence of mixers and in dusty, foggy and narrow environments. Even clear liquids are measurable and no longer a limitation for laser level devices.” It has a IP 67 / NEMA 4X enclosure

and is approved for use in hazardous areas (class 1/division 1 (zone 1). It is suitable for applications in challenging industrial environments such as bulk handling, mining, aggregates, oil and gas, chemicals, food and beverages, power, pulp and paper, pharma, water and waste water.

First LLT100 for Thai pharmaceutical plant ABB and its various local associates have won an order for a LLT 100 laser level transmitter from Thai Meiji Pharmaceutical which is upgrading its new manufacturing line of crystallization tanks with stirrers.

hai Meiji Pharmaceutical manufacturers using state-of-the-art Japanese technology and distributes its pharmaceutical and veterinary products to international markets. In this instance, the customer’s requirement was to install a non-contact level measurement device in a small crystallization tank with a stirrer. The challenges were the presence of the stirrer and the narrow space of the tank which is a difficult application for level measurement using other technologies such as ultrasonic or open-path radar. The wide beams of ultrasonic and radar can interfere with the stirrer, side of the tank, or uneven liquid surface, affecting the accuracy of the measurement. In contrast, ABB says its LLT 100 laser level transmitter generates a small and narrow beam, unaffected by space and liquid surface. “Thai Meiji has been satisfied with ABB’s new application for laser level measurement. It is exactly what they were looking for,” said ABB’s local dealer, TG Control. The first order with one unit of the laser level transmitter was delivered and installed in August, 2016. A second order of seven more units will be delivered in 2017.

Australian Bulk Handling Review: July/August 2017

LLT100 installed in a crystallization tank with a stirrer.

WEIGHING & LEVEL MEASUREMENT TECHNOLOGY

Sugar, a hygroscopic granular product, is a key ingredient in Welcome Food Ingredients’ manufacturing process.

Automated system improves re-bagging of granular sugar Welcome Food Ingredients required a more efficient system to re-bag granular sugar used to manufacture its sauces, pastes, dressings and dips for food industry customers.

ood hygiene procedures require sugar and other granular ingredients to be decanted into food quality plastic bags weighing 10 kg, but previous methods proved complex and time consuming. The company says it now accomplishes the task in one-third less time with less labour while meeting ATEX requirements using an automated bulk bag weigh batching system with integral flexible screw conveyor from Flexicon Europe.

Re-bagging was labour intensive “With the old process, we received sugar on 1-tonne pallets, comprised of forty 25kg bags,” says Tony Swann, Welcome Food Ingredients safety, health & environment manager. “We used a combination of vacu-lifters and manual handling in an eight-stage process to transfer the sugar into appropriately sized plastic bags before they could be loaded into the cookers. The new transfer system has reduced re-bagging to just three stages.”

A flexible screw conveyor moves granular sugar from the bulk bag discharger to a gain-inweight hopper.

Contact: ???????????

Australian Bulk Handling Review: July/August 2017

WEIGHING & LEVEL MEASUREMENT TECHNOLOGY

Operator attaches strap to one of four Z-Clip bag strap holders before the lifting frame and bag are hoisted and rolled into the discharger.

Electric hoist raises the lifting frame and bulk bag, which are rolled into position by a trolley.

Here, the operator pneumatically raises the Tele-Tube telescoping tube prior to securing the bag spout using a Spout-Lock clamp ring.

Once the bag spout is secured by a Spout-Lock clamp ring, the operator releases the drawstring (red). Constant downward tension is maintained by a Tele-Tube telescoping tube as the bag empties and elongates.

Bulk bag discharger simplifies operation One tonne bulk bags are positioned alongside a Flexicon BulkOut BFC-S-X stainless steel bulk bag discharger, which has an integral cantilevered I-beam with an electric hoist and trolley. The bag straps attach to a cross-shaped lifting frame, and the hoist lifts the bag into position on the discharger frame. An ATEX-rated earth clamp is then attached to the bag. The operator attaches the clean side of the bag spout to the clean side of the discharger by means of a Spout-Lock clamp ring, which is mounted atop a Tele-Tube telescoping tube that maintains constant downward tension on the bag as it empties and elongates, promoting material flow into the 110 litre hopper.

Flexible screw conveyor transports sugar to weigh hopper

The system controller starts, slows and stops the flexible screw conveyor according to the amount of sugar gained by the gain-in-weight receiving hopper suspended on load cells.

Australian Bulk Handling Review: July/August 2017

From the hopper a flexible screw conveyor that is 3.0 m long and 115 mm in diameter, transports sugar to a 40 litre capacity conical stainless steel weigh hopper resting on three load cells. A gain-in-weight control system meters sugar into the weigh hopper at maximum feed rate. The load cells transmit weight gain information to the controller which stepsdown the feed rate to a trickle and stops the conveyor immediately before reaching the target weight to compensate for material-in-flight. Weighments of sugar are discharged dust-free through a slide gate and downspout into a 10 kg capacity blue plastic bag that is clamped beneath the weigh hopper. Once filled, the bag is manually tied off and placed in a plastic storage stillage. The weighing and filling cycle is repeated for subsequent bags.

WEIGHING & LEVEL MEASUREMENT TECHNOLOGY

Operator ties off and removes filled 10 kg plastic bag for storage.

DUST EMISSIONS MONITORING •

Bag Leak Detection

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Fabric Filter Baghouses

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Cartridge Collectors

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Dust Collector Maintenance

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Cyclone Overflow

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Isolate Bag Leak Location

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EPA/MACT Compliance

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Bin Vent/Nuisance Collectors

Discharger, filler improve operating efficiency

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Indoor Fugitive Dust

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Positive Pressure Baghouses

“The bulk bag discharger and filling system has simplified and improved what was a complex, multi-stage handling process,” explains Tony Swann. “Each week we typically re-bag around 30 tonnes of sugar, sometimes operating for 20 hour per day. With our old method, we were handling the equivalent of 100 tonnes of sugar per week.” He says, “Our staff disliked having to manually handle 25 kg bags and are now more comfortable with packing 10 kg bags using the new equipment. It also offers benefits for the future as it can be extended if required. Additional items of equipment like sieves can be incorporated if our customers request their use. “The fact that Flexicon could supply an ATEX-rated food quality handling system with all stainless steel components was of great importance to Welcome Food Ingredients. We’re pleased with the operating improvements it has allowed us to achieve.”

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The flexible screw conveyor is driven beyond the point at which sugar is discharged, preventing material contact with bearings or seals.

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Australian Bulk Handling Review: July/August 2017

CONVEYOR MAINTENANCE

Merger creates conveyor maintenance giant

Technicians undertaking condition monitoring inspections.

Workers undertaking a belt splice at NCIG.

German conglomerate REMA TIP TOP’s merger with conveyor maintenance specialist ConvaTech has created a stronger and better resourced business well placed to service the largest materials processing companies. ABHR editor, Charles Macdonald reports.

he May 2016 deal saw the privatelyowned, Newcastle-headquartered ConvaTech brought into the REMA TIP TOP fold. The 14-months since the transaction have seen the facilities and staff of the two organisations combined. This sometimes challenging process has seen, for example, five premises in Perth consolidated into one facility. For ConvaTech, the merger was the latest significant step on the company’s remarkable 32-year journey. The business was formed in 1985 in Newcastle, originally as a distributor of Belle Banne belt cleaners and related componentry. From the start, the fledgling business added personalised service to what were fairly generic products. Shortly after, and fortuitously, large companies as part of a broader industry trend started to outsource elements of their maintenance. Craig Philpotts, general manager industry Australia for REMA/ConvaTech and a 29-year veteran of the business, recollects the birth of the service division: “It was not just selling the product from a cardboard box but being able to install it, maintain it and − what really set us apart − guarantee our results. It wasn’t about a belt cleaner but about a clean belt.” A pivotal contract with BHP, at that time spinning off its Newcastle steel division, deepened ConvaTech’s service offering. “They gave us the ability to adopt the same principle that we applied to belt cleaning to the whole conveyor,” said Craig. “That was where we really formed the thought of total conveyor maintenance.”

Australian Bulk Handling Review: July/August 2017

The business mushroomed in the years that followed, quickly growing from 6 to 100 staff as it expanded into Western Australia, South Australia and Queensland. It installed belts on large overland conveyors at the largest mines in Australia, New Caledonia and Indonesia. REMA TIP TOP, for its part, was formed by two German brothers in 1923. As far back as 1945 it perfected a cold vulcanization material that allowed better rubber repairs, an early nod to its later conveyor repair products. Today REMA operates in more than 150 countries, with 6,300 employees across sectors including automotive, material processing and surface protection. It is a full-service provider and an OEM of products including conveyor belts, material handling hoses, and wear and corrosion protection materials and systems. By 2016, ConvaTech and REMA TIP TOP knew each other well as competitors but with some shared values and beliefs around customer service. REMA TIP TOP’s heartland was Western Australia where it has a major contract with BHP. ConvaTech’s base was on the east coast, with significant contracts in the Hunter Valley and Queensland Coalfields, as well as, in other states, at Olympic Dam, with FMG and at Rio Tinto’s Dampier Port. While the two companies operated in the same space, there were important differences, with REMA TIP TOP more product-led than ConvaTech. “Service was the cornerstone to our success and that’s what REMA recognised with ConvaTech,” said Craig. “It was a

great opportunity for both companies to capitalise on the strengths of each other and to create a company that can really service the needs of any materials handling client throughout Australia.”

Balance sheet strength REMA TIP TOP’s size and billion-dollar plus turnover is very re-assuring to potential customers. Craig gave the example of a recent meeting with a port that had not done business with the old ConvaTech for a long time. “Previously, they didn’t see us as the company that could properly support their site. But when we got together with Rema they saw the opportunity and we are now servicing them. “Being able to demonstrate that we are part of a global organisation – it gives you instant runs on the board, it gives you a strong tick in the box.”

A strong network, nationwide Following the merger, the new company has facilities in or close to all Australia’s major mining areas. Fixed teams of staff are based on site at mines, ports and process plants for regular scheduled maintenance. Larger teams of on-demand staff are available for larger shutdowns, with these staff being provided by REMA/ConvaTech partners like Alliance Labour Solutions. According to Darren Gilbert, national key account manager for REMA/ ConvaTech − “We are the biggest for sure in conveyor maintenance. None of our competitors would have the number of sites that we do or the size.”

CONVEYOR MAINTENANCE

Reducing customers’ costs and boosting availability Mining companies nowadays have a laser-like focus on costs and availability. REMA/ConvaTech, for its part, is responding to this need. One tool used is REMA/ConvaTech’s Asset Reliability Management Approach (CARMA) which uses data and analytics for customers’ benefit. In practice, CARMA sees REMA/ ConvaTech technicians at 22 sites across Australia daily harvesting a wealth of data on sites’ conveyors. The data will include, for example, belt thickness testing, electronic inspection and thermography. It allows REMA/ConvaTech’s analysts and engineers to come up with innovative solutions to eliminate any issues on the conveyor system. “CARMA collects valuable data on the conveyor condition, performance and costs,” explained Darren. “We can

then report regularly to our customer on availability and reliability.” “CARMA is all about understanding the life cycle of components,” said Craig. “It’s about being able to optimise the conveyor, driving down the total cost of ownership of the conveyor system."

The future: even closer partnerships with its customers Looking into the future, REMA/ConvaTech managers see its technologies and people allowing closer ‘partnership’ type arrangements with its customers. Under such a scenario, REMA/ConvaTech will offer its customers guarantees around availability, reliability and safety with its products and services offered on the basis of cents per tonne or a monthly or annual fee. Both parties stand to benefit in a marked departure from

the traditional adversarial nature of many client-supplier relationships and the grind of dollars per hour.

A bright future for employees REMA/ConvaTech has always cultivated a committed, enthusiastic company spirit. Jason Purcell, NSW services manager, summed it up: “The REMA TIP TOP deal has made us stronger; we have become one of the biggest in the world at what we do. “There’s plenty of opportunity for everyone at this global operating company. Plenty of people have come from ground level up to management level. “The merger gives us even greater scope to expand in other states and countries. If you are passionate and a are a hard worker and are committed to the company, you have got a job for life. It’s great.”

ConvaTech services crew surveying the conveyor system at NCIG.

Australian Bulk Handling Review: July/August 2017

GRAIN HANDLING

Accelerating yields in Russia and the Black Sea are one factor boosting stocks and putting pressure on prices.

Limited upside for wheat prices as ‘high-stocks’ game continues As planting of the Australian wheat crop wrapped up, any prospect of a significant recovery in global wheat prices in the 2017/18 season remains dampened by the high stocks-to-use (S/U) ratio, according to agribusiness banking specialist Rabobank.

n light of this, Rabobank is forecasting CBOT wheat prices to increase only marginally over the coming 12 months – in the vicinity of 10 to 15 per cent – to reach US490c/bushel by mid-2018. In its recently-released industry report, Australian wheat outlook 2017/18 – the high-stocks game continues, Rabobank says with Australian wheat stocks also at historically high levels, the greatest prospect for local prices is the likely depreciation of the Australian dollar, which should push prices into firmer territory over the next 12 months. Report author, Rabobank senior grains analyst Cheryl Kalisch Gordon says the “world is awash with wheat” with the global S/U ratio (defined as the level of carryover stocks as a percentage of total use) now at 33 per cent, well above its historical average of 29 per cent. “To see the global grains market return to a S/U ratio of 29 per cent – which is considered the point that delivers more attractive prices – we would need to see global production fall by 29 million tonnes this season,” she says. “While the US have cut their wheat planted acreage to its lowest level in 100 years, it would take a significant production failure in one or more major supply regions to see the market start to recover strongly.” Dr Kalisch Gordon says while wheat acreage around the world is fairly static, up just one per cent in the past five years, it is the yield advancements in Russia and the Ukraine, and also parts of the EU that is driving the increase in global wheat production. World wheat yields are now estimated to be around eight per cent higher than they were five years ago. “Simple agronomic advancements, such as strategic herbicide and insecticide use, are delivering strong yield growth in the Black Sea region,” she says, “and with the region also renowned for its rich, black top soils, there is significant upside to their production – even without any increase in planted area.” With global wheat production increasing by around three per

Australian Bulk Handling Review: July/August 2017

cent each year (in the five year period to 2015/16), it has “welland-truly outstripped growth in demand, with consumption only growing by an average annual rate of just under two per cent during the same period”, she says. “Consumption growth goes hand-in-hand with economic growth and we have come through a period of lower world growth. While consumption does continue to increase with income growth and westernisation of diets, it would need to increase by a massive, and extremely unlikely 13 per cent, to return the global grains market to equilibrium this year.”

Where are the stocks? The report says with “much of the stock accumulation occurring in China”, Chinese wheat stocks need to be “at least partially taken out of the equation” when looking at global market price dynamics. “Stocks in China account for around 45 per cent of global wheat stocks, with China holding an estimated 100 million tonnes in storage at the start of 2016/17,” Dr Kalisch Gordon says. “However with China accounting for just 1.1 per cent of world wheat trade, their stock levels but also their consumption should be arguably discounted when assessing the prospects of a global price recovery.” Dr Kalisch Gordon says even if China was to be removed from the equation, the global S/U is still 25 per cent higher than its 10-year average, indicating just how high stock levels are around the world. In contrast, and more importantly for Australia, she says the Ukraine has very low stocks at just under two million tonnes. “This is important to note, as the Ukraine accounts for 10 per cent of global wheat trade, and their wheat has been increasingly competitive in Australia’s all-important South-East Asian market,” she says. “And with their stocks at such low levels, this will limit their export capacity over the coming year.”

GRAIN HANDLING

Australian outlook The report says Australia is also heading into the 2017/18 season with high wheat stocks, estimated at close to eight million tonnes, the highest level for almost 20 years. “Despite low wheat prices, the area planted to wheat is expected to be in line with last season at around 12.9 million hectares,” Dr Kalisch Gordon says. “That said, production is anticipated to be down around the five-year average, and there is further downside with the unfavourable weather forecasts.” In light of this, Dr Kalisch Gordon says, the greatest prospect for Australian wheat prices is the expectation of a softening

“The world is awash with wheat,” Rabobank senior grains analyst Cheryl Kalisch Gordon.

AUD/USD exchange rate which could ease to USc 0.72 by the end of 2017. “While the upside to Australian prices, through lower new season production, will be muted by high stocks both within Australia and also globally this season, there are some other factors that could provide support over the next 12 months,” she says. “Namely, Ukraine will have reduced capacity to be aggressive with their export program into South-East Asia this season and there is also expected to be less high quality wheat out of the US and Canada, which could see the spread between higher protein wheat and mid to low protein wheat widen further in coming months.”

Glencore tilts at Bunge, gets lukewarm response Following media speculation, Swiss-based commodities trader and miner Glencore announced in late May that it had “made an informal approach to Bunge Limited regarding a possible consensual business combination.”

n response, an underwhelmed Bunge, a global agribusiness and food company, said in a statement that “it is not engaged in business combination discussions with Glencore Agriculture Limited or Glencore Plc. Bunge is committed to continuing to execute its global agri-foods strategy and pursuing opportunities for driving growth and value creation.” Glencore has spoken of its desire to expand its agriculture business, despite selling a 50% stake two years ago to Canada Pension Plan Investment Board and British Columbia Investment Management Corp. At that time, Glencore was struggling under a heavy debt load, prompting the sale of various assets. Glencore’s CEO Ivan Glasenberg has said in the past he would like to own more infrastructure in the agriculture sector as well as grow Glencore’s presence in the US and South America. In that regard, Bunge and Glencore appear to have complementary assets. Glencore’s agricultural business is big in Canada and Australia, while Bunge’s efforts are centred on the US, South America and Asia.

Analysts have speculated that Glencore might have to pay around US$13bn for Bunge. Potentially, this could put at risk the special dividends that Glencore’s management has suggested could be in the offing for its owners. Bunge operates in over 40 countries with approximately 32,000 employees. It buys, sells, stores and transports oilseeds and grains; processes oilseeds to make protein meal for animal feed and edible oil products; produces sugar and ethanol from sugarcane; mills wheat, corn and rice to make ingredients used by food companies; and sells fertilizer in South America. Founded in 1818, the company is headquartered in White Plains, New York. Glencore Agriculture has a significant presence in all principal import and export markets. Its operations span more than 35 countries worldwide including marketing offices in 34 countries. Its origination and marketing business is built around a network of assets comprising 274 storage facilities, 36 processing facilities and 23 ports in various locations around the world. It also has a global shipping fleet and rail assets.

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Australian Bulk Handling Review: July/August 2017

GRAIN HANDLING

Prescient decision on rail fleet paying dividends for CBH

A CBH loco and rail cars, products of a $175m investment in locomotives and wagons five years ago, in action.

The decision by WA grains co-operative CBH Group five years ago to pour $175m into new locos and wagons is paying dividends as the organisation bursts supply chain records.

BH broke the state shipping record for the month of April with 1.6 million tonnes shipped. It followed the largest ever amount of grain being shipped over a one month period when January’s shipping volumes broke through 1.8 million tonnes. In addition, there were record rail movements across the state in March to help achieve the largest amount of grain ever transported via rail during a one month period (964,832 tonnes during the month). CBH group general manager operations, David Capper, said the successive records demonstrated the ability of CBH’s supply chain to respond to a record harvest. “Without the appropriate infrastructure and dedication of our regional and 56

Australian Bulk Handling Review: July/August 2017

port teams we wouldn’t be able to consistently break records,” Capper said. “It’s important that we’re able to export growers’ grain to international customers at the time they’re wanting it and demand is normally higher in the early part of the year. So far, we’ve exported around 62 per cent of the record 16.6 million tonne crop brought in during last harvest, not accounting for domestic outturns. “We’re pleased to be able to reach these milestones while combating challenges such as flooding in February which impacted our road and rail capacity during February and March. We appreciate the ability to collaborate with our stakeholders and customers to work through these challenges.”

“Rail freight rates now sit around 20 per cent lower than 2011 rates, in real terms,”

CBH Group chief executive officer Andrew Crane.

GRAIN HANDLING

Capper said CBH had utilised a number of strategies to increase shipping volumes. “We’ve continued to increase the total tonnages available through our shipping stem, aided by initiatives including better berth utilisation and increased capacity to bring grain from our upcountry network to port,” he said. “We’re looking forward to continuing to respond to the needs of our customers and growers as we roll out the Network Strategy, focused on delivering an optimal supply chain from paddock to port.” Aiding CBH’s current performance is a decision made five years ago to invest $175m in a new fleet of locomotives and wagons. In 2012 CBH launched the rail fleet consisting of 22 locomotives and 574 purpose-built wagons. It was the first dedicated new grain rail fleet to arrive in Western Australia in more than 30 years. On 15 June 2012, the first train ran from Kwinana to Hyden and in 2014 another three locomotives were added to the fleet. The rail fleet has since moved more than 35 million tonnes with an expectation to hit 40 million tonnes shortly.

CBH Group chief executive officer Andrew Crane said the investment was a strategic decision for CBH Group which had brought significant material benefits for Western Australian growers. “Our investment was driven by a singular focus to continue lowering supply chain costs for Western Australian growers,” Dr Crane said. “It is always pleasing when a business case delivers to and exceeds the benefits envisaged. In the first year of operation CBH reduced rail costs by seven per cent. These reductions have continued with rail freight rates now sitting around 20 per cent lower than 2011 rates, in real terms. “This is a great result and we are continually looking at ways we can continue to keep the Western Australian supply chain competitive against alternative international origins,” Dr Crane said. “We’re pleased to be able to demonstrate how our key investment has returned value to growers and I’d like to personally thank our rail operator Watco for its help in achieving this positive result,” Dr Crane said.

“We’re ……focused on delivering an optimal supply chain from paddock to port,”

CBH group general manager operations, David Capper.

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GRAIN HANDLING

GrainCorp sitting pretty Reporting bulging first half profits, GrainCorp management indicated that productivity initiatives were bearing fruit, with more to come.

rainCorp reported a thumping $100 million net profit for the first six months of 2017 compared to $32m for the same period in 2016. Managing director & chief executive officer Mark Palmquist said the result is consistent with full year guidance of a net profit of between $130 million and $160 million, versus a 2016 figure of $53m. “GrainCorp’s strong first half performance benefited from the large Australian grain harvest and higher export volumes, combined with our intense focus on improving network efficiency and managing costs,” Palmquist said. “Our storage and logistics team performed very well in response to the significant challenges of the record harvest and compressed export program. We provided a high level of service to growers and efficiently managed our supply chain labour costs. “This has been achieved through our strategy of developing a modern, efficient network through Project Regeneration which resulted in average receivals per site rising to 70,000 tonnes from 40,000 tonnes last harvest. “Following harvest, our grains businesses and the broader industry are

A bumper harvest, too, kicked GrainCorp’s results along nicely. 58

Australian Bulk Handling Review: July/August 2017

contending with significant supply chain disruptions, due to an extended industrial dispute affecting our Victorian rail provider and earlier bad weather. Nonetheless, it is pleasing to see a stronger result from GrainCorp Marketing which has also benefited from increased exports from the east coast and Western Australia. “GrainCorp Malt has continued to perform strongly, despite an unfavourable foreign exchange impact. We expect the expansion of our malt plant in Pocatello, Idaho to come online in July this year, which will more than double available capacity at the site. The group is also improving its sales mix with a focus on higher margin products. “GrainCorp Oils did benefit from increased canola supply, which drove down procurement costs, as well as stronger demand for meal and continued high utilisation at GrainCorp Liquid Terminals. There has been continued pressure on margins in GrainCorp Foods, with the business focused on improving production efficiency at West Footscray.” Palmquist said GrainCorp remained committed to strengthening its core business by improving the underlying performance of its business units.

“Project Regeneration…. resulted in average receivals per site rising to 70,000 tonnes from 40,000,” Mark Palmquist, managing director & chief executive officer, GrainCorp. “GrainCorp is currently in a very favourable strategic position. Our program of major capital works projects is largely due for completion over the next 12 months and we will enjoy the benefits in coming periods. In addition, strong volumes and cashflow, combined with the sale of Allied Mills and a German malt house, provides balance sheet flexibility that will allow us to consider growth options in line with our strategic priorities.”

GRAIN HANDLING

CBH’s Interflour opens new Vietnamese malt facility CBH Group has welcomed the opening of Interflour’s US$70 million Intermalt facility in Vietnam, which the Group says will provide Western Australian grain growers with direct access to the Asian beer market.

Intermalt facility in Vietnam.

BH chairman Wally Newman and chief executive officer Andy Crane attended the ceremony, alongside directors and senior leaders from Interflour, and representatives from the Vietnamese government, in July. Newman said CBH’s involvement in downstream grain processing, through its 50% shareholding of Interflour, had diversified the co-operative’s income stream and resulted in increased market opportunities for Australian grain. “CBH’s investment in Interflour 12 years ago was ground-breaking and today’s opening of the Intermalt facility in Vietnam marks a new phase of growth for the business as it moves into barley processing and expands across South East Asia,” he said. “It will be a new chapter for Western Australian barley growers who now have direct access to Vietnam’s burgeoning beer market – the fastest growing beer market in Asia.” The CBH chairman said growers delivered 1.5 million tonnes of malt barley into the CBH receival network in the past harvest. As part of the final commissioning phase, Intermalt has already purchased 42,000 tonnes of malt barley, with 32,000 tonnes coming from the Kwinana and Albany port zones of the WA grain belt. Intermalt is located in Cai Mep, Vietnam, and will be the largest malting plant in South East Asia, CBH said. It will have the capacity to produce 110,000 tonnes of malt a year and will service major brewers in the region including Heineken Vietnam. “Not only is the Intermalt infrastructure impressive, but so too is the growth and opportunity it affords our growers, our businesses and the Asia Pacific region as a whole,” Newman said. “Our current and future growers can look forward to benefiting from Interflour’s expansion and this new venture generating value that we can then return to them a number of ways including through our investment rebate.” Heineken Vietnam’s Matt Wilson said the company was happy to see Intermalt entering the local market. “Heineken Vietnam always seeks to use local suppliers where possible in order to drive jobs and wealth in Vietnam,” Wilson said. “Because of this, we are very happy to see Intermalt entering the local market with the potential

to supply us with locally produced malt in the future and increase our contribution to the Vietnamese economy.” Interflour has 10 mills operating in Indonesia, Malaysia, Vietnam, the Philippines and Turkey.

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Australian Bulk Handling Review: July/August 2017

GRAIN HANDLING

Seaco spruiks palletwide bulker for grain handling Peter Folkard, regional vice president for Oceania & Americas at container giant Seaco, believes that the company’s special container allows fast, safe and efficient transport for bulk cargos not suited to a standard dry freight container.

sing containers to carry grain is becoming increasingly popular. The method can cater for the seasonal and peak demand periods which fluctuate with commodity prices and weather conditions. Peter Folkard of international container giant Seaco is keen to plug the company’s palletwide bulker as one logical choice for the agricultural and bulk handling industries. “The roof consists of three loading hatches which maximises operational efficiency,” he explained. “The full width front hatch with a side mounted release allows the grain to be discharged in a controlled manner. “For sampling and partial discharge, the two bleed hatches

Seaco is urging the grain handling community to consider its 20’ high cube palletwide bulker.

can be utilised, minimising the loss of product. The steel flooring and the strengthened panels help reduce maintenance cost by providing a solid and sound structure during loading, discharge and transit. “Bulkers with BK2 certification are also available where special gaskets are installed to prevent leakage at the openings. All these features will allow the user to benefit from savings in operational time and cost, hence maximizing profitability.” Seaco is competing hard in the Australian market following its absorption of competitor Cronos Containers. The company offers a variety of specialised containers for handling bulk powders, grains, granules and concentrates, as well as bulk liquids.

FRAS-rated polyurethane for grain handling sites Fire, explosion and other high risk hazards usually occur when grain dust and other combustible materials accumulate, become airborne and connect with ignition sources such as hot bearings, motors or mis-tracking conveyor belts.

eil Kinder, Kinder Australia’s chief executive recently highlighted that, “over the last 35 years high fire hazard industries, particularly the grain industry, have experienced more than 500 explosions globally, killing more than 180 people and injuring more than 675.” A study early this year conducted by Grains Research and Development Corporation and Kondinin Group revealed that around seven percent of grain harvesters each year catch fire, with a staggering one in 10 causing damage to expensive machinery and/or surrounding crops (Source: Insurance Business, 3 January 2017). “Fire risk mitigation requires careful planning and consideration within bulk materials handling operations, particularly in grain handling,” says Mr Kinder. “Flame Resistant and AntiStatic (FRAS) polyurethane certification is now a key requirement within bulk materials handling operations. FRAS’ unique properties and formulation self-extinguishes meeting electrical resistance standards and is stringently tested to MDG3608, section 3.3 requirements.” Mr Kinder went on, “Blue Polyurethane 83A FRAS certified polymer formulation delivers a highly durable, longer lasting wear and abrasion resistance characteristic.” He explained that FRAS also provides an extra layer of protection against damage to expensive plant and equipment and helps to stop the spread of fire to nearby crops and other combustible material. “FRAS K-Snap-Loc Dust Seal System was installed at one of our customer’s sites, an international leader in food ingredients and agribusiness,” Mr Kinder explained. The customer was previously using a ½ inch thick FRAS rated rubber, necessary to comply with OHS regulations to avoid dust 60

Australian Bulk Handling Review: July/August 2017

FRAS-rated polyurethane, appropriately used, can help reduce risks of fire or explosion at grain handling sites.

explosions. The rubber had developed memory fatigue, and was no longer soft enough to conform to the belt sag between the idlers. “As a result, our customer was experiencing a lot of product escaping the skirting which was causing spillage. On average, skirting had to be changed every two years,” said Mr Kinder. The customer used the K-Snap-Loc Dust Deal System to provide an effective seal at conveyor transfer points. “Since installation, our grain handling customer has seen an immediate and ongoing reduction in maintenance costs, not to mention an extension of the existing skirting’s wear life and significant reduction in fire hazard at the customer’s grain handling operation,” concluded Mr Kinder. Contact: conveyorsolutions@kinder.com.au

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CRUSHING

Boral has invested in new crushing equipment to better service market demands in the South Australian region.

Boral’s Linwood quarry opts for Metso crushers To satisfy growing demand, Linwood quarry near Adelaide has upgraded its plant with a jaw crusher and two cone crushers, all from Metso. Boral reports greater throughput and reduced maintenance as a result of the new additions.

ocated in the Adelaide suburb of Seacliff Park, Boral’s Linwood quarry is positioned within one of South Australia’s most important sources of hard rock. Quarrying started here over 130 years ago; in 1882, the quarry was first operated to supply limestone to the nearby Brighton Cement works. Boral, Australia’s largest building and construction materials supplier, acquired the quarry in 1994. Today Linwood’s operations are focused on providing aggregate, critical in the production of composite materials such as concrete and asphalt. Linwood is currently the largest capacity quarry servicing the Adelaide metropolitan area. In recent years, the region has seen a flurry of large construction projects such as Adelaide’s Desalination Plant, the city’s Northern and Southern Expressways and the Royal Adelaide Hospital. As a consequence of these projects, the demand for aggregate products has progressively increased, challenging the quarry’s production capabilities. In 2013, site management identified the need to upgrade their crushing and screening plant with the latest technology in order to meet this growing demand.

Australian Bulk Handling Review: July/August 2017

Improving primary crusher throughput The requirement for new equipment first became evident in the quarry’s primary crushing section. The plant’s 30-year-old primary jaw crusher was struggling to keep up with production demands. The machine’s reliability and downtime were affecting overall plant performance. Maintenance costs had risen sharply and the availability of spares had become an ongoing problem. After considering the cost of refurbishing the existing crusher, Linwood’s management decided that investing in a new machine was their best option. Following a detailed analysis of the quarry’s requirements, the team selected Metso’s C140 jaw crusher. Quarry manager, Andy Baker explains the decision: “Minimising the need to modify our existing civils was a key prerequisite for the new machine. Essentially we needed a modern like-for-like crusher that would fit into the existing footprint, increase throughput and be easy to maintain – Metso’s C140 met all these criteria,” he said. Whilst improving throughput and reliability was a priority, Linwood’s management also recognised the upgrade as an

CRUSHING

Linwood’s quarry manager, Andy Baker.

opportunity to improve site safety. As part of the crusher installation, new walkways and access platforms were designed to improve access to the quarry’s primary crushing station. Once the C140 was installed, Metso says the crusher’s performance and reliability significantly improved product quality and throughput. The new machine’s ability to deliver more consistent output also immediately reduced the load and wear rates in other key areas of the plant. Where personnel previously needed to constantly monitor the crusher to ensure a consistent product output size, this was now an automated process. Andy comments, “Now we can simply program the gap setting and be confident about what product we are going to get. The C140’s hydraulic adjustment provides a massive advantage for us in terms of overall efficiency and safety. It eliminates manual adjustments and associated hazards. This saves us time and keeps our production rates up,” he said. The plant’s primary crusher upgrade represented a big change for quarry staff, as it brought the latest technology to the primary crushing process in the form of advanced automation and safety. Metso’s area manager - Andy Gough says that post-commissioning

Aggregate shape was an ongoing issue in the tertiary circuit.

support was very important to ensure a smooth transition period. “The new machine offered many benefits, however it was a significant change for the site. We worked hard to maintain a presence at the quarry post commissioning, offering support services during this critical period,” he said

A win in tertiary crushing quality and efficiency Shortly after the new crusher was installed in 2014, its increased production capacity shifted the site’s bottleneck to the tertiary crushing circuit. Tertiary crushing involves further reducing aggregate in size while shaping it into final end-products. Whilst it’s important to keep up with upstream feed rates, high precision is required to ensure the right product shape. Linwood had two cone crushers responsible for this task that were nearing the end of their effective service lives. By weight and volume, cubically shaped aggregate is characteristically much stronger than flatter, elongated material. A problem with the existing crushers was their inability to reliably produce aggregate that met the required index of elongation and flakiness. To get the right shape, operators had

Boral project manager Santanu Ghosal overseas cable installation for the new crushers.

Australian Bulk Handling Review: July/August 2017

CRUSHING

to recirculate the output product through the crushers, and/or channel it for additional screening and polishing. Recirculation required additional processing time, which could have been utilised producing new feed material. Another method employed by the quarry’s team to improve shape was to set the crushers with tighter closed-side settings. This increased downstream plant load causing the screens and conveyors to use more energy or become overloaded. Running the crushers longer also increased machine wear, energy consumption and reduced overall production rates. With output quality so heavily dependent on operator intervention, another problem was the constant risk of end-product stock piles being contaminated with inferior product. The combination of these inefficiencies meant there was also less yield per unit of feed. Site management considered replacing their tertiary cone crushers with units from Boral’s extensive install base. Eventually, the team decided that the installation of two new machines would provide the best solution. After an exhaustive selection process which took into account all of the quarry’s requirements, in 2015 Metso was awarded with a contract to supply two HP3 cone crushers.

Selecting the latest crusher technology When Linwood first compared Metso’s HP3’s specifications with their existing crushers, it was a challenge to reconcile their performance and operating requirements. One of the first things that the team noticed was how different the crusher’s size, power and capacity were. The HP3’s design was physically smaller than the old crushers, yet Metso claimed that the machines had a 20% higher throughput capacity and could produce a higher precision product with one-pass production. According to Peter Small, Metso’s capital sales manager, there are a number of factors that allow the HP3 to outperform similar sized machines. He says that while automation with integrated control is an important factor, it is the efficiency of the crushing process that makes the biggest difference. Peter provides some insight: “The HP3’s efficiency is derived from a design that increases the concentration of aggregate inside the crusher. It applies more crushing force and relies on a greater degree of inter-particle crushing. Getting these elements to work relies on complex calculations and detailed analysis of process variables, feed material characteristics and final product specification.” Peter says that an essential part of Metso’s crushing solution is BRUNO, the company’s crushing and screening simulation software tool. BRUNO calculates and tests process models based on empirical crushing and screening expertise. “Being able to demonstrate the capabilities of alternate configurations and designs gives our customers great confidence in the equipment and the designs we propose,” he said.

Metso’s capital sales manager for aggregates, Peter Small.

Australian Bulk Handling Review: July/August 2017

Sailing into unchartered waters When Linwood needed to select its new crushers, the HP3 had just been released. There weren’t any of these machines operating in Australia, which meant Linwood’s decision makers couldn’t call upon the experiences of their usual references within Boral or the broader quarrying community. The availability of spares for the first and only units in Australia was also a concern. Linwood recognised that the next generation HP3 offered many benefits. The technology would future proof the site’s tertiary circuit and enable the wider integration of automation across the entire plant. Santanu Ghosal, Linwood’s project manager, elaborates, “The benefits were clear to us, but choosing the HP3s was still a leap of faith. Ultimately I think it was Metso’s people that gave us the assurance we needed. We had access to a responsive team of local and international experts; and had enjoyed great post-sales support with our C140 primary crusher.” Andy Baker says that Metso’s local and global support network was a significant factor in Linwood’s decision making process. “The support we received helped us to fully explore and understand the options and benefits the HP3s could offer, specific to our situation. For me, a key differentiating factor was the integrated control and automated operation of the HP3s we knew this was the single biggest technology step towards improving our product quality and efficiency.”

Overcoming installation challenges Replacing the old crushers with the new HP3s was always going to be a challenge while maintaining aggregate production rates at the quarry. From an electrical point of view, the HP3’s larger motor required new mounting and cabling arrangements from the crusher through to the switch room. The mechanical work included installing new cooling units and a bigger standalone lubrication system. A redesign of the feeder to a new location was also required. Alongside this work were the site’s safety improvements, which included extended platforms and improved working areas. The team estimated that the electrical and mechanical upgrades would take the tertiary crushing station offline for at least 17 days. This made the timing of the installation a critical consideration. Linwood’s management originally considered performing the installation over Christmas, but were concerned about the availability of personnel, parts, and materials during this period. Whilst management planned to stockpile product in preparation for the installation, at the same time they had major projects to supply and knew their reserves wouldn’t last 17 days. In order to help mitigate the loss of production, a trailer mounted cone crusher and screen was refurbished to supplement supply while the main plant was offline. Performance and efficiency were not optimal,

Linwood’s project manager Santanu Ghosal.

ether g o T s n o ti lu o S g in c Pie

For More Information Visit

www.kockumsbulk.com.au Call 03 9457 8200 to speak to your local representative

CRUSHING

The HP3’s touch screen has simplified the adjustment of crusher parameters.

but the mobile station closed the gap in production whilst installation and commissioning was in progress.

Improved site productivity and safety During the selection process, a high degree of automation was a requirement for the site. Once the new HP3s had been installed, feedback from the quarry’s operators has been particularly centred on this aspect. The HP3’s touch-screen interface allows operators easy access to troubleshooting, throughput and motor current information. Mechanical settings, which previously had to be manually adjusted, are now performed in a matter of seconds via the machine’s touch screen. Stray metallic objects, called tramp iron, that enter the crusher can stall and even damage the machine. The HP3’s tramp release system with dual-acting hydraulic cylinders and fixed return point lets the crusher easily eject tramp iron. If the crusher stops under load, the dual-acting hydraulic cylinders provide a powerful stroke that clears the crushing cavity. In both instances the crusher’s settings are instantaneously restored without the need for operator intervention. The HP3’s liner fastening system doesn’t require the backing material that is common with other crushers. When liners are

Metso’s vice president – aggregates Shaun Fanning.

changed or reconfigured, hydraulic motors rotate the bowl completely out of the adjustment ring threads. These two innovations save a lot of time and labour.

Technology upgrade – making the big difference The upgrades to Linwood’s crushing circuit have improved the site’s production capabilities and modernised its crushing process. Commenting on these outcomes, Andy Baker believes the site is now capable of producing more, while maintaining high product quality and improving safety. “The throughput we are getting has surpassed our expectations. Our ongoing maintenance costs have come down, while the automation and access platform upgrades have improved plant safety. Overall, we can now more reliably meet market demands for our keyspecification products,” he said. Commenting on Linwood’s successful application of new crushing technology, Metso’s vice president for aggregates Shaun Fanning highlights the importance of the project. “We are extremely happy to support Boral’s long-term growth plans through such an important project for the Linwood site.” Contact: Shaun Fanning, Metso Australia, email − shaun.fanning@metso.com

GRAIN HANDLING

ARTC upgrades track to Broadbent facility Australian Rail Track Corporation (ARTC) executive general manager – Hunter Valley, Jonathan Vandervoort, welcomed the opening of the 3.5km section of rail line to the Broadbent Grain facility in Moree earlier this year.

he upgraded section of the Moree-Inverell rail line connects with ARTC’s network in Moree. Mr Vandervoort said on the back of a big grain season, it was great to see new rail infrastructure available to support farmers in the region thanks to the NSW Government’s Fixing Country Rail program. ARTC has seen a threefold increase in tonnage and train numbers to the Port of Newcastle this harvest compared to the same time last year. “We have been investing significantly in rail infrastructure right through our Hunter Valley network up to northern NSW 66

Australian Bulk Handling Review: July/August 2017

– making rail more competitive and accessible for farmers than ever before – and this new section line adds further capability,” Mr Vandervoort said. “With increased train axle loads now available between the Port and Moree on ARTC’s network, the new connection to Broadbent Grain’s site means heavier, more efficient trains can now run out of the facility. That lowers transport costs and puts dollars back in farmer’s pockets.” The bulk rail loading capabilities in Moree also enable a 48 hour cycle to Newcastle.

GRAIN HANDLING

Drive systems provide conveying power in grain mill An Austrian grain milling company has opted for Nord gears and drives for a major new expansion.

ased in Wallern in Austria, Arnreiter Mühle processes grain, malt, and oilseeds mostly for the baking and food industry. The family-owned mill has a 200-year history. Since the early 20th century, it has been continuously modernised and expanded. During a recent modernisation, a high-capacity mill with separate, state-of-the-art grinding technology and refining facilities was erected. The new building accommodates a wide range of processes that are carried out with a high degree of automation. Grist shape and characteristics are modified by means of steaming, flaking, crushing, grinding, extruding, roasting, cooling, drying, and husking. Thereby, shelf life, digestibility, and baking properties are improved and bitter constituents are reduced.

Geared motors drive the belt and bucket elevators that are used to transport raw materials from the silos.

Parallel and integrated processes The Arnreiter mill has a 1,400 kW connected load. Up to 80 tons of grain can be ground daily. In addition, the refining facilities have a capacity of up to 20 tons per day. All processes, from raw produce storage to bagging and loading, are automated. There is control level access to all applications via Profibus. A large number of explosion-proof Nordbloc helical geared motors Automatic separation: A Nord helical geared motor drives the “We need highly flexible facilidrive rotary dischargers, for instance after the scale that tallies the screw conveyor that removes low-density particles. ties,” says Walter Arnreiter, mangrinding yield. aging director of the mill. “First of all, they must enable variable and parallel processes with sepadrive components, geared motors, mechatronic units and cabirate product flows and additives that can be released from one net inverters. source into different lines. And we must also ensure product flow with minimal residues.” Clean application The main raw materials are temporarily stored in silos locatThe machines used in the Arnreiter mill are mostly systems made ed in the upper stories. Geared motors from Nord Drivesystems by Swiss process engineering specialist Bühler which has been drive the belt and bucket elevators that transport the materials working with Nord for many years. from there. Separators and aspirators from Bühler are used to clean and Consecutively, the major part of all product transport takes classify granular products such as wheat, rye, barley, oat and place in the extensive pipe system that has a total length of 2,500 maize. Air-recycling aspirators remove dust and husks. A radial metres. Free-flowing and non-flowing products are volumetricalfan creates an air current to lift the medium and blow the lowly dispensed by means of a great number of rotary dischargers, density particles into a special separator from where they are all of which need reliable geared motors. “Nord systems carry out discharged by a screw conveyor driven by a Nord helical geared many different tasks in our machines,” says Arnreiter. motor. The clean heavy product is discharged from the machine through finger valves. “We rely on low-maintenance drives from Nord which we emExplosion protection a prerequisite ploy in continuous operation mode. They perform reliably,” says Mill operators must implement a proven, reliable explosion Martin Rachbauer, maintenance manager at Arnreiter. protection regime since the dust atmospheres prevalent in many areas pose a high risk. Nord Drivesystems assisted in the Contact: Martin Broglia, email - Martin.broglia@nord.com recent expansion by supplying explosion-proof versions of its Australian Bulk Handling Review: July/August 2017

ENGINEERING

Tech-savvy duo’s website links professional engineers and their clients Two experienced Queensland engineers with a passion for the internet have launched an online marketplace called Eng Access. It aims to match customers for engineering services in Queensland with the state’s 12,000 registered engineers.

(L to R) Dr Stuart McCarthy and Dr Matthew Robinson, founders and operators of Eng Access.

ueensland stands alone as the only state or territory to legally require engineers to be registered in order to provide engineering services or products. While this bolsters standards and safety, it can be hard for registered engineers in the state and their potential customers to find each other. Dr Stuart McCarthy and Dr Matthew Robinson, founders of Eng Access, have seen this problem first hand. While both working in Brisbane for engineering firm BMT WBM, in McCarthy’s words “we had frank conversations based on our observation of people cold calling looking for a Registered Professional Engineer of Queensland (RPEQ).” A dawning awareness of a potentially troublesome issue was compounded when Robinson himself ran into trouble when trying to source a particular RPEQ. “He’s a mechanical RPEQ and he needed a residential structural RPEQ and he had a dog of a time trying to find one,” explained McCarthy. “We respect and appreciate the legislation and understand intimately its intent of safety in the community and responsibility for the profession. But if you can’t find one it can become a burden.” This personal experience was the genesis of the development of Eng Access which will help customers ranging from a homeowner wanting an RPEQ to sign off on a retaining wall, to a coal terminal manager seeking services at a stockyard. The idea is that the site will provide a modern alternative to word-of-mouth recommendation or networking. “As the world becomes more visibly focussed, there ought to be simpler ways to find the expertise that you require without having to cold call businesses,” said McCarthy.

Australian Bulk Handling Review: July/August 2017

For bulk handlers, in particular, RPEQs are in continual demand in Queensland. “For any work around bulk materials handling machines − audits, project work around stacker reclaimers, shiploaders, conveyors − at some point an RPEQ will have to be the responsible person,” said McCarthy. “The legislation makes the individual the responsible person and not the company they work for.” McCarthy and Robinson know the bulk handling sector very well. McCarthy had a long stint at BMT WBM leading up to his departure in 2016. Over their careers both have worked to offer solutions to customers − such as Hay Point, Dalrymple Bay, Abbot Point, WICET, and Curragh mine − in the bulk handling space. McCarthy is a mechatronic engineer interested in automation solutions. “I take responsibility for delivering smart turnkey solutions to help customers with productivity and safety – that ties into bulk handling – to get humans out of dangerous environments, and to boost productivity.” Robinson is a mechanical engineer with a PhD in aerospace engineering. Despite their different backgrounds, both share a strong interest in digital technology. “That’s been a core driver for my partner and I,” said McCarthy. “We are digital and tech aware and passionate about technological initiatives.” In terms of competition, existing freelancing and hire sites like hipages and Upwork can sometimes turn up RPEQs. “They are not as streamlined and as focussed as what we have undertaken,” said McCarthy. “Ours is different – it ought to make life a lot easier for the client – we are focussing on RPEQs which gives the customer confidence that the people that they are getting quotes from are competent and certified as required. Within these other platforms, unfortunately ‘engineer’ is one

“There ought to be simpler ways to find the expertise that you require without having to cold call businesses…” of the most polluted professional descriptions out there. A lot of people call themselves engineers but within the framework of RPEQ they are not necessarily competent and therefore not able to provide services and products into Queensland. Even if a bulk handling machine is built offshore, eventually a RPEQ

ENGINEERING

will have to sign off that it is fit for purpose to be used in Queensland.”

“Unfortunately ‘engineer’ is one of the most polluted professional descriptions out there.” Eng Access’ backers believe that the site might also assist with price competition on engineering jobs. “With the resources (sector) becoming far more cost-conscious stakeholders are looking for competitive prices,” said McCarthy. “There will always be a place for known experts but if you are looking for more competitive quotes there is no simple way at present.” A $100,000 grant from the Queensland Government’s ‘Ignite Ideas Fund’ helped take Eng Access to a more professional level. A pre-requisite for the grant was that McCarthy and Robinson already had a viable product with scalable potential. “The grant has enabled us to take our ‘Minimum Viable Product’ and turn it into a higher performing production system – a better marketplace,” said McCarthy.

www.engaccess.com links Registered Professional Engineers of Queensland with potential clients.

Progress to date While Eng Access has been in the hands of Beta testers for some months, the site went live in early June. Initial efforts are focussing on signing up RPEQs to the platform.

“We have been cautious about getting the fundamentals right but we now want to press the button to get a core RPEQ group on the site so we can then enable clients to post jobs they need help with.”

NEW PRODUCT

Razerlink Mobile Conveyor fits multiple applications Superior Industries, a US-based manufacturer and supplier of bulk material processing and handling systems, has completed manufacture of its first Razerlink Mobile Conveyor − a multi-functional machine designed to load, unload, transfer, and/or stockpile material.

ccording to Superior engineers, by combining mobility with telescoping conveyor technology, the Razerlink Mobile Conveyor limits downtime and accelerates material handling. Additionally, one-time-handling of material aids in maintaining high quality material spec. Each unit is tailor-made to the conditions of the customer’s operation, whether it be a barge, rail, quarry, mining or construction site application. Mobility options include conveyor tracks, drive tyres, or towable tyres. For applications not requiring telescoping capabilities, the new machine can be fitted with a fixed length, radial, or luffing conveyor. The unit’s feed design can come in the form of a drive over ramp, back up ramp, or feed hopper, which accommodates most loading styles. The units are built in 48-inch (1,219mm) or 72-inch (1,828mm) wide models and can transfer material at rates up to 1,500 TPH.

Superior’s new mobile conveyor – the Razerlink.

Australian Bulk Handling Review: July/August 2017

CONVEYORS

7km Flyingbelt transports 1,500tphr of limestone in Brazil Sempertrans and Agudio have combined forces to install a Flyingbelt − a combination of ropeway and conveyor belt – over a distance of seven kilometres between a limestone mine in South Eastern Brazil and a cement plant owned by LafargeHolcim. The project is valued at 25 million Euros.

The 7km Flyingbelt uses a single 14.4km rubber belt as well as 60,000 metres of rope and 25,000 rollers.

Australian Bulk Handling Review: July/August 2017

empertrans and Agudio describe the Flyingbelt as “a completely new system for bulk transportation over long distances.” It uses a trough-shaped belt to carry materials high over otherwise impassable terrain. In difficult, hilly conditions the Brazilian system carries 1,500 tonnes of limestone per hour at a height of up to 36 metres. The sevenkilometre installation is the longest Flyingbelt in the world. “With the Agudio Flyingbelt we have installed a very innovative bulk materials transportation system. The Sempertrans conveyor belt not only overcomes − at great height − terrain that can only be accessed with difficulty; it also transports material efficiently and in an environmentally-friendly way. More than 40 truck journeys every hour are saved,” commented Thomas Fahnemann, CEO of Semperit Group, parent company to Sempertrans. “We are the only conveyor belt manufacturer worldwide that has the technical expertise to deliver the right belt for the special construction of a cable conveyor belt.” In this instance, the conveyor belt was produced in the Sempertrans plant in France and shipped to Brazil. The system uses a single 14.4km rubber belt as well as 60,000 metres of rope and 25,000 rollers. “The customer LafargeHolcim was convinced by the lower longterm operating expenses and the higher transportation capacities,” explained Thomas Fahnemann. “The electricity consumption of the new conveyor equipment is only around one third of that of conventional ropeway systems and, instead of the previous maximum of 400 tonnes per hour, 1,500 tonnes of limestone can now be transported in the same amount of time. “In addition, the construction work needed on the ground for traditional conveyor belts, which encroaches significantly on nature and the landscape, was not necessary for the Flyingbelt in Brazil. “Following the successful completion of the project for LafargeHolcim, Sempertrans and Agudio plan to convince further customers about the new technology. New projects are in the pipeline, also in areas other than the core mining segment.”

CONVEYORS

Flyingbelt vs RopeCon Playing in the same space as Agudio and Sempertrans’ Flyingbelt is Doppelmayr’s RopeCon, another conveying technology targeted at difficult, hilly terrain.

ith its origins in mountainous Austria, Doppelmayr’s broad product range encompasses ropeways and skilifts of all types. RopeCon is targeted at the industrial sector and is capable of carrying up to 25,000tpa over valleys, rivers, roads and buildings. The system has a small structural footprint and transports material on a flat belt with corrugated side walls.

The belt performs the haulage function and is driven and deflected by a drum in the head or tail station. The belt is fixed to axles arranged at regular intervals to support the belt. Running wheels are fitted to either end of the axles. These run on track ropes with fixed anchoring and guide the belt. The track ropes are elevated off the ground on tower structures.

Second RopeCon allows more flexible discharge In Switzerland, the city of St Gallen is back-filling a lengthy valley at nearby Tüfentobel with 5.3 million cubic meters of inert material from surrounding construction sites.

The Tüfentobel landfill site has added a second RopeCon. Material is passed from the first to second RopeCon in mid-air for more flexible discharge.

o avoid noise, dust and disruption to nearby residents, project planners opted for one of Doppelmayr’s RopeCon rope conveyors, in place of trucks, to move the massive volumes of material. Since 2005, the original RopeCon has discharged material onto a debris cone directly where it is to be used. The belt has been extended in several stages. This has kept transport routes as short as possible for both the trucks supplying the material and the bulldozers spreading it from the discharge point. In March 2016, a novel concept was implemented which has further increased the flexibility of the RopeCon rope conveyor. A second RopeCon was installed directly into the rope span of the original system, which now discharges the material onto the new conveyor at a height of approximately 20 metres. The new RopeCon system can operate in both directions. This allows for two different discharge points which can be fed alternately. The second RopeCon system requires no support structure of its own but rather uses the track ropes of the original system. The running wheels of the second installation return onto the track ropes on a set of rails. An important advantage of the extension concept was that even during the assembly work the original system could be kept in operation to the greatest extent possible. Long shut-down periods were thus avoided. Contact: www.doppelmayr-mts.com

Australian Bulk Handling Review: July/August 2017

AD INDEX

Advertisers Index Advertiser Page

Advertiser Page

Allied Grain Systems . . . . . . . . . . . . . . . . . . . 59

Flexco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mideco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Australian Society for Bulk Solids Handling . . 51

Flexicon Corporation . . . . . . . . . . . . . . 76 (OBC)

REMA TIP TOP . . . . . . . . . . . . . . . . . . . . 2 (IFC)

Belle Banne Conveyor Products . . . . . . . . . . 41

GEA Nu-Con . . . . . . . . . . . . . . . . . . . . . . . . . 29

BinMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

HammerTek . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Bintech Systems . . . . . . . . . . . . . . . . . . . . . . 33

Jenike & Johanson . . . . . . . . . . . . . . . . . . . . 21

ContiTech Australia . . . . . . . . . . . . . . . . . . . . 13

Kilik Engineering . . . . . . . . . . . . . . . . . . . . . . . 57

Dana Brevini . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Kinder Australia . . . . . . . . . . . . . . . . . . . . . . . 23

Dyna Engineering . . . . . . . . . . . . . . . . . . . . . . 19

Kockums . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 65

TUNRA Bulk Solids . . . . . . . . . . . . . . . . . . . . 37

Enerpac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Metso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Vortex Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Schaeffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SEACO Global . . . . . . . . . . . . . . . . . . . . . . . . 61 SEW Eurodrive . . . . . . . . . . . . . . . . . . . . 1 (OFC) Thomson Environmental Systems . . . . . . . . . 51

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BEARINGS & SEALS

Bearing contamination: how to prevent a problem that causes 25% of all premature failures

Schaeffler’s largest ever Sealed 241/1250 SRB, which stands at nearly two metres high and weighs approximately 8 tonnes. It is targeted at high pressure grinding applications in mining.

Bearing reliability is a crucial component of productivity and uptime in expensive machinery and plant throughout industries such as bulk handling, mining, manufacturing and primary production. If a bearing fails, production can grind to a halt.

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earing failures can be caused by a number of factors, including: Fatigue, which can occur naturally over time, but also occurs prematurely if the incorrect bearing is chosen for the task. Incorrect installation or mounting, which can lead to significantly higher wear and tear and ultimately premature failure. Examples include misalignment, incorrect fits – too loose or too tight, out-of-roundness in shafts or housings. About 25% of bearing failures occur because of incorrect mounting2. Lubrication problems, which can occur if too little, too much or incorrect lubrication is applied to the bearing. Incorrect or insufficient lubrication is the single biggest cause of bearing failure, accounting for more than 45% of problems. Poor maintenance or monitoring, because even the best precision bearings are not ‘set-and-forget’ technologies. Their maintenance needs change with service and local conditions, so good monitoring and suitable maintenance is vital. Contamination, which can occur when foreign substances enter the bearing. It is often considered to be the major component of lubrication problems. Contamination is particularly prevalent in aggressive process and manufacturing environments, such as mining, primary production and bulk handling.

Bearing contamination challenges “Despite it being an eminently preventable problem, a staggering 25% of all bearing failures are caused by contamination,” says Martin Grosvenor, manager, industrial projects and services, Schaeffler Australia. “Contaminants can include airborne dust, dirt or any abrasive substance that finds its way into the bearing. The main sources of these contaminants are dirty tools, contaminated work areas, dirty hands and foreign matter in lubricants or cleaning solutions,” explains Grosvenor. Symptoms of a contaminated bearing include excessive vibration and wear, which is best detected before it becomes expensively obvious in the form of unscheduled maintenance, or worse, production breakdown.

Schaeffler solution In challenging environments or operations where the risk of contamination is high, such as continuous casting plant, conveyor belts, elevator plant or food industry applications, Schaeffler says its FAG Sealed Spherical Roller Bearing (SRB) is well suited to the task. FAG SRBs are a special rolling bearing design where the inner ring runs inside the outer ring on two rows of rollers. The bearings have an angular adjustment of up to 2° and are not only Australian Bulk Handling Review: July/August 2017

BEARINGS & SEALS

Close-up of the effects of bearing contamination

designed for high load carrying capacity but can also compensate misalignments, due to the fact that the symmetrical barrel rollers orient themselves freely on the concave outer ring raceway. FAG Sealed SRBs offer the same benefits as open SRBs, but with seals typically consisting of nitrile rubber or high performance fluoro rubber* depending on the application and operating conditions. (*Seals made from fluoro rubber comprise particularly high performance materials that may release vapour when heated to approx. +300 °C. This may occur if, for example, a gas torch is used in the dismounting of a bearing. In such cases, the appropriate safety data sheet must be observed). “The seals effectively close off the bearings, giving them an increased operating life compared with open bearings, because they are protected from contaminants. Additionally, they require significantly lower quantities of grease to keep them lubricated (up to 80% less in some applications1), which means they can assist in reducing environmenA cutaway showing Schaeffler’s tal impacts too,” said Grosvenor. Sealed Spherical Roller Bearing.

X-life Sealed SRBs Schaeffler’s FAG Sealed SRBs are also available in X-life ranges (marked by the suffix E1), which have improved kinematics, optimised surfaces, are made from higher performance materials and do not have a rigid central rib. Schaeffler says that these enhanced characteristics of the premium X-life range mean that under identical operating conditions, basic dynamic and static load ratings as well as the basic rating life of the bearing is significantly improved. In certain applications, this means that a smaller bearing arrangement can be designed.

Schaeffler introduces largest ever Sealed SRB Designed to help industry reduce costs and boost efficiency, Schaeffler has developed the world’s first sealed 241/1250 spherical roller bearing for high-pressure grinding roll crusher applications. Featuring an outside diameter of nearly two metres and previously only available in an open configuration (i.e., without seals), Schaeffler’s new sealed version of this massive roll support bearing is designed to prevent the crushing materials from contaminating its internal components. Schaeffler says it developed the sealed 241/1250 bearing to help the mining industry cut costs and boost efficiency. Until 74

Australian Bulk Handling Review: July/August 2017

now, miners have typically been forced to inject high quantities of grease into the bearings to prevent contamination. While necessary, this practice wastes resources and significantly increases a mine’s preventative maintenance expenditures. By introducing a sealed bearing for this challenging application, Schaeffler says its innovation promises to also increase mining productivity. The bearing’s sheer mass – as evidenced by a total weight of approximately eight tonnes, including rolling elements that weigh 60 kg each – presented an engineering challenge that very few companies are able to master, even before the complex sealing arrangement is factored in. The outside diameter of the moulded seal, which features unique design elements that were first developed for marine applications, measures approximately 1.4 metres. The state-of-the-art sealing properties are provided by metal shields installed on both of the bearing’s side faces, each of which features an optimised polymer seal that prevents the ingress of crushing material. According to Schaeffler industry manager for raw materials, Mike White, “The new sealed version of our high performance 241/1250 bearing is expected to offer significantly longer operating life, while substantially reducing the cost of preventative maintenance to the end user. We are very proud to be the first bearing manufacturer to offer this design improvement to the mining industry.”

Conclusion – the importance of maintenance and monitoring High quality bearings are a worthwhile investment because they will operate reliably for longer. In order to optimise the performance and operating life of such a valuable investment, proper maintenance and monitoring is essential. In some cases, it can as much as double the operating life of the bearing. One method is to install monitoring technology such as Schaeffler’s FAG SmartQB (incorporating SmartCheck technology) ready-to-use monitoring solution for electric motors, pumps, and fans. The company says it is easy to install and does not require any specific knowledge about vibration diagnosis, including for common installations such as vibratory, grinding and rolling processes. Another innovative new method is to use the bearing as the monitoring device. Schaeffler has recently introduced to Australasia its new VarioSense roller bearings that report on their own condition and load through built-in sensor clusters. They can monitor machines, processes, bearing condition and load across diverse industries where downtime is costly and maintenance is expensive. To complement advanced bearing technologies and monitoring solutions, a maintenance programme tailored to each individual application is ideal. In addition to checking that the bearing is operating properly and without contaminants, this should include relubrication to ensure the bearing does not suffer any premature damage. Schaeffler is one of the world’s largest family businesses, with sales of around 13.3 billion euros per annum, 86,600 employees, and a worldwide network of manufacturing locations and research and development facilities.

References 1. Sealed FAG Spherical Roller Bearings – The cost-effective and environmentally friendly solution (http://www.schaeffler.com. au/content.schaeffler.au/en/mediathek/library/library-detaillanguage.jsp?id=12520768) 2. Rolling Bearing Damage - Recognition of damage and bearing inspection (http://www.schaeffler.de/content.schaeffler.de/EN/ mediathek/library/library-detail-language.jsp?id=114073) Contact: Martin.Grosvenor@Schaeffler.com

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