Bulk Handling Review May - Jun 2018 by Prime Creative Media

www.bulkhandlingreview.com VOLUME 23, ISSUE 3 | MAY/JUNE 2018

SPECIAL

Dust control features DSH takes on super-dusty phosphate ore, pg 25 Premier Tech takes over Kockums, pg 48 Technical paper: Causes of coal silo collapse, pg 54

Pneumatics, powder handling feature, pg 38 Kansas bulk solids centre targets pneumatics, pg 40

The Most Common Load Zone Issues & How to Solve Them 500_Cover.indd 1

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CONVEY FLEXI-DISC™ Tubular Cable Conveyors gently slide fragile foods and non-foods through smooth stainless steel tubing routed horizontally, vertically or at any angle, over short or long distances, dust-free. Single or multiple inlets and outlets.

DUMP FLEXICON® Manual Dumping Stations allow dust-free dumping of bulk material from bags and other containers. Automatic reversepulse filter cleaning allows continuous, efficient operation. Available with integral bag compactors for total dust containment.

CONDITION BLOCK-BUSTER® Bulk Bag Conditioners loosen bulk materials that have solidified during storage and shipment. Variable height turntable positions bag for hydraulic rams with contoured conditioning plates to press bag on all sides at all heights.

FILL SWING-DOWN®, REAR-POST and TWIN-CENTREPOST™ Bulk Bag Fillers can fill one bulk bag per week or 20 per hour at the lowest cost per bag. Numerous performance options. Available to industrial or sanitary standards.

CONVEY PNEUMATI-CON® Pneumatic Conveying Systems move a broad range of bulk materials over short or long distances, between single or multiple inlet and discharge points in low to high capacities. Available as dilute-phase vacuum or positive pressure systems, fully integrated with your process.

AUSTRALIA sales@flexicon.com.au 1 300 FLEXICON

UNLOAD BULK-OUT® Bulk Bag Dischargers unload free- and non-free-flowing solids from bulk bags automatically. Allows untying, discharging, retying and collapsing of bulk bags—all dust-free. Available with weigh batching controls.

CONVEY FLEXICON® Flexible Screw Conveyors transport free- and non-free-flowing bulk solid materials from large pellets to sub-micron powders, including products that pack, cake or smear, with no separation of blends, dust-free at low cost. No bearings contact material. Easy to clean quickly, thoroughly.

TIP

SUCCEED

TIP-TITE® Container Tippers dump bulk material from drums (shown), boxes or other containers into vessels up to 3 metres high. Dust-tight (shown) or open chute models improve efficiency and safety of an age-old task.

The FLEXICON® Lifetime Performance Guarantee* assures you of a successful result, whether you purchase one piece of equipment or an engineered, automated plant-wide system. From initial testing in large-scale laboratories, to single-source project management, to after-sale support by a worldwide network of factory experts, you can trust your process— and your reputation— to Flexicon.

USA UK GERMANY SPAIN SINGAPORE SOUTH AFRICA CHILE

+1 610 814 2400 +44 (0)1227 374710 +49 170 8 187 613 +34 930 020 509 +65 6778 9225 +27 (0)41 453 1871 +56 2 2415 1286

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CONTENTS MAY/JUNE 2018

Published by:

Level 14, 309 Kent St, Sydney NSW 2000, Australia Tel: (02) 9994 8086 www.mohimedia.com

6 Fenner Dunlop carcass boosts belt life for Pilbara miner

33 N epean’s Miles Fuller updates

8 Certified rotary airlocks available in Australia through Rotolok

34 PROK’s new belt monitoring

9 Eriez releases new range of metal detectors

35 ContiTech flags ‘pay-per-tonne’

10 Ward, CRS, Seaco supply contaminated spoil system to Crown project at Barangaroo

50 N ew Zealand quarry company switches from fixed plant to mobile crushing and screening equipment from Metso

12 BULKtalk: Steve Davis of Rio Tinto looks at safety in bulk materials handling systems

Publisher Michael Mohi Tel: +61 (2) 9994 8086 Email: Michael.Mohi@mohimedia.com Editor Charles Macdonald Tel: +61 (2) 9994 8086 Email: charles.macdonald@mohimedia.com Online Reporter Oliver Probert Tel: +61 (0) 406 111 902 Email: Oliver.Probert@mohimedia.com Art Director Meng Koach Tel: +61 (2) 9994 8086 Email: meng.koach@mohimedia.com National Advertising Manager Peter Delbridge Tel: +61 (0) 400 700 765 Email: peter.delbridge@mohimedia.com Production Manager Ronda McCallum Tel: +61 (0) 411 045 046 Email: ronda.mccallum@mohimedia.com Subscription Enquiries Email: subscriptions@mohimedia.com

16 Local pulley manufacturing for Dyna Engineering 18 Rockbox solution for narrow seam mine. Fenner Dunlop supplies Ashton Coal. 20 Contitech’s well-planned belt replacement cuts a third off shutdown time at Pilbara site

progress on Sandvik acquisition

system

belt technology

66 Electrical and automation: Siemens appoints APS master distributor; NHP sole distributor for Rockwell 67 Recycling plant saves money with Memolub automated dispensing system, says Systematic Lubrication Solutions 68 Di Matteo Group touts accuracy of cement dosing technology

53 P aradyn Systems: cloud, AI boosting supply chain software capabilities

70 Advanced Spiral Technology: Aussie-made flight forming system

54 T echnical paper: evaluation of failure mechanisms behind catastrophic collapse of 10,000t coal silo at South African power station: AP Wiid and B Marrai

72 Techmine and Enerpac’s hydraulic pump and lifter for efficient conveyor belt lifts

64 L arge scale 3D printing key to new method of steelwork erection, says Yenem Engineering

DUST CONTROL FEATURE 23 R ST foaming system targets dust around

conveyors and crushers

28 E ric Maynard of Jenike & Johanson looks

at the US’ new dust hazard analysis protocol and considers the implications for Australia

24 D SH Systems’ hopper going global 32 D ust prevention and suppression by 25 D SH hopper the solution for super-dusty

Dust-A-Side for central QLD mine

phosphate ore at Dutch fertiliser facility

PNEUMATICS, POWDER HANDLING, FOOD 38 Seven bulk bag dischargers from Flexicon

double productivity of Spanish food plant 40 Kansas center focussing on powder handling,

pneumatics; US equivalent of TUNRA, Wolfson

46 NSW hydrated lime plant’s Vortex

loading spouts 48 A new chapter for Kockums Bulk Systems

as Premier Tech of Canada takes over

44 BinMaster’s teflon-coated sphere for

SmartBob level sensor; Emerson spruiks Rosemount scanner

Printed by:

COVER STORY How to solve some common load zone issues www.bulkhandlingreview.com VOLUME 23, ISSUE 3 | MAY/JUNE 2018

24 Lilian Fowler Place Marrickville NSW 2204, AUSTRALIA Tel: (02) 9549 1111

SPECIAL

Dust control features DSH takes on super-dusty phosphate ore, pg 25 Premier Tech takes over Kockums, pg 48 Technical paper: Causes of coal silo collapse, pg 54

Pneumatics, powder handling feature, pg 38 Kansas bulk solids centre targets pneumatics, pg 40

When trying to maximise productivity and increase output, looking at your system as a whole is vitally important, says conveyor productivity expert Flexco. Problems such as spillage, mistracking, broken equipment like skirting systems and idlers as well as severe carry back are all results of a poorly equipped load zone. Flexco Australia’s managing director, Mark Colbourn, discusses some common load zone issues and how to address them before they cause unscheduled downtime. For the full story, see page 36

The Most Common Load Zone Issues & How to Solve Them

ISSN 1444-6308 Circulaton: 5,263 (audit period ending September 2015) Member Circulation Audit Bureau (Australia) Copyright © 2018 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.

Australian Bulk Handling Review: May/June 2018 3

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EDITORIAL

US bulk solids centre a welcome addition Around the world there are a few organisations working to push forward the science of bulk solids handling.

both dense and dilute phase. Reflecting its US origins, the private sector plays a big role at the Kansas

pneumatics opportunities that have been Kockums’ life blood. With little growth in its mainstay

centre with Coperion K-Tron and Vortex

sectors, Ivan has engineered a clever sale of

the major players. Unlike Tunra, owned

Kockums to Canadian firm and packaging

by the University of Newcastle, and The

specialist Premier Tech. Kockums gets a

by Emeritus Professor Alan Roberts in 1975,

Wolfson Centre, the Kansas centre is not a

deep-pocketed parent with the resources

may be the pre-eminent research body,

university offshoot. Instead, it is owned by

to take it global. Premier Tech gets a new

with particular expertise in mechanical

the city of Salina.

avenue of growth, with Kockums helping it

Tunra Bulk Solids in Newcastle, founded

conveying systems.

As a state, Kansas, along with Missouri

In the UK, The Wolfson Centre at the

and Nebraska, is the heartland of US bulk

vertically integrate into the process upstream of the packaging line.

University of Greenwich does good work

solids handling. Most of sector’s supply and

in the fields of pneumatic conveying and

equipment firms are based there, serving

Moving on

storage and flow.

large manufacturing, food processing and

This is the last edition of the magazine that I

bioscience sectors.

will edit. I’ve thoroughly enjoyed my 13-years

In North America, engineers at private firm Jenike & Johanson, in addition to

at Australian Bulk Handling Review and I

designing thousands of bulk handling

A new chapter for Kockums

facilities, also publish and research at a

Sometimes Ivan Price – until March owner

high level.

of powder handling stalwart Kockums Bulk

colleagues at ABHR and I’m sure that readers

have made some good friends in the industry. I’d like to wish all the best to my

Now, the US has a bulk solids research

Systems – and his CEO Francois Steyn,

will continue to enjoy the magazine under its

facility in the vein of Tunra and Wolfson. The

must wish that Australia was stronger

new editor.

$7m Bulk Solids Innovation Center at Kansas

in manufacturing and sectors like food

State University is working to improve the

processing. It is industries such as these

efficiency of pneumatic conveying systems,

which give rise to the powder handling and

Tailored drive solutions for your Bulk Material Handling needs

Charles Macdonald Editor - ABHR

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CONVEYORS

Carcass boosts belt life for Pilbara miner A major producer of iron ore in the Pilbara has boosted belt life with a switch to Fenner Dunlop’s UsFlex on its primary ore conveyors. ABHR’s Charles Macdonald spoke to Paul Young, national ECS manager at Fenner Dunlop. PRIMARY ORE CONVEYORS TAKE AN ABSOLUTE battering in the baking heat of the Pilbara. They handle the lump product that has been blasted and then loaded into trucks. Ripping and impact damage are perennial problems. In 2016, Fenner Dunlop worked with a big Pilbara miner to address the problem of excessive downtime caused by ripped belts. After examining the problem, Fenner recommended, for a trial, use of its UsFlex straight warp carcass, made from polyester. “We are the only belt manufacturer globally that weaves its own carcasses,” said Paul. This patented process takes place at the company’s factories in Australia and the US, using specialised equipment. “The UsFlex carcass is a straight warp weave and what that does is create an exceptionally rip resistant product,” explained Paul. “The previous belt was a steel belt and what happens there is that if any tramp metal or sharp product gets caught in that belt it’ll rip the belt longitudinally. Whereas, the straight warp weave is very impact and rip resistant and if any penetration does happen, the weave is designed such that it takes it straight to the edge and it won’t rip the belt longitudinally.”

ABOVE: Paul Young.

The benefit of UsFlex and its extended belt life is less need for shut downs and regular maintenance. Its longitudinal rip and impact resistance, well above industry standard, provides better protection from punctures and tears. Following a successful trial, Fenner Dunlop supplied the UsFlex belt and a straight changeover with the previous belt was performed. According to Paul, results have been impressive with a significant belt life increase. Paul Young has been with Fenner Dunlop for just over five years. He cut his teeth splicing conveyors in the underground coal industry 30 years ago.

“We are the only belt manufacturer globally that weaves its own carcasses”

Michelin buying Fenner for $2.4bn Fenner has two divisions: engineered conveyor solutions (ECS) which produces heavy conveyor belts; and advanced engineered products (AEP) which produces sophisticated polymer products for industrial markets. Michelin sees Fenner as a way to break into the reinforced polymer market, and it believes that advanced materials and engineered products will prove critical to its

future success. It also wants to offer mining customers a wider range of products.. “Mastering high technology materials is key to creating value in the coming years,” explained Dominique Senard, CEO of Michelin. “Fenner will enable Michelin to accelerate its growth in this area, and to strengthen its position as a key player in the recovering mining markets with a comprehensive offering.”

6 І Australian Bulk Handling Review: May/June 2018

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Improve your crusher’s productivity by up to 30% with our new generation upgrades This is how we make the big difference, the Metso Way.

Now the robustness and reliability of Superior™, Nordberg™ and Symons™ can incorporate the performance that only Metso’s modern crushers achieve. Without having to buy a new machine, you can get our new generation crusher upgrades to improve your crusher’s safety, performance and maintenance to make you more profitable. Find out how our new generation of upgrades can make the big difference for your crusher at metso.com/CrusherUpgrades. #TheMetsoWay

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NEWS

Applications open for $6m in project funding

LEFT: Rotolok’s USDA Dairy Accepted line of rotary airlocks are designed for use in sanitary applications.

Certified rotary airlocks available in Australia ROTOLOK NOW HAS ROTARY AIRLOCKS available to industry that have attained approval and certification from the United States Department of Agriculture (USDA) for use in the dairy, food and chemical industries. This USDA Dairy Accepted line of rotary airlocks are designed for use in sanitary applications in the food, dairy, pharmaceutical and chemical industries where regular cleaning is required to prevent product contamination. The product contact surfaces of the airlock are manufactured in 316 stainless steel and polished to a 150-grit finish,

Weighing Bagging Palletising 60

Fully automatic format change in 60”

ensuring that there are no lodgement points allowing the product to flow smoothly. Furthermore, the airlock is equipped with a slide rail mechanism allowing for the quick and easy removal of the rotor from the airlock body. This addition substantially reduces the amount of downtime and the number of man hours required for the cleaning and maintenance of the rotor and airlock internals. The USDA certified rotary airlocks are available in sizes ranging from 150mm diameter up to 400mm diameter.

Companies in the mining supply chain are invited to apply for funding, especially those involved in robotics and automation, from the METS Ignited Collaborative Project Fund. The application process for the third tranche of the Fund opened in May, with $6 million in project funding to be awarded to mining equipment, technology and services (METS) businesses fostering collaboration and innovation. The Australian Government has provided $15.6m over four years (2015-19) to METS Ignited to incentivise collaboration and address sector priorities. It is an industry-led growth centre that works with industry, miners, and research organisations to improve the competitiveness and productivity of the Australian METS sector. Companies that participate in the mining supply chain are invited to submit a short application form in order to be considered for a portion of the funding. For this round, METS Ignited is emphasising the importance of projects in the areas of robotics and automation. Applications are open until 31 August 2018. For more information, visit: www. metsignited.org

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NEWS

A new range of metal detectors Separation technology specialist Eriez has launched a new series of metal detectors which it calls the Xtreme range. IN THE NEVER-ENDING BATTLE AGAINST TRAMP metal and contaminants, Eriez’s Jaisen Kohmuench believes the Xtreme range offers a possible solution. “This feature-rich, multi-frequency unit is designed to achieve the highest levels of sensitivity to detect small ferrous and non-ferrous metal contaminants in sanitary and non-sanitary environments,” he said. The art of metal detection strikes a balance between absolute detection of all metal contaminants and elimination of false signals that slow down production. The Xtreme detector pushes that detection/ productivity curve with the ability to detect 0.2mm spheres. As is the case with all metal detectors, it’s critical that sites have specific products tested to understand achievable results. “Combine the Xtreme’s benchmark-setting

sensitivities with its feature packed controls in a highpressure wash down aperture head... all at the price of a midrange detector, and you’ve got the best dollar-for-dollar value on the market today,” said Jaisen. In its base package, the metal detector offers a seven-inch screen interface, multiple pre-programmed languages, easy set-up and reporting, multiple USB and interface ports, remote access and the standard high-pressure wash down design.

ABOVE: Eriez’s Xtreme metal detector in action.

BELT MONITORING SYSTEM HX270 BELT MONITORING ENABLING PROACTIVE MAINTENANCE HX270 automatically monitors belts for signs of damage 24/7, and will immediately shutdown a conveyor when it identifies a serious fault. It can even alert operators to minor defects. Minimising the extent of or normally catastrophic belt damage and highlighting minor damage enables better outcomes: • Improved productivity • Better utilisation of stoppages • Decreased unplanned stoppages • Longer belting life.

Quality Conveyor Components prokcc.com | +61 8 9347 8500 | 1800 PROKCC 536_Eriez.indd 9

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NEWS

Contaminated spoil system for Barangaroo’s Crown Specialist Sydney company Container Rotation Systems (CRS) has designed and supplied a sealed, containerised waste handling system for use at the Crown Resorts construction project at Barangaroo. THE BROADER BARANGAROO DEVELOPMENT is seeing the transformation of a disused container terminal in the heart of Sydney into a 22-hectare waterfront precinct, complete with office towers, residences, retail, restaurants and entertainment. Construction is currently underway on Crown Resorts’ six-star hotel and casino complex at the site. Project manager on the Crown project, Lend Lease, and its engineering contractor, Ward needed a solution to the problem of contaminated fill emanating from underground site workings. The material had to be safely and efficiently removed from site and transported through the heart of Sydney before disposal at Badgerys Creek on Sydney’s outskirts. CRS’s system consists of: half height containers with sealed lids, supplied by global container firm Seaco; special container spreaders for working underground; and a specially designed Eurospec 32 container rotation system at the dump site. The Barangaroo project is the first civil sector contract for CRS which has previously supplied container rotating systems, and related gear, to mining projects in Australia, Africa, South America, and Asia. “There is good scope for potential growth in the civil sector in Australia and globally, in tunnelling and

construction projects,” said Murray Bridle, owner and managing director of CRS. With this in mind, CRS has established a rentals business which reflects the fact that civil projects might need a system for far shorter terms that the four or five-year contracts predominating in mining. “The rentals business caters for the spot or shortterm market where someone might have a four or sixmonth project,” explained Murray. “CRS has a whole solution that they can rent. It’s very quick to mobilise and fast to deliver.” The Crown project’s use of CRS’ system also responds to equipment constraints in the booming Sydney infrastructure market. “By using a containerised system it answers the overload of truck and dog systems,” said Murray. “There is so much infrastructure in Sydney that truck and dogs are at capacity. The container solution is also very cost effective.” CRS’s Eurospec has a gross capacity of 32 tonnes and employs the latest single beam technology. “We have patented a new locking system for the lid so that it’s physically locked while allowing the use of automated lid-lift on the Rotainer system,” concluded Murray.

TOP: CRS’ system in operation at Badgerys’ Creek. ABOVE: The system at work at Barangaroo in the bowels of the Crown casino and hotel.

“The rentals business caters for the spot or shortterm market.”

10 І Australian Bulk Handling Review: May/June 2018

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Totally Australian made We believe pulleys with 100% local content

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CONVEYOR SAFETY

talk

Safety in bulk materials handling systems

Safety extends beyond guarding, into safe practices for construction, operation and maintenance, and in some situations, into decommissioning and rehabilitation. This article relates mainly to resource industry experience, but is universally applicable. The aim for all installations should be to make the likelihood of any unsafe activity as low as reasonably practicable (ALARP). STEVE DAVIS In his regular BULKtalk column, Steve Davis* of Rio Tinto considers the basics of bulk handling that sites often struggle with.In March/April 2018 he looked at conveyor design issues. *Steve Davis is the principal advisor – bulk materials process at Rio Tinto, based in Perth. Steve has worked in bulk handling for 30 years, for both resource companies and professional engineering firms, in Australia, South Africa, the Middle East and Canada. His experience encompasses such commodities as iron ore, coal, potash, phosphates, petcoke, sulphur, sands and grain. FIG 1: Poor guard design.

IN AUSTRALIA, BULK MATERIALS HANDLING safety practices are covered by the 2015 issue of the AS/NZS 4024.3610 series documents on Safety of Machinery – Conveyors. The new AS/NZS 4024 series integrates the previous AS 4024 series, Safeguarding of Machinery (updated), with AS 1755, Conveyors – Safety Requirements (which is now obsolete). This series of documents contains, as clearly stated, the minimum requirements for machinery safety, including conveyors. Anything that is not a conveyor in a bulk materials handling installation is a machine, so the new standard covers everything. In Australia, various acts and regulations require the use of available safety standards. These are legal requirements. Current Work, Health and Safety (WH&S) Legislation as implemented by each of the states and territories has an emphasis on identifying hazards in the design process. The legislation requires engineers to consider the potential risks involved during the life of a design to ensure that it is safe to build, operate, maintain and demolish. Many other countries have similar safety guidance and regulations for conveyors and other machinery. Don’t assume that the Australian guidance is totally adequate elsewhere, and if overseas designs have better minimums, these should be considered in design. For reference these include Canadian (CSA), US (MHSA), European (BS, DIN, ISO) and many others. Those involved in the engineering design

process should have a detailed understanding of the designers’ obligations under the WH&S legislation. Most equipment supplied to operating organisations (operators) is designed, constructed and installed by external parties (suppliers). The main onus is therefore on suppliers to deliver compliant equipment, constructed and installed to the minimal applicable standards, plus sensible provision for safe operation and maintenance over and above the minimum. Operators are also responsible to provide guidance on the nature of the operations and to refuse substandard safety performance from suppliers. If every bulk materials handling system constructed complied with available standards and guidance, our installations would be inherently safer than they are today. Unfortunately, many have non-compliant guards and poor access to maintainable features (Figure 1). If they complied with more than the minimums, would we see a noticeable reduction in LTIs?

Productivity Better safety in design results in higher plant productivity. Every mechanical and electrical component in a materials handling system will fail at some time. As there are many components, for most operations there will be a series of trips and failures throughout the year, each incurring downtime for isolation, repair and restarting. Simply put, the longer it takes to make repairs,

- Con - Sho

FIG 1

12 І Australian Bulk Handling Review: May/June 2018

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Containerr

FIG 2

the lower the productivity of the operation. If productivity is low in early years, whilst facilities are added from operating cost, the NPV of the project is lower than it should be. Providing good access to repair points, space where needed, methodologies such as rotable items for safe repair, guards that are easy to remove and replace, and similar specifics, results in shorter outages and higher productivity, with the added benefit of safer maintenance. Adding on-line condition monitoring for managed maintenance strategies will improve productivity further by avoiding many unplanned outages.

Older plant In the resource industry, we have operations that have been continuously in use for over 100 years. The original safety provisions were likely to be

minimal, and many will have been upgraded in capacity. We have many more and larger operations that date from the 1950s through to today. A focus on safety has realistically been ramping up since then, and has accelerated over the last 20 years. Safety is now the stated priority of most operators and suppliers. Many plants have less satisfactory guarding and access than is desirable. The cost to upgrade some of the older plants to current standards, even if practical, can be excessive. What options do operators have? The hierarchy of controls (Figure 2) for accident prevention is possibly the best guidance: Walk the plant; fundamental safety omissions should be obvious, but use the standards as guidance to identify less obvious unsafe potentials. Get expert assistance from safety specialists.

FIG 2: Hierarchy of controls and risk matrix.

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CONVEYOR SAFETY FIG 3

Among many issues, consider: •C an you, or anyone between 1.5m and 2.0m tall, touch anything dangerous, including through, under, over or around guards or by opening a door or hatch? Look for guards and other safety components that are ineffective, or are not installed or need maintenance. Figure 3 shows examples that can lead to complacency. •A re all inspection points, hatches, instruments, maintenance points, ladders, and walkways safely accessible and demarcated? Are there any trip hazards? Are there any projecting components that could cause injury? • I s there space to safely remove, adjust, monitor, and repair all components? Are there any poor ergonomic and manual handling practices involved? •D o your maintenance processes ensure that all energy sources, electrical, potential and kinetic are isolated, locked and released before work begins? •C onsider fire and explosion risks and emergency personnel egress, chemical spills and the like. Hold a risk assessment and rank the risks using a standard risk matrix (Figure 2). Mitigate highest risks first through elimination, if practical and cost effective, or through substitution, controls and PPE as applicable. PPE is insufficient alone and will require administrative control and signage.

New designs New designs should comply with minimum standards and other good safety practices. There are many types of risk assessment, Hazop, Hazid, CHAIR, SIL and the like that should be used to review what is required for a safe design plant. These are usually relatively well implemented; however the detailed outcomes are not always transmitted into a safe design outcome. Safe design will only be achieved if the engineers and designers responsible for the design understand, and are committed, to achieving safety by the best means available, and take on board guidance from operations. Considerations include:

• I dler roll change-out methodology that is safe, especially return idlers. When retractable or drop-

FIG 3: ineffective guard arrangements.

down idlers are used they still need access. Cable trays form an excellent barrier to idler access as do conveyor covers that are fixed or difficult to remove. •C leaners and ploughs are both items needing regular maintenance (monthly at least) and potentially have to be removed for this. Consider cleaners that are designed for ease of maintenance, several are available. Is the walkway wide enough for removal and work space? Where does the plough discharge to and how will the discharge be accessed? •P ulleys and drives will likely have to be replaced. A lifting beam is nice over drives, except when electrical cables and pipework are in the way. Consider a safe method to remove pulleys without cutting the belt. •B elts will need to be replaced and spliced. Design should incorporate suitably located splice stations with wide walkways, electrical power, weather enclosures, facilities for clamping and pulling the belt, locations and support for splice platens, any belt turning rolls required and so on. Belt reeling devices should be included in every new design. •W ear liners will wear out. Make provision for safe and easy replacement of liners. Rotable chutes are one method; liner systems that have innovative fixing methods are available. •L ook at chute flange connections; do they need a bolt every 150 mm? On a large chute this may require 40-50 bolts to be released and reconnected for each flange, and hours of time. Rotable chutes must be easily replaced. • S elect wear materials that are appropriate for the duty, and select a design and installation that does not restrict material flow without any ledges, valleys and large gaps between the liners. If completing bulk materials testing (recommended for all new projects) test using the proposed liner material. Why test steel when ceramics are to be used? In most cases the capital cost of providing good installations is similar to poor installations. The cost of engineering design may increase, but not if specialist suppliers are used. As an example, many arrangement drawings will be annotated with a hatched area and a note stating, “supply guards to AS/NZS 4024”, assuming that reference to AS1755

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AUSTRALIAN PATENTED TECHNOLOGY No. AU 2010200824 B2

A MULTITUDE OF POTENTIAL IN PRODUCTIVITY & SAVINGS. Transmin’s Innovative Low Profile Feeder (LPF)TM At Transmin we’re always seeking to help clients achieve greater productivity on-site. It was that search for process innovation that led us to develop the Low Profile Feeder (LPF)TM. With its low height advantage, the LPF acts as both an extraction feeder and conveyor in one, with the added ability to reverse direction and incline within a single machine – eliminating the need for additional transition points. The result = increased productivity and a substantially reduced capital expenditure.

A multitude of applications:

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 Standing reclaimers with hoppers – for front end loaders/direct-dump receival  Stockpile reclaimers – submerged in pre-cast tunnels  At the crushing station – directly underneath sizers and crushers  Ore bins – directly underneath the ore bins  Side-tip truck receival hoppers  Rear tipping truck receival  Direct rail-wagon receival  Filter press receival

 Belt tracking – no adjustments necessary.  Minimal space occupied within the plant vertically.  No belt slippage.  Minimal product spillage.  Simple modular sections for belt change out.  Conventional belt cleaners for ease of cleaning.  Change of direction can be achieved by the introduction of a bend.  Proven track record.

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CONVEYOR SAFETY

is no longer used. This pushes responsibility to a detailing subcontractor, who most likely has no idea what this means, and may even pass the comment on to the fabricator. The fabricator will, in all likelihood, make guards that are angle framed and painted yellow, and look good from a distance. The guards resulting often:

•H ave gaps in the guard system that allow unacceptable access (Figure 4)

•A re too heavy for one or two people to lift •H ave nowhere to store when removed •A re flimsy and deform on removal, making them difficult to replace

•C orrode after a short period •O ften need to be “amended” on site to fit at all In situations where the supplier does complete a detailed design for the guards, the results may not be better, but the engineering and design cost is higher than the guard cost. Another example is bearings, access hatches and access to cleaners in transfer chutes. Many chutes are still supplied with basic design that leaves:

FIG 4

FIG 5

• S haft penetrations in chutes that are not covered, leaving rotating component access and access into the chute •D oors don’t have an internal mesh, don’t seal, and have poor latch designs •L eave gaps in the chute (around cleaners) There are many specialist suppliers of guard systems and access doors and similar components, and also drive coupling guards and other specific protection. These are generally a better solution, with more consistent installation than the “inhouse” designs, examples in Figure 5. The bulk materials handling industry has good understanding of the benefits of safety in design, and many innovations to assist in realising the goals. Can we all incorporate these ideas and promote better and safer outcomes for the future?

FIG 6

FIG 4: Ineffective guard arrangements. FIG 5,6: Simple and effective guard systems.

CONVEYORS

Local manufacturing for pulleys Perth-based conveyor equipment manufacturer, Dyna Engineering has moved to 100% local manufacturing content for its conveyor pulleys in a bid to reduce lead times. WITH AN EVER-INCREASING

FIG 4: Final inspection of conveyor pulleys at Dyna’s workshop prior to protective wrapping and despatch to the customer’s site.

number of project jobs requiring shorter completion deadlines, Dyna Engineering was sometimes finding it difficult to genuinely commit to the required finishing due date stipulated in some tenders. In many cases, this was due directly to the longer off-shore pulley manufacturing componentry fulfillment cycle. The company thought it could also be ‘asking for trouble’ in terms of project risk if it kept pressuring its off-shore manufacturing suppliers too much and too frequently for shorter production lead times to meet those tighter project deadlines. In addition, a growing number of local customers now require total Australian content in any new equipment. According to the company’s sales engineer, Reddy Emmadi (above), Dyna has a reputation for

good quality engineering work. “We have absolutely no intention of letting customers down through unacceptably long lead times for off-shore manufacturing of pulley componentry. So, we have now removed one of these problems by expanding our own local manufacturing content with our conveyor pulleys”. Dyna Engineering has capacity to manufacture pulleys up to 1.5m diameter and 3.5m face width, covering most applications. Pulleys are constructed from either steel pipe or rolled steel shells and incorporate steel-plate end-discs and quality shafting materials. “All our pulleys are designed by computer software incorporating the latest design theories and many years of experience to ensure infinite shaft and shell life,” Reddy said. “We can also recondition used pulleys to give new life. Reconditioning is recommended when the shell and shaft are in good condition but the bearings, locking assembly, or lagging may be worn.”

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ABHR_Ad_highres_outlined.pdf

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14/5/18

1:53 PM

TRANSFER POINT ENGINEERING

Rockbox solution for

narrow seam mine Fenner Dunlop’s redesigned rockbox transfer system and ongoing conveyor modifications at Yancoal Australia’s Ashton Coal underground mine are improving conveyor availability, reducing costs and minimising the potential for shutdowns usually associated with mining a narrow seam.

THE CURRENT SEAM AT YANCOAL’S ASHTON

that they could successfully adapt the rockbox ABOVE: Rockbox at Ashton mine in the Hunter Valley ranges from 1.8 to technology to this project.” Coal transfer. 2.2 metres high against an average height of 3.6 The new components were all made to be metres throughout most of the region’s open cut installed during the mine’s weekly one-shift and underground mines. The narrow seam is not maintenance shutdown period and, in a nod to site unique to the Ashton mine and is generally confined safety and maintenance accessibility, the transfer to mines in the eastern half of the Hunter Valley point and integral rockbox were re-designed for mining zone. floor mounting. According to Ashton engineering manager From Ashton’s point of view the project is a Barry McKay, the seam is a symptom of the success and exceeding expectations. challenging geology of “They have worked the area and “something very closely with us “ Water became a primary design we have to deal with.” to meet construction consideration. Cutting more rock meant With the longwall and installation time using more water to control the dush.” system set up to cut at constraints and avoid 2.5 metres the decision any unnecessary was made to stay with the established cut height shutdowns,” said Barry McKay. “Along with a 6% and have a primary separation of coal, sandstone improvement in system availability, we are seeing and mudstone as the product was conveyed to an improvement in overall efficiency, considerably the wash plant. Fenner Dunlop, as conveyor less wear on the belts and associated installed contractor to the mine, was asked to design an equipment and tangible savings in the conveyor appropriate system. maintenance budget.” Water became a primary design consideration. Cutting more rock meant using more water to control the dust – water that has to be separated off early to avoid damage to the conveyor system The Ashton Coal Project (ACP) is a coalmine located 14 km and components. Fenner Dunlop’s solution was northwest of Singleton in the Hunter Valley. It is adjacent to the open-cut mines of Glendell (Glencore), Rixs Creek and Rixs Creek to redesign the existing transfer point on the North (Bloomfield Group), Hunter Valley Operations (Yancoal) and trunk conveyor to include a rockbox which quickly Ravensworth Operations (Glencore). separates excess water from the mined product. The ACP is operated by Yancoal Australia and includes an underground coal mine, a coal handling and preparation plant, a “It’s a unique solution to something that could rail siding and an open cut mine that has now been completed. The have been a real problem for us,” said Barry McKay. Ashton underground coal mine is approved to produce 5.45 Mtpa of “Rockboxes are not an established part of the coal which is mainly exported through the Port of Newcastle. underground mining de-watering landscape. It’s a credit to the design ingenuity of Fenner Dunlop, CONTACT: Mick www.chutetechnology.com.au Egan, Fenner Dunlop Australia, email: mick.egan@conveyor.net.au along with their understanding of the coal industry,

About Ashton Coal

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LUBRICATION

Automatic lubrication system celebrates 25 years in production Delta International Sales, which is responsible for sale of GreaseMax lubricators in all countries outside the EU, is celebrating a milestone in the product’s success. OVER THE LAST 25 YEARS, THE German engineered GreaseMax system has attracted a wide range of loyal clients who have benefited from this chemically operated, single point, continuous automatic lubricator. GreaseMax lubricators are used in all industry applications for bearing, linear motion and bush lubrication as well as seal greasing and purging. GreaseMax’ s effective, efficient design requires no electrics or mechanical items for its operation. Its proven design provides accurate lubrication and total in-service reliability. It is easy to use and simply installed, with little user training required. GreaseMax operates for a set period after which it can changed over in seconds. Aside from the advantages of better mechanical reliability, the GreaseMax system requires less downtime from bearing failure and therefore lower maintenance costs, better production rates and lower cost of production. A safe product, GreaseMax has safety certification from the German TÜV organisation. There is also no need for personnel to hand grease moving equipment when GreaseMax is installed. GreaseMax can generally be set up to allow changeovers without the requirement for plant operations or equipment items to be isolated and

shut down. This is expected to provide benefits in two areas: production improvements and ROI benefits as production equipment remains online; and a reduction in personnel time for the required management process to isolate and re-activate process equipment. GreaseMax’s unique functionality comes from a chemical reaction that starts when the activator cap is screwed into GreaseMax. Gas so generated expands a diaphragm, causing pressure on a piston, which results in the discharge of the lubricant. When the cartridge is empty the piston becomes visible in the transparent cone. The GreaseMax steel body allows it to be used in hot applications and where pressure is needed, on long feed lines for example. GreaseMax greases bearings and seals and is also suited to purging and preventing ingress of contaminants.

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538 Delta.indd 19

17/05/2018 12:40:29 PM

CONVEYORS

Well planned belt replacement cuts a third off shutdown time A collaborative approach to belt replacement by Contitech and its customer at a major Pilbara site reduced shutdown time from 144 to 96 hours. IN ANY REPLACEMENT OF A SIZEABLE CONVEYOR belt, shutdown time is unwelcome but inevitable. Consequently, sites are keen to explore approaches that can trim downtime, and maintain productivity and profits. In this instance, the project scope required installation and splicing of 5,460m of 1500mm wide ST3150 17mm x 7mm conveyor belt on a causeway conveyor delivering ore to a major Pilbara iron ore port. Site management had been considering several ways for the belt replacement program to be executed, involving different shutdown options for various methods and different scopes of work.

A collaborative solution was eventually developed jointly by the site with Contitech’s Pilbara conveyor team. It effectively meant the total project was completed in 48 less shutdown hours than originally anticipated. “The challenge for us was to jointly develop a safe and efficient method that would enable the replacement of the entire belt within a couple of days,” explained Scott Marvelley from Contitech’s team. “We understood that whilst some aspects of the work would cost more up-front and need additional time in the planning and preparation phase,

BELOW: 5,478m of old belt was removed and consecutively reeled onto four ‘spider reels’ in only 12 hours with no crane lifts required..

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“ We understood that whilst some aspects of the work would cost more up-front and need additional time in the planning and preparation phase, the overall time saving benefits for the customer would far outweigh this.” the overall time saving benefits for the customer would far outweigh this. This conveyor is critical in delivering ore to the port. Each hour of gained production time would result in more train unloading. And each trainload is worth literally millions of dollars.”

Reducing risks “One of the other critical objectives was maintaining as safe a workplace as possible” Scott added. “As with any large maintenance activity there will always be associated hazards. The challenge was being able to identify those hazards and implement the right controls to mitigate and, if possible, eliminate any associated risks. “For us, risk management always starts with a formal risk assessment with key project stakeholders based on a well-defined work method statement. Potential issues and hazards are identified and dealt with early in the process. “The critical risks identified for this project were machine isolations, lifting operations and stored energy/line-of-fire. The client was provided with a full scope and documentation package

506 ContiTech.indd 21

including supporting engineering computations, lay-out drawings, safe work procedures, operating manuals and timelines/ Gantt charts,” he said.

Scope of works Contitech’s plan included the pre-splicing of the entire length of the new belt, then replacement of the old belt, pulling from the tail. The new belt consisted of 13 lengths at 432m that were flaked out perpendicular to the conveyor system along an adjacent access roadway. During the shut-down, the 5,478m of old belt was removed and consecutively reeled onto four ‘spider reels’ that were sitting ready in four large belt winders lined-up one behind another and adjacent to the conveyor, in a process that took only 12 hours to complete. The approximate gross weight for each completed reel of old belt was 115 tonnes, however no lifting cranes were required at any time. “This was quite an achievement and obviously contributed significantly to lowering safety hazards for the procedure,” said Scott. Some of the primary equipment utilised included a large modular belt winder and foldable spider reel,

17/05/2018 11:48:32 AM

CONVEYORS

a 200kN belt pulling machine, an air-conditioned splicing station, belt flaking machinery, 3 x large ‘DPU’ belt winders and spider reels, a 300-tonne mobile slew crane and multiple belt- turning frames which turned the new belt onto the conveyor through 100° and the old belt out of the conveyor through 180°. “In some ways you could say this could have been a potentially difficult belt change-out,” said Ian Copeland, ContiTech’s key account manager. “But by taking a fresh and innovative perspective on the tasks and methodology, with full consideration for safety and risk reduction, we were able to execute the job incident-free and within the promised time-frame. “If I had to summarise the key success factors, the first would be that our own engineering and operations teams worked closely together to plan and execute the process from beginning to end. “Secondly, and very importantly, that we had a very supportive, knowledgeable and proactive client with whom we built a good working relationship

ABOVE: Multiple belt-turning frames turned the new belt onto the conveyor through 100° and the old belt out of the conveyor through 180°.

CONTACT: scott.marvelley@contitech.net.au

info@bbcp.com.au (02) 9618 9400 www.bbcp.com.au

Vee Ploughs

right from the start. They contributed significantly to the development of the process we ended up putting in place. There is no way it could have happened without their collaborative input and suggestions. “And thirdly, that we had the right equipment for the job and the right mix of skills and experience on hand in both technical and trades.”

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Engineering Services 17/05/2018 11:48:33 AM

DUST CONTROL

Foaming system targets dust around conveyors and crushers Dust suppressing chemicals company Reynolds Soil Technologies has released a mechanical foam dispensing system and Hi-Foam product. THE MECHANICAL FOAMING SYSTEM MIXES compressed air, water and the Hi-Foam chemical. When applied, the foam captures and engulfs fine particles in a ‘dust blanket’ that aims to prevent dust from becoming airborne. RST operations and technical director David Handel said its technicians worked closely with customers to design and install the mechanical foaming systems on a case by case basis, assessing the site’s individual needs for best results. “Each site installation of our foaming system is unique – we work with the site to understand its dust suppressant needs and design the application equipment for our product accordingly,” he said. “Our Hi-Foam foaming system is popular with conveying and crushing operations where moisture limitations on materials is critical, as the system effectively produces a dust supressing foam that treats large areas with minimal water and dosage requirements. “When applied, the foam wets dust particles to increase their weight, causing them to continue their journey through the conveying and crushing system without ever becoming airborne. “The way in which a product is applied to a site can significantly impact performance, that’s why being able to design and customise both the product and the application is important.” The foaming system utilises a dosing feeder that injects the additive directly into the system’s

water line, allowing for the manual concentration adjustment of the solution. The air and water then mix in an expansion chamber capable of supplying a dust supressing foam to six dosing points introduced at specific stages in the crushing and conveying circuit.

ABOVE: RST director David Handel. The company’s new system applies foam to conveyors and crushers while minimising water usage.

Making Belt Weighing possible, in more places than ever before AUTONOMOUS WEIGH ROLL UNIT Disruptive Belt Scale Technology No wiring at all for power or data simplifies application and improves reliability Minimal down time for installation improves feasibility Short term installations direct to hand held device Long term process scale applications linked to DCS and device at same time Greatly reduced overall cost makes ad hoc installations practical

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Get the app Australian Bulk Handling Review: May/June 2018 І 23

18/05/2018 2:24:52 PM

DUST CONTROL

Kiwi dust suppression system going global DSH Systems of Auckland, producer of its eponymous Dust Suppression Hopper, is supplying ever larger units to more and more countries worldwide. ABHR editor Charles Macdonald spoke to DSH’s CEO, Ian Walton. SOMETIMES WORDS JUST AREN’T ENOUGH. To fully understand the capability of the Dust Suppression Hopper, only pictures will do. Before and after pictures. Typically, the before shot of the loading of, say, fertilizer into a truck or ship, will show, well….not much, with the air thick with dust and blocking out everything else. The after shot, in contrast, will show – in perfect clarity – an almost solid column of fertiliser descending from the DSH hopper, with no dust to speak of. Invented in 2006 by husband and wife team Trevor and Judy Schwass in Auckland, the patented DSH hopper is increasingly going global under CEO Ian Walton. “We’ve grown and expanded big time,” explained Ian. “We have expanded geographically and also size-wise in terms of the hoppers. We used to have hoppers which were a size one or two, with 200 to 300 tonnes per hour truck-loading. Now we are up to a size nine and we have a unit in Brazil ship-loading 3,000 tonnes per hour of sugar.”

The demand for larger units has very much been driven by end users. “I’d like to say it’s all been planned but it’s actually been customer driven,” said Ian. “A customer in grain, say, will be using one of our small units for loading from a warehouse on to a truck; they are very happy with it, but at the other end they are loading ships and they have big dust issues. They are saying ‘your technology works really well, can we use it for loading much bigger applications?’ So it’s been customer-driven rather than driven by us.” DSH Systems has a network of international distributors, typically manufacturers or suppliers

RIGHT: The ICL fertiliser site in Amsterdam where powdered phosphate is mixed with acids and minerals. Pictured are ICL executives and those of Vlint, the DSH Benelux distributor. BELOW: Unloading of fine powdered phosphate previously created a lot of dust at ICL’s fertiliser plant. The DSH hopper, pictured, has solved the problem.

“The demand for larger units has very much been driven by end users.” of some form of bulk material handling equipment. However, all steel manufacturing is done in New Zealand, as is production of polyethylene units

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aimed at the fertiliser industry. An exception is the US where DSH’s partner manufactures on its behalf. While the US is still the company’s biggest market, it is also very active in Western Europe, Asia and South America. Ian nominates Eastern Europe, Ukraine and Russia as fledgling but growing markets. “Overall, the big growth area is in barging and shiploading where we are getting bigger units in,” said Ian. In terms of end markets, the US’s booming fraccing sand industry is emerging as a healthy market. In the UK, the burgeoning wood pellet market is another sector with big dust issues and much pellet damage courtesy of traditional loading methods. “We did a very large job for wood pellet processing in Immingham, which is a large dock in the UK near Hull,” explained Ian. “We are exploring that market further now; wood pellets

for energy generation is a massive market now. We are working on that at both ends: in the US where they are processing the wood pellets and putting them on to ships and trucks, and at the other end in the UK where they off-loading them and filling massive silos prior to burning.”

everything under control...

Your one stop valve source for all your conveying and dust collection requirements ROTOLOK AUSTRALIA PTY LIMITED, Unit 1, 6 Bonz Place, Seven Hills, Sydney NSW 2147 Tel: +61 2 9620 4735

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18/05/2018 2:26:55 PM

DUST CONTROL

DSH cuts dust at Dutch fertiliser facility

Gerard Oudshoorn, business coordinator at ICL. He trialled and then bought two DSH hoppers.

MOBILE CONVE

YING IN FOCUS

Astec offer channel in s direct Australia

Global fertiliser producer ICL has turned to DSH hoppers for a major facility handling super-dusty phosphate ore. ICL’S AMSTERDAM FACILITY HAS A lengthy history going back to 1906. Gerard Oudshoorn, a business coordinator at ICL, explained what happens at the site. “To get a dry fertiliser granulate, we mix shiploads of phosphate with all kinds of acids and minerals,” he explained. “The ships that moor at the site are loading a powder phosphate ore into a funnel on a belt conveyor. In the past the product was loaded into storage from a height of nine metres, with a chute. To make sure we did not have too much dust we could only load at 30% of maximum capacity. But even with this loading capacity there was some dust escaping.” On the recommendation of DSH’s Benelux distributor, Vlint, ICL investigated the DSH hopper. Using a smaller unit, CSL tested the technology at 30% loading capacity. “After some small changes and adjustments, this was a great success,” said Gerard Oudshoorn. “During loading there was much less dust and emission

of dust outside the storage ceased.” Following the successful test, CSL bought two larger-sized DSH hoppers which allow loading at 60% capacity with no dust problems. “Another big advantage is the ships can be unloaded much faster and can leave much quicker,” said Oudshoorn. “Our dust problems around storage are history.” Ger den Heijer, a product specialist at Vlint explained that use of the DSH hopper in Europe is growing fast. “For hygroscopic product we can deliver a polyethylene hopper,” he explained. “For food, stainless steel. For other products like corn and wheat but also sand and grit we use Corten Steel or Hardox DSH hoppers. “Besides effective dust reduction, the DSH units form a very strong and fixed column which makes loading more efficient. Other advantages are that you do not need any electronics and in most cases no de-dusting any more. It also saves money on maintenance.”

Following Astec Industries’ $45m company is acquisition of now offering Telestack of direct distribu Northern Ireland complement tion of some to existing distribu in 2014, the Telestack equipm tors. Charles ent in Australi Macdonald reports. a, as a

ccording to

40 Australian Bulk

ABOVE: Astec Industries’ gear in action.

John Williams ,

national product manager mining at Locally, John Australia, Astec is seeing increased some Telestac is now being “It is picking k equipme activity. re-badged nt up,” he said. and re-brand increase in Bulk Handlin “We have ed as Astec activity. We seen an g Solution haven’t sold s. we did last Telestack’s a lot more year but my distribution than phone is ringing there are more arrangem Australia ents in – with Tricon more and enquires for on the eastern pricing. OPS in the “Mines are seaboard and west – pre-date looking for an off-therather than Astec’s takeover “They are shelf solution tying up time continuing . and capital to press the engineered what they in a unique flesh and do. They are product.” do selling Telestack now an Astec With compani which is Industries es like Astec business. lattice-work sure they paying to We want to are supporte transport frames for make d and doing mobile equipme breakbulk, want to do,” everythin priced nt as explained g they per cubic metre, John to see more “We are independ John. is keen containerised ent from those solutions. happened have access This has guys; we all with a new to the same 46m telescopi product line. different avenue “This turns ng stacker. We are just up in three for custome a 40 foot containe and can be rs to take.” Astec’s Australia assembled rs n business in Australia shipping more a broader will have ; the saving range of products access to than offsets in the cost of together,” than Telestack For example putting it said John. , it will offer alone. products from subsidiaries Globally, Astec other Astec such as Osborn calls its subsidiar like Australia of South Africa Kolberg-Pioneer ies in countrie ‘shop stores’. and of the US. s They don’t but do provide “Internationally manufacture installation, Astec are servicing consolidating in the process “We don’t and support. want to discount their brands,” of distributors time they said John. our existing have allowed and agents “For a long who brands Telestack are looking thing and to do their range,” said float out there after the own John. “It’s in the world, customers we are bringing about saying ‘we are here, but now them in and to too; feel free feel free to known as making to use us them more Astec.” use them.’ or Choice is not the custome a bad thing r.” for Handling Review:

March/April

“ Mines are looking for an offthe-shelf solution rather than tying up time and capital in a unique engineered product.”

2018

439_Conveyo

rs.indd 40

CORRECTION

22/03/2018

10:01:16 AM

It has come to the attention of Australia Bulk Handling Review that some comments regarding Astec Australia in the article “Astec offers direct channel in Australia” are not correct. The article was published in the March/April 2018 edition of Australia Bulk Handling Review on page 40. Any statement or implication in the article that the distribution arrangements in Australia between Telestack and Tricon and OPS have changed is incorrect. Telestack products are distributed by Tricon Equipment and OPS in Australia.

26 І Australian Bulk Handling Review: May/June 2018

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From Pit to Port

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18/05/2018 PMam 17/5/182:29:31 11:33

r DUST CONTROL

What is a Dust Hazard Analysis (DHA) and why do I need to worry about it?

Ask an Engineer

The US National Fire Prevention Association (NFPA) recently published the 2017 edition of NFPA 61 (Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities). It contains a new section describing a dust hazard analysis (DHA) protocol. Eric Maynard considers the implications for operators. Are you aware that a catastrophic explosion at Imperial Sugar’s Georgia refinery 10 years ago killed 14 workers, incurred US$ 60 million in damages, and was caused by simple ignition of a sugar dust cloud in a covered belt conveyor [1]? How about the massive plant explosion at Didion Milling in Wisconsin in May 2017 (see Figure 1) that killed five workers and injured eleven due to a dry corn product deflagration in a fluid bed dryer [2]? OSHA (Occupational Safety and Health Administration) fined Imperial Sugar nearly US$9 million dollars in 2008, which represented the third largest fine in the history of OSHA. Imperial Sugar was cited for 118 willful and 99 serious violations. Didion Milling was also cited for willful and serious violations, which carried penalties of about US$2 million dollars. So, what are you going to do regarding combustible dusts handled in the food and agricultural industries in Australia? Are you using dust collectors, bucket elevators, ovens/dryers, mills/grinders, mixers/blenders, pneumatic

conveying systems and silos/bins/hoppers to store, process, and transport your powders and bulk solids (example shown at Figure 2) through your factory? All of the material handling equipment above can be subject to combustible dust flash fire or explosion hazard. In fact, FM Global incident data over 25 years showed that 20% of combustible dust events occurred in the food industry. Are you taking the steps necessary to ensure safety at these facilities, or, are you taking the “wait and see” or “it has never happened to us” approach? Adopting a “safety-first” or “zero-for-life” safety culture will require a comprehensive dust hazards analysis (DHA) when you know combustible dusts are or can possibly be involved. A DHA is defined as a systematic review to identify and evaluate the potential fire, flash fire, or explosion hazards associated with the presence of one or more combustible particulate solids in a process or facility [3]. Per NFPA 61, the DHA must be performed within five years of effective date of standard, which means you must have this done by June 2021{7.1.2.2}. FIG 1

There are five focus areas with a DHA, namely: 1. Understand your process; 2. U nderstand your material(s)/ dust(s) combustibility & explosibility behaviours; 3. Identify process hazards; 4. M itigate hazards based on limit controls and standards; and, 5. Take action to improve safety

ABOVE: In this regular column, experts from specialist bulk materials engineering firm Jenike & Johanson answer readers’ queries around problems at their sites. In this edition, Eric Maynard is the author. Eric is a senior consultant and director of education with Jenike & Johanson. Since joining in 1996 he has published over 40 articles on the storage, flow, and pneumatic transport of bulk solids. He is the principal instructor for various courses around bulk handling and pneumatic conveying and has presented at over 300 training events world-wide. He has designed more than 750 bulk material handling and conveying systems. FIG 1: Aftermath of dust explosion at Didion Milling in Wisconsin, USA.

Per NFPA 61{1.3.1}, the standard shall apply to “All facilities that receive, handle, process, dry, blend, use, mill, package, store, or ship dry agricultural bulk materials, their by-products, or

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KOTZUR

dusts that include grains, oilseeds, agricultural seeds, legumes, sugar, flour, spices, feeds, dry dairy/food powders, and other related materials.” The owner/operator of a facility with agricultural combustible dust shall be responsible for: • Identifying credible fire, flash fire, and explosion hazards associated with their facility; • Assessing consequences of credible fire, flash fire, and explosion hazards; • Managing credible fire, flash fire, and explosion hazards; and, • Communicating the hazards to affected personnel {4.1.2}. FIG 2

Furthermore, the owner/operator of a facility with potentially combustible dusts shall be responsible for determining whether the materials are combustible or explosible, and, if so, for characterizing their properties as required to support the DHA {5.1}. Note the careful word choice of materials and not a specific reference to only dust, as just about any finely divided solid agricultural material, even in flake form, can present a flash fire or

explosion hazard when suspended and ignited in air. For reference, an explosion occurs with the bursting or rupture of an enclosure or container due to the development of internal pressure from a deflagration {3.3.14}, while a deflagration is the propagation of a combustion zone at a velocity that is less than the speed of sound in the unreacted medium {3.3.9}. Essentially, the deflagration is the process, while the explosion is the result.

FIG 2: Example of combustible wheat bran dust entrained in air during filling of vessel.

Designing, manufacturing and installing bulk solids storage and handling solutions world wide.

524 Ask An Half Engineer.indd 29 KOTZUR Page Horonizontal 01.indd 1

Kotzur Pty Ltd

Kotzur Bulk Solids Handling Pty Ltd

60 Commercial Street, Walla Walla NSW 2659 Ph (02) 6029 4700 www.kotzur.com

19-29 Enterprise Street, Wilsonton Industrial Estate. Toowoomba QLD 4350 Ph (07) 4634 4622 www.kotzur.com

formerly Downfields Engineering Pty Ltd

18/05/2018 19/03/2018 2:35:53 9:44:17PM AM

DUST CONTROL

FIG 3

FIG 3: Dust explosion pentagon illustrating five components required for explosion.

The five ingredients for a dust explosion, as shown in the explosion pentagon (Figure 3), are: 1. Combustible dust (fuel) 2. Ignition (e.g., hot surface, friction, electrical spark or discharge) 3. Dispersion 4. Containment (dust explosion; if eliminated, hazard of flash fire not eliminated) 5. Oxidant (typically oxygen) NFPA 61 is composed of nine chapters and annex explanatory material that are available to review on-line. Chapters 1 through 4 contain information on administrative needs, referenced publications, definitions, and general requirements for the standard. Chapters 5, 7, 8, and 9 are key sections in NFPA 61, especially Chapter 7 which outlines what is required for the DHA. In Chapter 5, hazard identification is discussed, with information regarding the necessary tests needed to assess combustibility and explosibility of particulate solids. Tests such as Go/No Go screening, minimum ignition energy (MIE; ASTM E2019), minimum explosible concentration (MEC; ASTM E1515), and minimum ignition temperature of a dust layer (MIT; ASTM E2021) are useful in indicating a material’s susceptibility to ignition. As for assessing the material’s explosion strength, a 20 litre or 1 cubic meter explosion sphere is used to determine the deflagration constant (called Kst) and maximum explosion pressure. These values are used in explosion vent design, as well as selection of explosion protection equipment that that is designed to contain, isolate, or suppress. Chapter 7 on DHA may appear to be “short and sweet” given it is only half a page; however, there is a lot of work to be done FIG 4 to meet the requirements for the DHA. The methodology for the DHA shall include identification and evaluation of the process or facility areas where fire, flash fire, and explosion hazards exist. When a hazard is identified, safe operating ranges shall be defined and safeguards must be put in place to prevent or protect against the hazard. The DHA shall be performed or led by a qualified person, which, by possession of a recognized degree, certificate, professional standing, or skill, and who, by knowledge, training, and experience, has demonstrated the ability to deal with problems related to the subject matter, the

FIG 4 & 5: Silo filled with agricultural material collapsing with resulting dust flash fire.

work, or the project {3.3.30}. Now that you are familiar with the activities involved with a DHA and the NFPA 61 standard for addressing combustible dust hazards in food and agriculture industries, are you prepared to avoid a black swan event? This is an event that is unpredictable or unforeseen, and usually with extreme consequences (Figure 4&5 provides an example). Those who have experienced an explosion or flash fire indicate: • It never happened before or was extremely rare; • They were surprised (never imagined it happening); and, • The impact was massive.

REFERENCES [1] http://www.csb. gov/imperial-sugarcompany-dustexplosion-and-fire/; report no. 2008-05-IGA September 2009 [2] http://www. nbc15.com/ content/news/ OSHA-proposes18-million-in-finesagainst-DidionMillin-Inc-458308143. html [3] NFPA 61 - 3.3.12, “Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities”, 2017 ed. [4] NFPA 652, “Standard for the Fundamentals of Combustible Dust”, 2016 ed.

Oddly, the same folks made rationalizations based on hindsight. In the end, in a response to frequent coal fires in Philadelphia, Benjamin Franklin wisely said - “An ounce of prevention is worth a pound of cure.” Contact: epmaynard@jenike.com FIG 5

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Focus on accuracy and efficiency in grain handling IECEx and ATEX approved electric actuators from LINAK add superior control and high accuracy to grain handling facilities Optimise your grain handling facility with intelligent LINAK actuators. Accurate positioning and precise feedback ensures optimised sorting and blending processes. The actuators LA14, LA25 and LA36 are the first LINAK actuators to receive an IECeX/ATEX approval for operation in dust explosive atmospheres. See more on www.linak.com.au

DUST CONTROL BEFORE

AFTER

Prevention and suppression at QLD coal mine Dust control company Dust-A-Side, based in Brisbane, has supplied a suite of measures to a large and dusty Central Queensland mine site. DUST-A SIDE’S GENERAL MANAGER NEIL HOSKIN says it is the only Australian company to specialise in both dust prevention and suppression and says some sites struggle to tell them apart. “We hear comments such as ‘aren’t they the same thing?’ and ‘can’t we just hose the material down and be done with it?’” Neil says. “But there are important differences between prevention and suppression measures.” Simply put, low pressure dust prevention uses lots of water to pre-wet material close to source, quelling coarse dust of 10 microns and up. High pressure dust suppression uses little water at high pressure to add a fine atomised mist to the air. It subdues tiny particles of under 10 microns, those associated with black lung. Neil is adamant that using a two-pronged approach of both prevention and suppression is the only way to ensure that the highest possible level of dust control is achieved. Dust-A-Side recently designed, installed and commissioned a dust prevention and suppression system at a dusty 27,343 hectare coal site in Central Queensland. The site produces around 12 million tonnes of black coal annually which is transported overland to a 30-year old plant via conveyors and trucks. Dust-A-Side delivered a low-pressure dust prevention system to the site which helped to eliminate dust through the entire process by first thoroughly wetting coal prior to processing. Then it supplied smart misting systems. The primary area requiring dust suppression was the tip area, where coal is tipped in from the conveyor and by trucks into large bins. When the coal lands at the bottom of the tip area, it created huge plumes of dust. Dust-A-Side developed auto-activation misting systems for the site. “Weight on belt” sensors on the conveyor set to specified levels (eg 1,500 tonnes) automatically activates the system, as do trucks picked up on radar.

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On cue, a pre-programmed misting system creates a wall of fine mist through which the coal passes. As it has been designed to operate at high pressure using low volumes of water, there is never an issue with over-wetting the coal. Other methods of suppressing dust at the site include the use of fog cannons in tip areas and spray bars with fans to force the spray even further into the feed bin. The control room for this dust suppression system is housed in a shipping container built on a concrete pad. It operates a system of hoses and features solenoids that give operators the ability to control which areas need spraying, and to what extent. “Flexibility is the key,” explained Neil Hoskin. “As different types of ore generate varying degrees of dust, it allows the operators to focus on problem areas.” In a bid to reduce water use, Dust-A-Side also supplied binders and surfactants to the site, including its AquaTarp, HydroTac and Hydrowet.

ABOVE: Before and after shots of dust around conveyor at the Central Queensland site. BELOW: Concentrated dust particles per square mml at the bottom of a tip area handling raw coal at the mine.

Conc(MG/M3)

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CONVEYORS

Nepean bedding down Sandvik acquisition In conversation with ABHR’s Charles Macdonald, Nepean CEO Miles Fuller says he is delighted with the quality of the products, facilities and people his company inherited when it bought Sandvik’s conveyor components and systems businesses in July 2017. ABOVE: Miles Fuller, chief executive, Nepean.

FOR THE LAST YEAR MILES FULLER HAS BEEN living out of a suitcase as he shuttles between the far-flung factories and offices of Sandvik’s conveyor businesses. As he meets customers and employees in various continents, he is heartened to hear about Sandvik rollers that are still operating after 50 or 60 years. Strategically, Nepean is re-branding its acquired businesses as Prok, Gurtec and Roxon – businesses that Sandvik itself hoovered up over the years. The exception will be Brazil where the business will operate as Nepean Conveyors. “We are really delighted with the acquisition,” explained Miles. “We are pleased to have validation from the market that the Prok, Gurtec and Roxon brands come back to the front of the market.” Miles believes that while Sandvik’s products are excellent, it may have downplayed its brands. “While Sandvik’s facilities and products are turning out to be better than expected, their sales and marketing may have understated the strength of the brands, the engineering and the products,” Miles explained. “Nepean is not traditionally a sales and marketing organisation. We have a bit of work to show the world how substantial the products are.” Pricing-wise, customers may see Nepean sharpening its pencil. “When Sandvik went to market it said ‘with our accounting cost and amortisation of all our global overheads, we need to have high prices in the marketplace,’” said Miles. “We are coming back to a more fundamental approach…the fair

price in the market relative to the value it creates. We are seeing lots of customers wanting to talk to us about good solutions and customers can take advantage of our desire to show them a measurable point of difference.” Nepean operates 13 diverse businesses, including conveyor systems, longwall components, galvanising, electrical equipment, and methane gas extraction. Different though its businesses are, they are all run with flat structures, low bureaucracy, high accountability and empowered staff. Miles Fuller calls this the Nepean “DNA”. Managers, supervisors and aspiring leaders are nurtured with Harvard Business School -designed management training and an annual get together called The Leadership Academy. As Miles and his colleagues – both technical and administrative – visit various Sandvik outposts, they are listening closely to staff on the ground. “We are not saying ‘this is how we do things’” said Miles. “We are saying ‘how do we get the best out of your business?’ The only trade-off is that they have to be committed to the Nepean DNA and that’s been easy.” Looking to the future, Miles expects further growth for Nepean which currently has around 1,100 employees. “I’m very keen to grow the company in North and South America and we will continue to make acquisitions where we think there is an opportunity to continue this similar model.”

“Nepean is re-branding its acquired businesses as Prok, Gurtec and Roxon.”

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NEWS

REMOTE MONITORING

New belt monitoring system The patented design features a roll mounted eccentrically between the crushing and the screening chamber

Thomas Jabs, head of mining systems in the industrial solutions business area commented: “With its efficient continuous operation the Barracuda will help significantly reduce both operating costs and CO2 emissions at the Yiminhe mine. This is a good example of our innovative mining solutions that create value for our customers and at the same time protect resources.” The second stream with coarse material is transported to the Thanks to its compact design and special bucket wheel concrushing chamber reduced between mount- systems The market isand increasingly relyingthe oneccentrically remote monitoring to improve the Barracuda is also able to remove hard material layed roll and thereliability, chamberwalls. conveyor reduce costs and minimise exposure tofiguration environment, ers. “Combined mining and loading within a single machine also In addition to higher production, this design also requires less health and safety risks. eliminates the need for dangerous and environmentally harmful maintenance. Keeping the fine material out of the crushing chamblasting and separate loading operations,” explained Jabs. “The ber reduces the power consumption of the electric motor and sigThe system twotherefore levels ensure continuing safe and efficient ONE OF THE KEY REASONS REMOTE new supports system will nificantly reduces the load on the THAT machine. An integrated automatic of automated response. open pit operation in Yiminhe.” gapmonitoring adjustment systems system with overload device also they offers good are in greatersafety demand, is that Thecan new protection in the event of of hours non-crushable foreign material. reduce the number maintenance personnel Critical defects stopbucket the beltwheel excavator overburden system combines As a Barracuda-C bucket wheel excavator with a capacity of “Theoperators symmetric the field roll permits the eccenand are arrangement spending out of in the and allow immediately. soon as the system 6,700 loose cubic metres per hour with a belt wagon, a conveyor tricteams roll crusher to be balanced with great precision,” said Thysto conduct more effective maintenance, reducing detects a defect that is beyond the system and a spreader. The scope of thyssenkrupp Industrial Sosenkrupp’s publicity. “With additional balancing weights it can unplanned down time. threshold level, taking into account lutions includes engineering, delivery, erection supervision and be balanced almost completely. This lowers machine vibrations With all these factors in mind, PROK has brought the size and depth of the belt commissioning of the complete system. when idling and significantly reduces the loads on surrounding the HX270 Laser Belt Scanning system to the Australian damage, the system can stop the conveyor in the same way The Barracuda will be used in Yiminhe to strip ABOVE overburden structures compared with other primary crushers. That makes How the system after more a decade of development its traditional ripcoal. detectors andbelt mine Afteroperate. being extracted by the Barracuda the material themarket, new crusher idealthan for use in mobile crushing by systems.” measures belt sister company in Europe. The HX270 system was developed Secondary levelsby can also set for serious system,defects. will be taken the beltbewagon toless the conveyor which will specificallybucket to addresswheel the many issues with other belt defects.transfer When these are identified the system site. can Dumping of the matethe overburden to the dumping Compact excavator monitoring systems onits the market. flag to the via a fault notice on the on-site rial operator will be carried out by the spreader system with a throughput Thyssenkrupp has won first order for its new Barracuda comrate up to tons perSMS hour.or email. The pact bucket excavator. China Huaneng Group Part ofwheel NEPEAN Conveyors, PROK claims to be thehas ordered terminal or of even by 10,000 an automated has a long thelargest bucketmanufacturer wheel excavator-based overburden system of quality conveyor products in the from the operator orthyssenkrupp belt service technician canand thensuccessful assess thepartnership with China Huaneng Among other things, mining unit of the solutions business world, across the company’s full range ofindustrial PROK conveyor rollers, idlers, area. fault remotely using theGroup: terminal on-site or even by in 2006 it supplied a fully mobile crushing plant and conveyor line to the Chinese Thepulleys, order is worth more than 40 million. The Barracuda is due belt cleaners and conveyor accessories. remotely logging on. mine which is still in operation today. to go into operation at the Yiminhe open-pit mine in Inner MonThe company was prompted to develop its own remote Faults are readily assessed without having to go into golia in 2018. monitoring system as it believed the various belt scanning

the field thanks to the simple to use GUI that presents

and monitoring systems on the market were either costly to

faults in an easy to use Windows environment, displaying

install or labour intensive to monitor and operate. They also

them in both an intuitive graphical representation and

failed to offer the real-time scanning functionality necessary

the measured extents of the damage, by position, area,

to minimise the effect of significant belt damage events.

length, width and depth.

The HX270 is a laser-based belt scanning and

Because the system accurately measures the position of

monitoring system, that provides live monitoring of the belt

faults, this same information can be used to position any

covers and fully automated analysis of the belt condition.

belt damage at a predefined location for field inspection. No

It can trigger an alert to an operator in the case of a minor

more having to stand by the side of the conveyor looking

defect, even stopping the belt in the event of a major defect

for a fault and hoping to position it in an accessible area by

or belt rip being detected to minimise the extent of damage.

activating an Emergency Stop.

The use of a laser scanning system allows the belt

The HX270 can be fitted to virtually any conveyor

surface to be accurately measured at a high resolution, and

system and does not require a special belt or the addition

it is this information that allows defects to be detected. The

of any sensors to the belt beyond a small RFID tag. PROK

fact the system actually takes surface measurements means

Operation of the eccentric roll crusher.

it can automate the response to defects, by comparing them to adjustable criteria.

believes the HX270 is more than just a high-quality belt

“The use of a laser scanning system allows the belt surface to be accurately measured at a high resolution.”

Model of the Barracuda compact bucket wheel excavator. The first model will go into operation at a scanner, but describes it as a mature and resolved belt Chinese mine in 2018.

protection system.

ARE YOU A DESIGNER / MANUFACTURER / RESEARCHER / OPERATOR OF BULK SOLIDS HANDLING SYSTEMS / EQUIPMENT / STORAGE?

... If so, you can now expand your capabilities by joining the Australian Society for Bulk Solids Handling. The Society has a mission to enhance the discipline of bulk solids handling through research, education and sound engineering practice. Further information on the Society’s activities, its Constitution and registration procedures are available from the: Australian Society for Bulk Solids Handling The University of Newcastle University Dr, Callaghan, NSW 2308 Phone: (02) 4033 9039 | Fax: (02) 4033 9044 Email: Danielle.Harris@newcastle.edu.au

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MEMBERSHIP IS OPEN TO ALL PRACTITIONERS IN BULK SOLIDS HANDLING AND RELATED TECHNOLOGIES. 537 Nepean.indd 34 ASBSH QP2016-ReDesign.indd 1

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CONVEYORS

ContiTech flags ‘pay-pertonne’ belt technology Continental’s ContiTech conveyor business touted its hi-tech credentials at the giant Hanover Fair, held in Germany at the end of April, with monitoring and sensing technologies that might allow a ‘pay-per-tonne’ model. CONTITECH’S FOCUS AT THE EXHIBITION WAS belt monitoring, with a scale model showing how it works. In the field, on a particular conveyor, sensors monitor every movement of the conveyor belt and the material conveyed. They inspect surfaces and report fill levels or incorrectly operating belts in real time. Databases store the information, and algorithms assess it and know when the belt needs to be serviced. The technology uses both optical sensors and radar technology. “Belt monitoring systems enable us to check the safety-relevant belt properties,” explained Jens Koster, who is responsible for business development, finance and digitalization at Continental’s conveyor belt group. “At the same time, this technology provides the conditions for new business models such as pay-per-ton and predictive maintenance of components or systems.” A web portal and app, ContiPlus, provides operators with data about their systems at any time. According to Koster, more than 500 users –

primarily in the United States, Canada, Mexico and Chile – already use the software to monitor around 1,700 installed conveyor belts. The thickness of the cover plate, among other things, is determined at every service interval, using a mobile ultrasound device, and is stored in a database. This results in a complete picture of the condition. The program can then use the data to predict when a belt should be replaced because of wear. Continental acquired South African company Advanced Imaging Technologies in 2017. It is known for its work on magnetics-based monitoring systems, which are used for the early detection of damage to steel cord conveyor belts. Advanced Imaging Technologies’ magnet sensor technology provides a high-resolution magnetic image of damaged or broken steel cords for the verification of potential alarm conditions. It makes it possible to monitor splice integrity and the extent of damage even over a longer period of time, enabling comparisons to be made with historic data.

ABOVE: Continental’s app allows operators to remotely monitor the condition of their belts.

“This technology provides the conditions for new business models such as pay-per-ton and predictive maintenance.”

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COVER STORY

How to solve some common load zone issues

ABOVE: It’s important to evaluate your operation as a whole and equip your load zone with the right protection.

When trying to maximise productivity and increase output, looking at your system as a whole is vitally important, says conveyor productivity expert Flexco. PROTECTING YOUR LOAD ZONE is about finding a solution which fits perfectly to your application and making sure your belt conveyor system is well-equipped to handle the tonnages it sees day in and day out. Problems such as spillage, mistracking, broken equipment like skirting systems and idlers as well as severe carry back are all results of a poorly equipped load zone. Flexco Australia’s managing director, Mark Colbourn, discusses some common load zone issues and how to address them before they cause unscheduled downtime.

Throughput – the beginning of load zone issues A common perception is that a lot of issues on a belt conveyor system start at the point of impact. What many dismiss, is that these problems actually start before the impact, within the transfer chute.

There are many factors that contribute to a poorly functioning transfer chute and many variables which need to be taken into account when designing a chute which will function at its optimum. A poorly functioning transfer chute can harm your sites throughput levels dramatically. The main issue that will occur is blockages. Blockages occur when the chute is ill-designed, not taking into account lump size, desired output (tonnes per hour), belt speed and the application. To combat blockages, a chute designer must look at the flow path as their highest priority. The flow path requires superior engineering to achieve the ultimate goal of a soft and centred loading with low impact. It’s worth finding a solution that can work to manipulate the material path, velocity and angles of moving material,

which will significantly minimise the impact onto your receiving belt. Traditional chutes offer almost no control over the flow path, so they plug frequently and require shutdowns for cleaning, meaning minimal throughput and increased downtime for maintenance.

Mistracking, spillage and belt wear The belt sees every gram of product that passes through your belt conveyor system – it’s amazing they last as long as they do. By the same token, the load zone sees every gram of material too. It’s important to consider a worst case scenario when selecting an impact bed to protect your load zone. Just as one large pothole can wreck your tyre, one large rock can wreck the load support if it exceeds design capacity. There are flow-on effects

“A poorly functioning transfer chute can harm your sites throughput levels dramatically..”

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which occur when the right equipment is not in place. The first is having insufficient support in the load zone. The accessories which are chosen to support the belt in your load zone should be based on the impact energy of your load. To find out the energy of your impact, multiply your maximum lump weight by your drop height. If you have relatively low impact energy, impact idlers may act as enough support for your load zone, in applications with a higher impact energy a heavy-duty impact bed will be necessary. If there is insufficient support for the belt in a certain area, the space between idlers will create gaps in the seal that lead to spillage and uneven belt wear. Spillage is another big issue which affects not only the load zone but also the health and environmental safety of your site. With an effectively designed transfer chute and impact bed, skirting would only be necessary in rare circumstances. However, urethane skirting is a good quick fix to help solve these issues temporarily, whilst waiting for resources to implement a highly-effective transfer chute and impact zone system. Spillage around the load zone can also quickly lead to mistracking. Mistracking can be a costly and sometimes dangerous problem. Evidence of a belt rubbing on a structure can also be viewed as a fire hazard, especially in underground coal mines. If caught early and fixed, a mistracked belt does little damage to the conveyor, however, if ignored other types of damage can occur. A belt that is constantly hitting a structure damages both the structure and frays the edge of the belt. In extreme cases, the width of the belt is reduced by several inches, which reduces the amount of material it can carry.

If a belt mistracks enough, it will spill material off the topside onto the area around it, which can result in safety violation. Mistracking commonly begins at the load zone and therefore can be solved there too. Installing a transfer chute which places emphasis on engineering for a soft and central load drop will ensure that spillage is kept to a minimum.

The long-term solution Flexco has a dedicated engineering and design team with the ability to assess your material flow and suggest solutions to improve your flow path and protect your load zone. Flexco’s Tasman Warajay Technology™ works to manipulate the material path, velocity and angles of moving material to “shape” the material path and as a result, significantly minimise the impact onto your receiving belt. The superior technology will also mitigate fugitive dust and minimise spillage. Coupling a Flexco FlowFirst™ transfer chute with a Flexco impact bed or CoreTech™

impact absorbing idlers will deliver superior dust and spillage control and unmatched defence against belt damage. Always evaluate your operation as a whole and equip your load zone with the right protection, such as a customengineered transfer chute, impact beds, skirting systems and impact idlers. This will limit the number of wasted resources put into maintenance and belt repairs and give you a tough defence against unscheduled downtime.

ABOVE: Mistracking can be a costly and sometimes dangerous problem. BELOW: Flexco can suggest solutions to improve your flow path and protect your load zone.

To learn about how to optimise your belt conveyor system, and solve the root cause of your load zone issues, contact technicalsupportau@flexco.com, or call 1300 098 435.

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PNEUMATICS, POWDER HANDLING & FOOD

Seven bulk bag dischargers double productivity Seven bulk bag dischargers from Flexicon have doubled productivity of powdered fruit and spice ingredients at a Spanish food plant.

AT MURCIA IN SOUTH-EASTERN SPAIN,

Product handling

Productos Sur (Prosur) manufactures powdered extracts from Mediterranean fruit and spices including savoury food blends, natural flavours, and food products based on natural antioxidants and natural preservatives. Seven bulk bag dischargers have doubled productivity, from 35 tonnes to 70 tonnes per day, in an expansion project that increased Prosur’s factory space from 3,000 m2 to 14,000 m2 . Built adjacent to its existing facility, the expansion has tripled packaging capacity, according to Francisco Hernández González, head of production department and production engineer. Prosur previously processed orders by transporting powders in 500 kg metal tote bins by pallet truck across the plant floor where the powders gravity fed through butterfly valves into the packaging machines. Today, on the top floor of the new facility next to the mixers, seven Flexicon Bulk-Out model BFHC-X half-frame bulk bag dischargers feed 70 tonnes per day to the packaging machines on the floor below. Bulk bags weighing 1,000 kg are filled with blended food ingredients directly from the mixers, before being loaded onto the bulk bag dischargers.

An electric hoist positioned over each discharger lifts the bag onto the half frame. The operator pulls the bag spout through a Power-Cincher flow control valve, in which four elliptically contoured bars cinch the bag spout concentrically, enabling partially emptied bulk bags to be retied and removed. A Spout-Lock clamp ring creates a sealed connection between the clean side of the bag spout and the clean side of a Tele-Tube telescoping tube, which raises the clamp ring for connection to the bag spout and then lowers, applying continual downward tension to promote flow. The bag spout interface devices contain dust. Further promoting the flow of material are Flow-Flexer agitation devices on each discharger that raise and lower the edges of the bag. Stainless steel material contact surfaces finished to sanitary standards meet Prosur’s hygiene specifications. Flexicon says the process is more

ABOVE: Operator pulls the bag spout through the PowerCincher flow control valve in which four elliptically contoured bars cinch the bag spout concentrically, enabling partially emptied bulk bags to be retied and removed. BELOW: Seven BulkOut model BFH-C-X half-frame bulk bag dischargers feed 70 tonnes per day to packaging machines on the floor below. An electric hoist positioned over each discharger lifts the bag onto the half frame.

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accurate and efficient than the previous one. The dischargers automatically empty the powders through a sealed chute into the packaging machines on the floor below. Through the plant’s central control system, high and low level sensors in the packaging machine hoppers send signals to open and close the PowerCincher flow control valves to accurately fill the hoppers.

Flexible for large and small orders Francisco Hernández González says that three bulk bag dischargers are dedicated for packaging large quantity orders, which require few product changeovers. The remaining four dischargers fill small batches that require frequent product changeovers. “Most of our production

is exported,” says González. “The bulk bag dischargers provide an efficient, automatic and simple way to transport the products from the blenders to the packaging machines, in a really short time.” The packaging plant operates for eight hours per day, five days per week. He concluded, “The bulk bag dischargers fulfilled our expectations. Compared to previous methods of handling, the dischargers allow us to process the same quantity of product in half the time.”

RIGHT: The Spout-Lock clamp ring creates a sealed connection between the clean side of the bag spout and the clean side of the Tele-Tube telescoping tube, which raises the clamp ring for connection to the bag spout and then lowers, applying continual downward tension to promote flow into packaging machine on the floor below. BELOW: The bulk bag discharger system handles Productos Sur’s (Prosur) powdered extracts from fruit and spices including food blends, natural flavours, and food products based on natural antioxidants and natural preservatives.

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PNEUMATICS, POWDER HANDLING, FOOD

US bulk centre focussing on powder handling, pneumatics A relatively new US$5m Bulk Solids Innovation Center at Kansas State University is a US equivalent of TUNRA in Australia and The Wolfson Centre in the UK. ABHR editor Charles Macdonald put some questions to the centreâ&#x20AC;&#x2122;s research director, John Lawrence. Charles Macdonald (CM) Can you please tell my readers a bit about the Kansas State Bulk Solids Innovation Center? When was it established, why, and what does it do? John Lawrence (JL) Kansas State University Bulk Solids Innovation Center (KSU BSIC) was started in 2015 and is dedicated to research, education, and training related to bulk solids handling. This university-level research center is the only one of its kind in North America. The majority of bulk solids handling equipment manufacturing companies in the USA are located in the state of Kansas and neighbouring states like

Missouri and Nebraska. However, that is not the main reason for starting this center. During 2009, officials from Kansas State University, Coperion K-Tron (a pneumatic conveying system equipment manufacturing company) and Vortex Valve (a slide gate, diverter, and loading spout manufacturing company) had a social gathering and discussed starting this center to generate knowledge helpful to the industries handling bulk solids. With federal, state and local funding, the center was built at a cost of US$2.5 million. In addition, US$2.5 million worth of equipment was donated by more than 40 different companies in the USA. The

ABOVE: Johnselvakumar (John) Lawrence, PhD., PE, research director, Bulk Solids Innovation Center, Kansas State University.

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FIG 2

FIG 1

FIG 1: Attendees at one of the Center’s short courses. FIG 2: Blower unit at KSU. FIG 3: Blower control system.

FIG 3

total cost of the center was US$5 million. Currently, the following activities are conducted: organizing and running professional development short courses; test services such as bulk solids flow property (hopper design) and pneumatic conveying characteristics (design parameters of pneumatic conveying systems); and teaching credit courses in the area of bulk solids handling. Currently KSU offers five online credit courses in the area of bulk solids handling. CM ABHR’s readers are well familiar with TUNRA, in Newcastle. Is your centre a US equivalent? Or are there differences? JL KSU BSIC is equivalent to TUNRA in Australia and The Wolfson Centre in the UK in terms of research and education objectives. However, our center is closer to The Wolfson Centre, rather than TUNRA, in terms of its area of focus. KSU BSIC and Wolfson are focused more on pneumatic conveying systems and storage and flow. In contrast, TUNRA is focused more on mechanical conveying systems. A big difference between the centers is their longevity. TUNRA and The Wolfson have been around for over 50 years and have established their credibility in the world of bulk solids handling. KSU BSIC is yet to achieve this. In the UK and Australia, public research on bulk solids handling is done by The Wolfson and TUNRA, with a few other university professors active in Europe. In the USA, public research on bulk solids handling is very limited with few professors

working in this area. However, the private company Jenike & Johanson does a good job in solving bulk solids handling problems for US industry and they have been in the field for over 50 years. Andrew Jenike started the company in 1966 with his graduate student Jerry Johanson. Another difference between the three centers is ownership. KSU BSIC is not owned by Kansas State University, whereas The Wolfson Centre is owned by University of Greenwich and TUNRA is owned by University of Newcastle. KSU BSIC is owned by the city of Salina, more particularly Salina Economic Development Corporation (SEDC). KSU, Coperion K-Tron and Vortex Valve are tenants to the center, which is unique while adding a degree of complexity. CM Overall, does the centre and its research tend more to powder handling and pneumatics, rather than mechanical and belt conveying? JL Currently, research at this center is focused on powder handling and pneumatic conveying systems. We are also in the process of developing capability around mechanical handling systems. However, we do not have space for this expansion in the present building and are looking for alternative space. It will likely take time. CM What are your current research priorities? JL Our current research priorities are working on different concepts to improve the efficiency of pneumatic conveying system design, both dense and dilute phase. We are looking at material

“KSU BSIC is equivalent to TUNRA in Australia and The Wolfson Centre in the UK in terms of research and education objectives.”

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PNEUMATICS, POWDER HANDLING, FOOD

“Our current research priorities are working on different concepts to improve the efficiency of pneumatic conveying system design, both dense and dilute.”

degradation and elbow wear and tear, as well as material flow in hoppers and issues around enhanced feed rates, uniformity of flow, and reduced material stickiness to the wall. CM Can you please tell me about your background, which was, I believe, in the private sector? JL I am an agricultural engineer with a specialisation in food processing engineering, more specifically grain/feed drying, handling and storage. My PhD research was on modelling the grain storage ecosystem. At the company Intellifarms, I did research on grain drying and storage, more specifically moisture sorption equilibrium moisture content characteristics study. The principles behind the handling of grain and grain flour are similar to all other bulk solids, such as pharmaceutical powder, chemicals, plastic and so on. The handling of all these bulk solids is influenced by moisture, temperature, relative humidity, density, size, shape and distribution. I see a great continuity in my research. I am also doing moisture sorption tests for various other bulk solids. CM How closely do you work with your big private backers – Vortex and Coperion? Do they help you focus your areas of research? JL The collaboration we have with industry and

the two companies you mention is unique. Even though both companies perform their proprietary work without involving KSU, indirect collaboration between us helps us identify problems which we work on. Coperion takes care of all equipment as well as the building. Vortex is supporting us as needed. Currently, Coperion and Vortex are not sponsoring any research to solve their problems. They are helping us indirectly, mostly in setting up the lab for various research and giving guidance on achieving certain tasks. Engineers from these two companies help us teach short courses which are held every two to three months. CM What are the main industries in Kansas, and the region. Presumably they shape your activities? JL The main industries in Kansas are advanced manufacturing, alternative energy, bioscience, food processing and logistics. Advanced manufacturing is in the field of aircraft and its components as well as auto parts, medical devices and plastics. In terms of bulk solids handling, companies like Coperion, Kice, Horizon, United States Systems and Magnum specialise in pneumatic conveying systems and are located in Kansas. Metal storage bin and hopper manufacturers like CST Storage

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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 and/or bouncing against the outside radius of sweep elbows create friction and heat, melting pellet surfaces, forming streamers.

Friable materials hit the outside radius of conventional impact elbows at high speed, degrading the material and generating fines.

Materials skidding against the outside radius of conventional elbows create friction and heat, causing product build-up.

Formation of streamers, angel hair and snake skins

Breakage and dusting of fragile materials

Plugging and build-up

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PNEUMATICS, POWDER HANDLING, FOOD

FIG 4

FIG 5

Teflon coated sphere for sticky situations BinMaster has issued a teflon-coated sphere for its SmartBob level sensor which is designed to cope with sticky powders. IT IS SPECIFICALLY ADAPTED FOR MEASURING

FIG 6

FIG 4: Lab 1 at the Kansas Center. FIG 5: Lab 2 at the Center. FIG 6: A pneumatic conveying demonstration at the Kansas Center

and Tank Connections are also located in Kansas. Manufacturing, transportation and warehousing are the main industries at Salina. The presence of several pneumatic conveying companies in Kansas is due to many factors. One is that when Kansas’ aerospace manufacturing sector, based around Wichita, contracted, many of the engineers that lost their jobs translated their turbine knowledge into design of pneumatic conveying systems. CM Do you do any work aimed at mitigating silo quaking and honking? JL We have not done any work related to silo quaking and honking. It is a big problem in bulk solids handling, and, in fact, we are seeing the same problem in our test lab with excess vibration during hopper unloading creating honking.

powders and solid materials that may adhere to the sensor probe such as silica or frack sand, powdered chemicals or minerals, additives and ingredients. The sphere coating is FDA approved allowing it to be installed in bins, tanks, or silos containing ingredients used in animal and human food processing or pharmaceutical environments. BinMaster’s SmartBob level sensor eliminates the need to climb bins and take manual measurements. Acting as an automated tape measure, the sensor takes measurements at predetermined time intervals or on demand. The sensor is automatically dropped to the material surface. When it makes contact with the surface, it immediately retracts and, by counting pulses, calculates a highly accurate measurement from the top of the silo to the material surface.

Emerson spruiks Rosemount scanner Emerson has launched a device aimed at those looking for higher silo utilisation and more accurate assessment of bulk solid stock. The company’s Rosemount 5708 3D solids scanner measures multiple material surface points. It is unaffected by dusty applications and allows 3D material profiling visualisation. According to Emerson, the end result is reliable and accurate volume measurement and an optimised filling and emptying cycle.

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PNEUMATICS, POWDER HANDLING, FOOD

NSW hydrated lime plant’s loading spouts Vortex in March 2018, provided a company in New South Wales with six loading spouts for discharging hydrated lime – also known as calcium hydroxide – from silos into enclosed bulk pneumatic tankers. HYDRATED LIME IS A DIFFICULT DRY MATERIAL with unique and complex characteristics. In this installation, Vortex’s customer’s hydrated lime process required a discharge rate of 150 tph from silo into tanker. The bulk density of hydrated lime materials is 0.4-0.8 t/m3. Moisture content is <1%. Material particle size is -75μm (categorized as dust). The maximum material temperature is 80°C. Adding further difficulty, the new equipment had to be able to mate up with pre-installed active cone discharge units. In this instance, the company opted for six Vortex loading spouts with vertical travel of 1.5 metres and a loadout capacity of 250 CFM (424.5 CMH). The spouts have a four-cable lifting system, three-piece, CNC-machined pulley system and centre mount motor. They also have a levelsensing kit and detachable dustless loading skirt. “Our loading spouts were sourced because they are customisable to meet the customer’s specified travel

distance and loadout capacity,” explained Laurence Millington, managing director, Vortex Global. Although the spouts will often be loading product into enclosed vessels, they are compatible in both open and enclosed loading applications. By attaching or detaching a dustless loading skirt, the spout ensures material dusts will be contained when loading into either open or enclosed vessels. At the Australian site, the customer specified that each spout be equipped with a level-sensing probe (pictured above) for when the spout is operating in open loading circumstances. This technology is beneficial because it allows automation in the open loading process. Installed at the spout’s scavenger, a levelsensing probe rests on the outside of the dustless loading skirt. As the material pile grows, the skirt flares outward and the level-sensing probe slowly begins to tilt. Once the probe reaches a tilted angle of 16 °, the spout is programmed to gradually retract. This feature is automated

ABOVE: Discharge scavenger for open loading applications & Four cable hoist system.

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CONTAINERISED BULK

According to Pellizzari, dust emissions are not a concern when using Flinders’ containerised system to load concentrate. “Copper concentrate is completely sealed in the container until it is in the hold of the vessel where the lid is lifted on and off during discharge. “WeRIGHT: have Centre a misting system to keep down the dust. It is such mount motor & a fine mist that basically, unless it collects dust, the water just Spout pulley. evaporates. We use it around the hatch [of the ship’s hold] and the water is metered to determine what moisture could potentially be added.”

The Oz Minerals system In its issues from 2012, ABHR detailed elements of the Oz Minerals system. There follows a recap of some of the more pertinent elements. Flinders developed a transport and storage solution, using containers, called the Enclosed Bulk System. Under the system, copper concentrates are loaded into OZ Minerals’ containers at Prominent Hill. These containers, featuring secure, locking top lids, are then moved by road to a rail head and transported by train to the Berth 29 facility. The basis of the Enclosed Bulk System is that containers are used to store and transport the copper concentrates, cutting down on handling of the product along the supply chain. The cutsdoes the number of points where copso method that thealso spout betransfer extended or retracted per concentrates couldinbe disturbed andthe escape the envinot become buried until cable into is repaired or ronment. OZ Minerals’ feature gravity iflocks to the material pile andcontainers also replaced. However, a cable ensure a fail-safe locking and robust security, safeoptimal flow rates can mechanism is broken in a four-cable guarding against accidental spills of copper concentrates on land be maintained. When lifting system, three cables transport and during storage. the spout reaches a remain, allowing the spout At the port, Flinders Logistics uses a crane with a rotating conprogrammed retraction to continue operations until tainer tippler to unload bulk from containers inside a ship’s hold. height, the conveying line maintenance canits DF MistTo combat fugitive dust the company developed above is commanded to halt be performed. ing dust suppression system. Under the DF Misting system used flow. The Vortex at material the copper concentrate tippler operation, bars loading are lowered In ship’s essence, a levelfeatures a The into the hold and positioned spout there atalso different levels. bars generate of finethe mist of differing depths.system sensing kit layers eliminates unique pulley Combining themonitoring bars with variousdesigned sizes of nozzles, Flinders need for visual to reduce the Lorisk gistics canthe generate droplets to match particle size of concenduring loading process of the spout misalignment, trates takematerial account waste of prevailing weather imbalance, conditions. This and and reduces retracting results in an extremely fine mist dispersing across the ship’s hold from overfilling of vessels. and cable wear. The to form a natural barrier which contains the dust particles inside When loading enclosed Vortex pulley system the vessel. vessels, spout damage utilises three-piece, DF Misting deploys high-pressure, purified water, which will and cable breakages can CNC-machined pulleys not calcify and clog the delicate nozzles in the sprayer system. be caused by tankers with chamfered radius to The water droplets in the hold eventually evaporate returning edges and precision cable theprematurely water cycle.pulling away from the loading grooves. Because the dock. Thus, a four-cable pulleys are designed so lifting system can be that the grooves match the difference between the exact diameter of continued operations the lifting cables, Vortex and loadout shut-down. says its pulley system As each lifting cable has reduces cable wear and 180 kgs capacity, a fourbacklashing as the spout cable system allows total extends and retracts. resistance of 725 kgs, The Vortex spout also which provides a greater features a centre mount service factor and improved motor. The drive unit is cable breakage resistance. centre mounted beneath the With two- and threemain support pan assembly cable lifting systems, if a for better protection from cable is broken, the spout is the elements, and is easily imbalanced and thus, cannot for service. (Left to right) Andrew Pellizzari, Flinders Logistics;accessible Peta Connelly, TBSH; Dewayne Cannon, TBSH; and Vincent Tremaine, Flinders Port Holdings.

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(03) 9457 8244 Call to speak to your local representative 53 Australian Bulk Handling Review: September/October 2017 www.kockumsbulk.com.au

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PNEUMATICS, POWDER HANDLING, FOOD

A new chapter for Kockums The purchase of Kockums Bulk Systems by Premier Tech of Canada marks the end of Australian ownership of the powder handling stalwart and the start of a greater international focus. In other respects, it’s business as usual for the group as Kockums’ chairman and CEO, Ivan Price and Francois Steyn, tell ABHR’s Charles Macdonald. THE KOCKUMS NAME GOES BACK TO THE Swedish-controlled but global engineering and shipbuilding group which operated in Australia in the 1970s and 1980s. After various local ownership changes, in 1989 Ivan Price led a management buyout of what had originally been Kockums’ powder handling business. Along with colleagues Sam LiRosi and Frank Tattersall, Ivan built the new entity, Kockums Bulk Systems, from a staff of three to a highly successful operation with a stable workforce over 40. There were many landmark projects for the Melbourne-based business. In 1995, it engineered the largest inland pneumatic conveying system in Australia, the 300 tonne per hour, 1.5km system handling flyash at the Bayswater Power

Station in the Hunter Valley. In 1996, it designed and built two pneumatic conveying systems for vacuuming cement from barges in Hong Kong harbour and transferring it on to Lantau Island, for construction of a new airport, at a rate of 160 tonnes per hour. In 2008, Kockums won the award for Bulk Handling Facility of the Year at the Australian Bulk Handling Awards. The trophy was for its delivery of a cutting-edge compounds plant for Lafarge Plasterboard in Melbourne. Kockums was also a winner in the same category in 2015 and 2016. However, in more recent times, Kockums was in need of a fillip. “The business had plateaued and was in need of new direction,” explained Ivan. “There

“Why don’t you vertically integrate into the process upstream of the packaging line?”

BEOW: (l to r) Ivan Price and Francois Steyn of Kockums Bulk Systems, now owned by Premier Tech of Canada.

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has been little growth potential in our mainstay powder handling project work in Australia in the last couple of years.” This realisation coincided with interest from Canada’s Premier Tech group, which, through its Premier Tech Chronos division, is a major international force in packaging. Premier Tech did business in Australia, but was without the on-the-ground customer support that Kockums excels in. Talks took some time, however, as the powder handling-focussed Kockums and packagingfocussed Premier Tech worked through the strategy of a tie-up. Francois Steyn, who took over as CEO of Kockums in 2012, explained, “We said to them – ‘why don’t you vertically integrate into the process upstream of the packaging line? That’s where we can help you inside the factory’.” Ivan Price concurred: “Premier Tech recognised that our product range and vast experience could be used to provide a new direction of growth in their group.” Powder handling will now play a bigger role in Premier Tech’s strategy, going forward. “That is now part of their future road map, to vertically integrate into the materials handling side of the process,” said Francois. With longer term strategy established, the deal was consummated in early March. For Kockums’ staff and customers, it’ll mainly be business as usual. “Everybody stays on and there will be no changes to the structure,” said Francois. “We are all excited. We get to do what we do and the fact is we now have an ambitious international parent with the resources to invest in our growth.” In terms of specifics, new packaging

opportunities are emerging for Kockums, in sectors like flour milling, milk powder and food. “Premier Tech is big in milling and they have a very smart bottom-up filling, open-mouthed bagger ideally suited to the milling and dairy industry,” said Francois. “Suddenly, we find ourselves a player in that part of the market.” In terms of branding, Kockums’ name will persist for some time before Premier Tech Chronos predominates. Francois will remain at the head of the company as managing director, with Ivan Price available on a part-time basis. Premier Tech has grown rapidly. It has made 14 acquisitions in under 20 years, including Chronos Richardson in 2002. Encouragingly, it’s a long-term owner and doesn’t trade businesses. “They do Warren Buffet-style acquisitions,” said Francois. “They look for companies that work well, with good management. They buy them, keep them and develop them.”

In at the pneumatics deep end Ivan Price was plunged in at the deep end when it came to his exposure to pneumatic conveying. Emerging from Auckland Uni in 1963 with an engineering degree, Ivan joined Mason Bros, one of New Zealand’s three major engineering firms. While he anticipated a broad-based engineering education, Ivan was almost immediately set to work under an engineer introducing Swedish company HW Carlsen’s pneumatic conveying systems and road tankers to New Zealand. When Ivan’s boss left three weeks later, Ivan, by default, became the

STRONG, SAFE, LIGHT

pneumatics contact. In the late 1960s and early 1970s Ivan spearheaded the introduction of the Swedish technology, now dubbed dense phase pneumatic conveying, into tankers and powder handling systems in Australasia. When Kockums of Sweden bought Carlsen’s pneumatic conveying road tanker division in 1969, Ivan transferred to Kockums’ head office in Melbourne. Over the next 20 years’ Ivan’s expertise grew as he engineered ever larger systems. By 1989, he was ready to play on a larger stage with the management buy-out allowing just this.

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18/05/2018 3:30:04 PM

MOBILE CRUSHING & SCREENING

New Zealand quarry company turns to mobile equipment Blackhead Quarries, which operates a number of quarries around Dunedin, is increasingly switching from fixed plant to mobile crushing and screening equipment from Metso, citing flexibility, cost and safety benefits.

ESTABLISHED IN 1986, BLACKHEAD Quarries – a joint venture between Palmer & Son and Fulton Hogan – operates near Dunedin, on New Zealand’s South Island. Opened in the 1950’s, the company’s Blackhead Quarry, located at Blackhead on the seaward side of Green Island, produces 300,000 tonnes per year. The company also operates quarries at Logan Point, in Dunedin and Balclutha as well as the Walton Park sand plant in Fairfield. The Balclutha quarry, located around 80km south-west of Dunedin is the largest producer of quality aggregates in the South Otago area and supplies

ABOVE: Fine tuning Barmac operating parameters on the LT7150. BELOW: Tony Hunter, general manager, Blackhead Quarries.

around 30 different products. With many infrastructure projects underway and planned in Dunedin, there is strong demand for quarry products.

Investing in the future Until recently, Blackhead Quarry’s Balclutha quarry operated a fixed crushing plant that required rock to be transported up to 5km from its primary sources to the ageing facility. In the interest of improving operational flexibility and safety, the company decided to invest in a new mobile crushing and screening plant for its Balclutha operations.

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Blackhead Quarries has extensive experience with Metso equipment, having bought its first Lokotrack mobile impact crusher back in 2005. With its latest acquisition, Blackhead now operates the largest fleet of Metso mobile crushing and screening equipment in New Zealand. But the company’s relationship with Metso and Mimico, Metso’s exclusive dealer in New Zealand, dates back a lot further than that. Much of the equipment in the company’s original fixed plants includes Nordberg, Allis Chalmers and Barmac machines which can all be traced back to Metso origins. Tony Hunter is the general manager of Blackhead Quarries. He has overall operational responsibility for all of the company’s quarries. He said that being near the sea, the Blackhead quarry’s fixed plant, that had been in place for over 30 years, was suffering from extensive corrosion issues. Management was worried about the safety of fixed walkways and the quarry’s 23 conveyors. “Five years ago, we decided it was best to build a whole new plant at Blackhead with only nine conveyors and no walkways,” he said. In doing so, the existing Nordberg C100 jaw crusher, a cone crusher and Barmac 9600 crusher were relocated. The new plant is fully automated and was designed to keep the amount of structural steel work to a minimum, which led to the elimination of walkways. “For maintenance we use cherry pickers, which give better access to the equipment than walkways and in our opinion, are much safer for our maintenance staff,” he said.

last about 3,500 hours, and Barmac tips only about 500 hours,” he said. “Bucket teeth can last anything from 800 to 2,000 hours.” So reliable, local supply of wear and spare parts is very important.

“The new plant is fully automated and was designed to keep the amount of structural steel work to a minimum.”

Hard rock drives need for reliable wear part supply Gavin Hartley is the quarry manager at Blackhead quarry, and has 10 years’ experience with the company. He describes his job as “making stones as cheaply and efficiently as possible while ensuring that staff are safe.” The Blackhead quarry produces a full range of quarry products, including base courses (for road base), sealing chip, asphalt dust and railway ballast. The rock quarried in the Otago area is a heavy, finegrained rock that is hard, brittle and abrasive. According to Hartley, “Jaws and liners typically

The importance of local support

ABOVE: Craig Upston discusses crushing circuit performance with Garth Taylor at Balclutha quarry, with a LT200HP cone crusher in the background.

“Here in New Zealand we are a long way from Finland, or other countries where rock crushers are manufactured,” said Hunter. “It’s important that we can get ready access to the support we need, because a crushing equipment failure can stop our production.” Garth Taylor, crushing & screening business manager at MIMICO, agrees: “New Zealand is a small country and Dunedin is a small community. “If Blackhead Quarries has two LT106 jaw crushers they only need one set of spare parts,” he explained. “They have two of New Zealand’s 12 LT1213 impact crushers. The significant population of Metso machines in New Zealand means that we keep a comprehensive range of spare parts to support our customers.” While there are now more brands of crusher available in the New Zealand market than ever before, Hunter likes to work with organisations that support the local quarrying industry. “The large number of Metso crushers in

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MOBILE CRUSHING & SCREENING

New Zealand means that there’s good support locally,” he said. “Wear parts are one thing, but these technically advanced machines can be stopped by the failure of a small component like a sensor. While we perform most of the maintenance ourselves, it is good to have local technical support. MIMICO provides all that we need and we have a great relationship.” Blackhead Quarries experienced the benefits of crushing and screening at the quarry face when it introduced its first mobile crusher in 2005. The company has been growing its fleet of Metso Lokotrack mobile equipment ever since, gradually reducing its reliance on fixed plant. “You can’t bust a rock without energy and even though it is fuel efficient, the mobile plant uses a lot of diesel – the machines have quite large motors to move them around as well as for processing rock,” said Hunter. “With our move to mobile equipment and reduction in the number of trucks, our diesel usage has remained about the same, but we no longer consume electricity in our fixed plants – so overall, our energy costs have gone down in the order of $100k per annum.” According to Hunter, the reduction in truck usage has also delivered significant benefits in respect to staffing levels, site safety and maintenance costs. Blackhead Quarries now owns a total of 10 Lokotracks across its sites, and is the largest user of these machines in New Zealand. “Our Lokotrack fleet has become very important to our business,” said Hunter. “Our original LT1213 unit was the first one in New Zealand and is still operating – and now we have more across our quarries. They are the core of our mobile fleet.”

Craig Upston, quarry manager at the Balclutha quarry, is a veteran of the industry. Having been with the company for 25 years, he is a third-generation employee. “The shape of the product is critical for our customers – if we don’t get it right it will be rejected,” he said. “Our Barmac crusher helps us to achieve consistent product shape and quality.” The Metso Barmac vertical impact crusher uses an autogenous (rockon-rock) crushing method. Its adjustable rotor speed and feed rate give operators precise control of the grade and shape of the final product. From Upston’s perspective, moving from fixed to mobile plant was a matter of future-proofing the quarry. “We were planning to replace our older Barmac with a new one, and because the market for Balclutha’s product has a lot of ups and downs, being able to move the crusher around to different sites creates better business flexibility,” he said. The quarry was originally opened some distance from the town of Balclutha, but with the growth of the town bringing suburbia closer to the quarry, the issue of dust has become more of a problem. By eliminating the fixed plant that was close to the road and moving to Lokotrack machines, quarry staff can choose where crushing occurs. The reduction of truck movement and decommissioning of the fixed plant has made it much easier for the company to manage dust. At first Upston proposed putting a new Barmac on tracks then in five years’ time adding a tracked cone and jaw crusher as well. As it turns out, the company’s management loved the idea and acquired all three Lokotrack versions in the same year.

ABOVE: Craig Upston, quarry manager, Balclutha quarry.

“Moving from fixed to mobile plant was a matter of futureproofing the quarry.”

Going mobile at Balclutha The company’s most recent addition to its Lokotrack fleet took place in 2017 at its Balclutha quarry, which mostly produces road and construction materials as well as manufactured sand. A significant part of the quarry’s production also feeds the concrete plant next door. The quarry’s demand tends to be seasonal – the Clutha district council for example has an annual road sealing season, and there are periodic maintenance gravel contracts.

Reducing dependence on fixed plant In July 2017, MIMICO supplied a Metso Lokotrack LT106 mobile jaw crusher along with an LT200HP mobile cone crusher and an ST3.5 mobile screen for the Balclutha quarry. An additional ST3.5 and an LT7150 mobile Barmac VSI (impact) crusher were supplied in October.

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PIT-TO-PORT SOFTWARE

Cloud, AI boosting supply chain software capabilities The cloud, artificial intelligence and smarter algorithms are revving up the capabilities of pit-to-port supply chain software. ABHR editor, Charles Macdonald spoke to Steven Weeks, commercial director of Paradyn Systems, the company behind BlendOpt software. CHOICES, CHOICES, CHOICES. For any bulk mining operation, operators and management confront a myriad of options around pits, products, rail and ports. Which combination will deliver maximum value and profits? How will a change of one parameter affect others? In the distant past, in an industry like coal, Excel was the tool du jour. A mine plan, in Excel, would be the starting point as companies sought to optimise their value chain, again with Excel. In the years that followed smarter software platforms derived from Excel allowed slight improvements, but only to specific tasks at one part of the process chain. Eventually more comprehensive solutions billed as ‘schedule solvers’ or ‘process optimisers’ emerged, but today, some of these are expensive with long deployment times. Paradyn says that its BlendOpt product, created in 2013, is cheaper and more quickly deployed than its competitors. It harnesses the cloud and artificial intelligence for greater computational grunt. “What we have done over the last five years is build an optimiser that looks at the whole chain from the mine site right through to the port,” explained Steven Weeks. “It’s about the speed of calculation, running thousands of multiple scenarios on what’s the best option.” The advent of the cloud has helped the software’s capabilities. “The main capability of the cloud function is it gives you a faster processing speed rather than running a platform on your personal laptop,” said Weeks. “Sending data for analysis to the cloud means you can buy time on a virtual server with a much higher speed and you can house more data.” Despite these advantages, some customers still have concerns over the security of their data. “It’s dealing with a mindset,” said Weeks. “Getting people to understand it’s not an issue to have their data linking externally to the cloud. It’s a bit of a challenge from that stand-point.” Irrespective, Paradyn has secured major customers including Anglo American, Vale, BHP, and Peabody.

The generational transition in the mining industry is helping Weeks’ cause. “We are finding that we are getting more acceptance particularly as the younger generation moves into the mining space,” he explained. “Our offering is quite visual so even though there are a lot of complicated algorithms and analytics behind the platform, the user interface is quite friendly and it’s open to using on your laptop or ipad; it’s quite visual and there’s a lot of acceptance.” Steven Weeks is a mechanical engineer. He has previously worked at BHP, in its steel and coal divisions, and at Sandvik, in a variety of roles including automation, machine health and data analytics. Paradyn was co-founded by James Whitacre, an artificial intelligence expert who previously led design of aspects of optimisation technology for SchneiderSolveIT’s Pit2Port software.

ABOVE: Steven Weeks.

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TECHNICAL PAPER

Technical Evaluation of the Majuba Power Station 10,000 tonne Coal Silo 20 Failure Mechanisms / Factors THIS PAPER PRESENTS THE FAILURE MECHANISMS and factors that resulted in the catastrophic collapse of one of the three 10,000 tonne coal silos at Majuba Power Station in November 2014, after 18 years of operation. The Majuba silo is of reinforced concrete construction, with a dual hopper outlet onto two belt feeders below. The silo is part of the coal live capacity storage system and as such was operated at full or near full level most of the time. Discharge is mainly by means of a single belt feeder, but two belt feeders are operated simultaneously when required. The material flow patterns inside the silo impose loading conditions which are extremely complex and are still subject to ongoing research. The requirement for the silo design is to combine the field of the evaluation of the material property analysis together with the functional analysis to achieve a successful structural design. The design of the Majuba silos was performed in the early 1990’s. Since calculations are not available, it was required to establish if the silo was correctly designed in accordance with the standards and coal properties adopted at that time, and then, to evaluate its response to more modern design standards in order to better understand the failure mechanism. For the above reason the initial investigation was performed with the ‘American Standard ACI 31391’ together with the coal properties as defined by Jenike & Johanson (1988), both utilized at the time of

A.P.Wiid, B.Marrai

design. Thereafter, the silo investigation was carried out in accordance with the ‘Australian Standard AS3774-1996’ and the recent ‘European Standard BS EN 1991-4’. The coal properties adopted for evaluation using the modern standards were those of the present-day coal used at the station.

BELOW: Majuba Power Station Overview

Introduction Initially, coal was supplied to the station from a nearby dedicated mine, before it was closed due to complex geology, which resulted in a difficult and unsafe mining operations. From then onwards, Majuba’s coal had to be sourced from numerous other suppliers, and is delivered by means of road and rail transportation. Majuba has three terrace coal silos with a capacity of 10,000 tonnes each. The central silo (silo 20), is serviced by two overland conveyors with inclined head sections and, in turn, supplies coal to the two wing silos by means of four over silo link conveyors. The cylinder wall thickness is 350 mm and the inner surface of the cylinder has a smooth concrete finish; the internal hopper is formed with mass concrete with a gunite surface lining; two rectangular openings are provided through the concrete slab from which two external steel hoppers are suspended below. The steel hoppers are lined with 3CR12 liners.

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TECHNICAL PAPER

FIG 1

FIG 2

FIG1: Configuration of the 10,000 tonne coal silos FIG2: Silo Geometry FIG3: The vertical crack in the silo with coal flowing out, followed by formation of the horizontal cracks

FIG 3

The in-feed conveyor system on the concrete roof of silo 20 feeds coal into the silo from two openings symmetrically placed about the centreline of the silo. The centre of each opening of the in-feed conveyors is 2.0 m offset from the silo centreline. With this configuration the in-feed and discharge presented very little eccentricity. The extraction conveyor system at the bottom of the silo consists of two belt feeders of which one was operating at 100% capacity while the other was standing idle as back-up. This operating philosophy caused constant eccentric discharge loading on the silo wall. Coal is supplied into the silo at a maximum rate of 3260 tph and the maximum throughput capacity of each belt feeder for discharge is 1200 tph.

The silo failure/collapse On the 1st November 2014, a vertical fracture developed on the south eastern face of the central silo, approximately two meters above the intersection of the internal hopper and the vertical wall. The vertical crack in the silo wall extended upward for approximately 10 m in height. This vertical fracture was followed by two horizontal fractures which then resulted in the sudden collapse

of the cylinder section. After the collapse of the central silo, a large pile of coal remained as surcharge above the hopper section that was still in situ. By removing the loose coal heap that remained above the hopper section during the cleaning operation after the collapse of the silo, a coal buildup (rock hard) was present on the shallow northern slope of the internal hoppers.

Observations and findings of the site inspection of the failed silo as well as the two remaining wing silos The inspected sections of the collapsed cylinder wall lying on the ground showed smooth concrete without any sign of degradation or erosion. The reinforcement inspected on site was not corroded, eroded or rusted. Tests performed confirmed that the steel reinforcement was indeed 450 MPa high tensile steel and the concrete strength exceeded 30 MPa. During the internal visual inspection of the two wing silos, extensive vertical and horizontal cracks were observed that were not visible from the outside even by using powerful binoculars. It must be noted that as part of the ESKOM

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TECHNICAL PAPER FIG4: Aerial image of the silo after the failure and the coal heap that remains above the hopper FIG5,6: The collapsed silo with the bottom part below the 28 m level remaining in situ. FIG7: Location of the initial fracture position and the presence of coal build-up in the hopper of the failed silo after removal of the loose coal heap that remained initially above the hopper FIG8: Visual inspection of the materials of construction of the failed silo

FIG4 FIG 5

FIG 6

FIG9: Visual inspection of the rebar of the failed silo

FIG 7

FIG 8

FIG 9

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FIG 10

inspection policy, the silos were visually inspected the previous year by an external consultant; besides minor spalling of concrete at the top of the silos, it was reported that the silos were in good structural condition. Furthermore, the silos were functioning quite well, delivering the correct amount of coal to the feeders, never giving any indication of malfunction.

Basic differences between a liquid and a bulk solid For the purpose of clarification, this section will attempt to explain some of the material flow conditions and the associated wall load conditions that may have potentially applied to the 10 000 tonne silo. It also explains the basic difference between wall loads applicable to a liquid versus a bulk solid for better understanding. In essence, the main reason for the difference in the wall loads imposed onto storage containers for liquids versus bulk solids is the presence of shear forces that is transferred between bulk solid particles, even under static conditions. The angle of repose or rest angle for a pile of material also confirms the presence of the shear forces between particles. From figure 12 it is evident that different internal flow patterns affect the distribution of the imposed wall load. There is also a notable difference between initial filling and discharge conditions in terms of the imposed wall loads. In the Majuba case where each silo is equipped with two belt feeders, different wall pressure distributions apply when running two feeders simultaneously, as compared to running a single feeder. In the case of running a single feeder, an over pressure applies to the wall on the far side of the feeder in operation, and an under pressure applies to the near side wall.

Investigation methodology applied The methodology applied includes: • I nspection after the collapse of the silo and testing of the materials of construction as well as inspecting the remaining two wing silos. •D esign review based on the original standard for the original and current coal properties. •D esign review based on the modern standards for the original and current coal properties for symmetric and eccentric flow conditions. •D esign review based on the modern standards for the change in flow condition as result of the internal coal build-up as confirmed by the visual inspection of the silos. •C ompilation of the causes that lead to the silo failure. •E xternal review by means of the appointment of an independent party (WITS that contracted Professor Roberts TUNRA Australia and David Craig (Ph.D.) Jenike & Johanson from the USA).

FIG10: Inspection of the two wing silos confirmed coal build-up and presence of cracks in the vertical walls ABOVE (TABLE): Summary of inspection findings on the wing silos

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TECHNICAL PAPER FIG 11

FIG11: Wall loads imposed by liquids versus bulk solids on container walls FIG12: Different material flow patterns for bulk solids inside storage containers and the associated wall loads imposed

FIG 12

Comparison of the American and modern Design Standards The main differences between the 1991 American standard (ACI 313-91) used and the modern Standards: •A CI 313-91 underestimate the “K” value in the Jansen Algorithmic using the Rankine static pressure K= 1-sin /1+sin , this yields wall load pressures far less than the pressures calculated with current Standards. •A CI 313-91 focus on symmetric loadings and it does not give any guidance how to deal with eccentric loadings. In using ACI 313-91, the following were incorporated: •E valuation of eccentric loading by incorporating the methodology of the Australian Standard (AS 3774-1996) to the wall pressures calculated using ACI 313-91. •W all loads were calculated for the original and current coal properties for comparison.

Comparison of the Australian Standard AS3774-1990 and the Eurocode EN 1991-4 The Australian Standard AS3774-1990, which first appeared in 1990, broke new ground in the level of

detail and comprehensive coverage of the subject of bin and silo loads. It included a methodology for dealing with non-symmetrical loadings due to discharge from eccentric openings. A revised version, AS3774-1996 was issued and remains as a valid Standard for bin and silo load determination and analysis. More recently, the Eurocode EN 1991-4 has appeared and is now widely accepted in view of its extensive, very detailed coverage of this complex subject of silo and bin loads. It does, however, contain a level of empiricism in the design procedures and equations presented. In effect, this may be regarded as a way of building-in suitable factors of safety to ensure safe design and operation. The Eurocode, to some extent, is ‘not very user friendly’. It contains a level of empiricism in the design methodologies and equations that are presented. For example, there is often a mismatch between the angles of internal friction recommended that are lower than the angles determined by flow property tests, and, in some cases, lower than the angle of repose, the physical significance of which is difficult to understand. One particular area of possible confusion centres around the selection of the so-called pressure

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TECHNICAL PAPER FIG13: Eccentric and symmetric discharge condition

FIG 13

•T he flow property analysis performed by Jenike & Johanson -1986, was used for the original coal. The following modern standards/ codes were applied: •T he Australian Standard AS3774-1996 – Loads on Bulk Solid Containers. •T he American Standard ACI 313-97 – Standard Practice for the Design and Construction of Concrete Silos and Staking Tubes for Storing Granular Material and Commentary. •T he European Standard Eurocode BS EN 1991- 4: 2006 – Action on Structures Part 4 – Silos and Tanks.

REFERENCES: 1. AS 3774 – 1996 – Australian Standard – Loads on bulk solids containers 2. BS EN 1991-4: 2006 – Eurocode 1 – Actions on structures – Part 4: Silos and Tanks. 3. ACI 313-91 – Standard practice for Design and Construct of Concrete Silos and Staking Tubes for Storing Granular Materials (including commentary) 4. BULK SOLIDS: Storage, Flow and Handling – By P.C. Arnold, A.G. McLean, A.W. Roberts – TUNRA Bulk Solid Handling 1982 5. Material Flow Analysis Report by Bulk Solid SA Reference BSFA 181 Dated 2003 6.Material Flow Analysis Report reference Jenike & Johanson 881956 dated 1988 7. TBSA Flow Properties Report SA 0018-1; Eskom Majuba Life-2015 8. TBSA Flow Properties Report SA 0018-2; Eskom Majuba Mill-2015 9. TBSA Flow Properties Report SA 0018-3; Eskom Majuba Strat-2015 10. WITS / TUNRA Report #8518 – 1000t Coal Bin, Majuba Power Station, RSA – Failure of Silo 20 and Wall Load Determination.

ratio ‘K’ values which express the normal pressure or stress acting on the silo wall to the average vertical pressure or stress over a horizontal crosssectional layer of bulk material. Different ‘K’ values will apply to the cylinder and to the hopper. Also the ‘K’ values will vary in accordance with the stress field set up within the contained material, the stress fields being ‘active’ for the initial filling case and ‘passive’ for the flow case. By way of illustration, for coal, Table E1 of EN 1991-4 lists the mean internal friction angle as 31° and angle of repose 36°, whereas the flow properties of the coal shows the effective angle of internal friction reaching a steady state value of 52°. For most coals, the asymptotic value of the effective angle of internal friction is usually around 50°. Table E1 of the standard lists the mean value Km= 0.52, while equation (4.7) of EN 1991-4 gives 0.53, which compares quite well. On the other hand, AS37741996 specifies that ‘K’ should not be less than 0.35. It needs to be noted that recommendations and empiricism have in-built safety factors to ensure safe load to handle funnel-flow. For the calculation of symmetric wall loads the Eurocode yields greater wall loads than the Australian standard. The reason for this is that the Eurocode presents a more conservative ‘K’ value than the Australian code. In the case of the eccentric discharge with the coal build-up, the modified Australian code presents the greater wall loads.

The design evaluation process Challenges encountered were: • Original design calculations not available. • Establishing which standard was used. •E stablishing the coal properties adopted for the design. Assumptions made: •A merican Standard ACI 313-91 was used for the initial design rather than the modern Australian and European Standards (AS3774-1996 and BS EN 1991- 4: 2006) that did not exist at the time of the original design.

Wall Loading Calculations The loading calculations were performed both for symmetric and eccentric loading. It was found that although the eccentricity of the container is minimal it still has an influence on the overall wall loads. Wall loads were also calculated for various coal buildup conditions as observed during the silo inspections after failure of the silo. Linear as well as non-linear modelling was applied. Non-linear modelling is the only means to enable the simulation of the complex wall load conditions. This complexity arises from the nonsymmetrical wall load distribution along the wall at a reference horizontal plane as result of the varying geometry of the silo, the eccentric versus symmetric flow conditions and the presence of non-symmetrical coal build-up that further impacts the flow geometry and boundary friction conditions. The non-symmetric wall load distribution therefore also applies to the horizontal and vertical planes. This then results in complex bending moments on the wall with varying magnitude in different planes. For the purpose of simplicity, the linear modelling results are presented, as this also shows the wall load versus wall strength relationship that contributed to the failure of the silo. From the simplistic linear model applied it is evident that the wall strength in terms of steel reinforcement is adequate when evaluated by means of the original American design standard ACI 313 for the original coal quality. When the modern Australian standard is applied to the original coal quality the finding is that the wall strength is not adequate from the 25m level upwards above the internal hopper opening. From the simplistic linear model for the current coal properties it is evident that the wall strength in terms of steel reinforcement is adequate when evaluated by means of the original American design standard ACI 313. When the modern Australian standard is applied to the current coal quality the finding is that the wall strength is not adequate from the 20m level upwards above the internal hopper opening. The simplistic linear model for the current coal

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W M o in

W ev • • •

St Th 13

Fo w

properties and simulating a progressive coal build-up inside the internal hopper as observed with the visual inspection of all three silos confirms that the wall strength in terms of steel reinforcement is inadequate when evaluated by means of the Australian design standard from the 20 m level upwards.

WALL LOADING FOR THE ORIGINAL COAL TO ACI 313 -91 and AS 3774-1996 - Symmetric Flow FIG 14

External review

•P rofessor Roberts TUNRA Australia Professor Roberts applied the Australian Standard as well as a non-linear model to simulate the complex flow conditions and the loads resulted from these. The crux of the findings is that ‘the complex load conditions on basis of non-uniformity and eccentricities of the wall loads which would cause bending stresses in the circumferential direction at various levels, resulting in the vertical cracks in the silo walls that were observed. In addition, the changes in stress fields from ‘active’ to ‘passive’ due to flow convergences giving rise to ‘switch stresses’, would no doubt have contributed to the vertical, as well as horizontal cracks, thus accelerating the onset of the ultimate collapse of the silo. With the onset of these cracks, combined with some likely localised distortion of the walls and the flow-induced dynamic loads, the structural integrity of the silo would have been severely compromised. It is probable that the variation

in horizontal pressures around the girth of the cylindrical section created bending moments that resulted in stresses greater than the wall could withstand’.

• David Craig (Ph.D.) Jenike & Johanson USA Doctor Craig applied the European Standard as well as a non-linear model to simulate the

FIG14: Wall loads along the long sides of the hopper opening for symmetric flow condition and with the original coal quality

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TECHNICAL PAPER Wall loading for the current coal to aci 313-91 and as 3774-1996 – symmetric flow FIG 15

Wall loading for current coal to as 3774-1996 – switch pressure along build-up FIG 16

FIG 15: Wall loads along the long sides of the hopper opening for symmetric flow condition and with the current coal quality FIG 16: Wall loads along the short sides of the hopper opening for symmetric flow condition for a progressive build-up of coal inside the internal hopper for the current coal quality RIGHT (TABLE): Summary of findings of the calculated wall loads

complex flow conditions and the loads resulted from these. The summarised finding is ‘that for eccentric loading (solids-induced loads), plus roof loads, our FE analysis shows that steel horizontal reinforcements in the cylinder in Silo 20 are not capable of carrying tension and bending due to non-uniform pressures. Assuming concentric loading plus roof loads, our FE analysis shows that steel horizontal reinforcements in the cylinder in Silo 20 are not capable of carrying tension due to uniform pressure with patch load. Under all loading conditions, the cylinder wall of Silo 20 meets the requirement of ACI 313-97 in compression. Based on our analyses, we conclude that the cylinder wall of Silo 20 was in a compromised condition to carry

the combined solids-induced loads per BS EN 19914:2006 and roof loads’.

Cause of the failure Causes for Failure: It is not possible to pin point one single reason for the silo failure. The silo failure occurred for a number of reasons acting over a period time, such as: •T he inadequate amount of reinforcement used in the silo walls resulting from an inadequate design standard. •T he continuous eccentric discharging condition which created additional loading on the walls and also caused vertical and horizontal bending moments.

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FIG 17

FIG 17: The complex wall load distribution and the bending moments that applies on basis of the non-symmetrical distribution of the wall loads in the vertical and horizontal planes.

REFERENCES: 11. JENIKE – Majuba Coal Silo 20 – Structural Assessment – TUNRA Bulk Solid – 2015

•T he presence of coal build up over time which

Conclusion

caused a continuous upward shift of the switch pressure during its progression thus causing additional forces and moments. •T he lack of design consideration for non-fixed switch pressures to the cylinder wall design. • I t must also be noted that due to the different hopper half angles, the switch pressure around the silo is not constant, thus creating vertical bending moments.

The silo failed as a result of the following: • I nadequate design standard and varying coal properties. •T he non-symmetrical and excessive coal buildup, and •E ccentric discharge. These have resulted in the cyclic over-loading of the steel reinforcement, and the subsequent collapse of the silo.

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12. Jenike & Johanson – Load Development and Structural Consideration in Silo Design – J.W. Carson, Ph.D.; R.T. Jenkyn, Peng. - 1993 13. 100 Years of Janssen - 5th International Conference on Bulk Materials Storage, Handling and Transportation: Proceedings Conference Paper, Research - A.W. Roberts

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NEWS

3D printing key to new method of steelwork erection

ABOVE Dave Meney. LEFT With AltConnect “joints use friction created from the bending action to resist tension and other actions from wind, earthquake and equipment.”

A small Western Australian structural engineering firm is championing a ‘spigot and socket’ method of connection, relying on friction, which it says might revolutionise construction and mining in decades to come. ABHR editor Charles Macdonald spoke to Dave Meney, owner of Yenem Engineering Serices. DAVE MENEY CALLS HIS CONNECTION method AltConnect. While a long way from commercialisation, he is keen to start a debate on a method which could potentially save tens of millions of dollars in steelwork erection each year. The new connection method challenges current methods used to construct mining structures where sections and plates are bolted and welded together. Instead, AltConnect joins primary structural members like beams and columns together without bolts or welds. It uses a system of spigots and sockets and relies on friction to withstand loads and forces. “AltConnect doesn’t require the extensive scaffolding and rigging that a conventional structure would require,” said Mr Meney. “I think it will be a game changer for the construction industry and the mining industry. “It’s going to dramatically reduce the speed of erection. If you’ve got a junction between a column and a beam, you’ve got the option of using this connection. If you’ve got three beams coming into it, same deal. That’s the game changer. No bolts or welds.”

Meney started working on his connector some years ago, during a downturn for the mining sector. More recently, rapid advances in 3D printing, and its potential use in producing large spigots and sockets, has added renewed impetus. “The catalyst for getting it to this point is 3D printing,” Meney explained. “The spigot and socket idea needs to be quite accurately produced so that it fits tightly, but not too tightly, and provides the friction that is the main driving force around its success as a structural element. “3D printing might have started with plastic toys and trinkets, but the technology has advanced to printing metal components. “Current technology limits the size of steel components but additive manufacturing technologies are being continually improved and the available build space in all systems will certainly continue to grow, changing the way we make and build things.”

“AltConnect doesn’t require the extensive scaffolding and rigging that a conventional structure would require”

Tolerances the key The new system uses tubular columns, spigots – the male tapered element to the connection, and sockets.

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“ We have got to get 3D steel printing out of the prototype market and into construction.” “We need to ensure that it is cost effective to produce these connection pieces, the spigots and sockets,” said Meney. “Telescoping pipe is not new, we’ve been doing that forever, but there is out of roundness tolerances, there’s dimensional tolerances, so you can’t depend on them being nice and tight when they are pushed together. “The need for a different sort of manufacturing process is key. The catalyst to getting this out there is we are almost in a position where we can print these things in steel using laser centring or other methods. Size is a problem at the moment: if we come up with a column diameter of 350 or 400, supporting mining equipment, we will end up with large connection pieces. “But it’s amazing how quickly the 3D printing market is growing. A few years ago we spent $3,000 buying a printer of small plastic parts. We bought one a few months ago to muck around with test models and paid $500. It’s getting to the point where everyone has got one. It’s like computers in the old days. Originally only a few people had one and now we all carry one in our pocket. “What we need is the technology market to see this and say, ‘hey, this is something we can make our 3D printers bigger for.’ Right now, if we went to market to print one of these we’d struggle but I think in 6 or 12 months it’ll be a completely different story.”

Commercialisation a long way off Key to turning Yenem’s concept into reality is collaboration with the right partners. “There’s a heap of commercialisation to go,” said Meney. “I’m a little designer with an idea that will in time revolutionise the construction industry. We can’t do it on our own, we need to find interested people to help us run with this.” For Meney, desirable partners will likely include: on the one hand, a technology company active in the 3d printing space which sees scope for producing larger metal components for Altconnect; and, on the other, a large mining company “prepared to take an investment on doing something different” in building, for example, a transfer tower at an iron ore mine. “Step one is being able to produce the parts,” explained Meney. “We can produce the parts if they are small enough as steel printing is a real thing now. What is not possible is big size stuff. We have got to get 3D steel printing out of the prototype market and into construction.” Yenem Engineering services’ main activity is designing mining structures and performing audits on them. It describes itself as “the go-to company for solving structural challenges”.

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18/05/2018 3:58:10 PM

ELECTRICAL AND AUTOMATION

Master distributor for Siemens electrical and automation

LEFT: (Standing L to R) Lloyd Thomas, chairman of APS Group, Jeff Connolly, CEO and chairman of Siemens Pacific, (seated L to R) Michael Freyny, the head of digital factory and process industries at Siemens Australia and New Zealand and David Hegarty, managing director and CEO of APS Industrial.

Siemens has appointed APS Industrial as a new master distributor of industrial low voltage electrical and automation products in Australia. LEADING THE NEW ENTITY WILL BE the former MD of Rockwell Automation Australia and New Zealand, David Hegarty with Lloyd Thomas, previously CEO of NHP. Jeff Connolly, CEO of Siemens Australia, said that APS Industrial will be a ‘game changer’ in the Australian market. “APS Industrial is a major move that indicates how serious we are about longterm growth in the region. We’ve listened to customers and want to give them ‘real choice’ that delivers the best products, combined with the best customer experience. We see APS Industrial as an extension of the Siemens’ family and the credentials of the board and senior management team speak for themselves”. The new locally owned and managed independent company, has acquired Ramelec and HiTech – two well established Australian distributors. Headquartered in Melbourne, the new group will have a national presence, including technical support across the country. The company will commence with the current staff of the acquired companies, together with new hires across leadership

66 І Australian Bulk Handling Review: May/June 2018

and customer-focused positions. “The setup of a master distributor ensures we can respond to and manage customer demand quicker than ever. Customers will soon have access to the broadest portfolio in the industry for all their industrial electrical and automation requirements,” added Connolly. While Lloyd Thomas will be chairman, David Hegarty will be the APS Industrial managing director and CEO, leading the national team. Hegarty said, “APS Industrial is investing to provide an extensive range of connected products with the best local technical and stock support. “In addition to the Siemens range, APS Industrial will provide complimentary products from other high quality global technology leaders.” In addition to David Hegarty and Lloyd Thomas the APS Group Board will include Bryan Haynes, former director of finance and operations at NHP, and Brian Watson AO, former chairman of J P Morgan Australia, founding director of the Australian Future Fund and a former board member of CSIRO.

(l-r) Scott Wooldridge (Rockwell Automation) and Stephen Coop (NHP).

NHP becomes sole distributor for Rockwell in Australia and region NHP ELECTRICAL Engineering Products (NHP) has acquired Rexel Industrial Automation’s (RIA) New South Wales and South East Queensland business assets related to the distribution and supply of Rockwell Automation products in these territories. NHP has been granted sole distributor rights for Rockwell Automation products, systems and solutions in the South Pacific including Australia, New Zealand, Fiji and Papua New Guinea. The arrangement became effective at the start of May 2018. “We are proud and excited to be expanding our relationship with NHP across the South Pacific region as we work together to further enhance the efficiency of our customers,” said Scott Wooldridge, managing director Australia and New Zealand, Rockwell Automation.

LUBRICATION

Recycling plant saves money with automated dispensing A NSW recycling plant is saving hundreds of thousands of dollars per year thanks to its use of an automated lubrication dispensing system. Shaun Albiston, general manager of Systematic Lubrication Solutions spoke to ABHR editor Charles Macdonald about the installation and lubrication more generally. INTENSE HEAT. DUST. VIBRATION. HIGH PRESSURE water blasting for cleaning. Conditions are tough at Australian mining, industrial and food plants and bearing failure is an ever-present risk if lubrication isn’t handled properly. Although less common nowadays, lubrication at some sites can be rather ad hoc, with sometimes poorly trained staff wielding grease guns in an arbitrary manner. “Generally, the customer will move away from manual lubrication because they are under or over lubricating, lubricating inconsistently, missing lubrication points, risking the addition of contamination and potentially cross contaminating lubricants” explained Shaun. “Incorrect lubrication can destroy a piece of equipment. Theoretically, you are trying to achieve a slow and steady application of grease, at a desired volume over a given period of time. Which will in turn push out the ingress of dirt and lubricate the equipment correctly.” Systematic Lubrication Solutions represents Memolub of Belgium, who have been producing positive displacement pumping technology since 1987. This technology can supply lubricant at pressures up to 25 bar, allowing pump units to be placed up to eight metres from the actual lubrication point. “The system is ideal for the lubrication of equipment that is either unsafe or difficult to access,” said Shaun. “In addition to the ability to pump over long distances, Memolub’s high pressure system can not only accurately supply lubricant to one bearing, but up to eight, reducing installation costs and lubrication maintenance time.” Unlike competitor systems, Memolub applies short and sharp pressure to grease, thereby reducing avoiding grease separation. “Other units out there hold the grease under a consistent pressure for a long period of time which forms separation inside the unit prior to it dispensing,” explained Shaun. “This gives you irregular flow rates and volume, and it leads to blockages and the unit not working.” The Memolub draws a specific volume of grease each and every time, and can be adjusted to 52 settings. Shaun pointed ABHR towards its work at the NSW recycling plant as an example of the benefits of automated lubrication dispensing. The plant recycles concrete and wood – “anything that comes off a construction site and is dumped”, says Shaun –

into products like sand, aggregate and steel. The site uses 208 Memolub units, delivering lubricant to 458 points. Each Memolub is serviced every four weeks by Systematic Lubrication Solutions. “I estimate that the Memolub system provides the customer a saving of around $73,000 a year on lubrication costs alone,” explained Shaun. “In addition, the plant cannot attribute a bearing failure over the past two years directly to lubrication issues. Based on previous maintenance history this has the potential of saving over $500,000 per annum.”

DOSING

Q&A

German company touts accuracy of dosing technology Cement companies face major challenges in ensuring accurate dosing at their sites. German company Di Matteo Group, which is pushing its WeighTUBE technology into Australia, believes it can help. ABHR editor, Charles Macdonald, spoke to the company’s head of automation and research, Dr Dominik Aufderheide.

ABOVE: Dr Dominik Aufderheide, head of automation and research, Di Matteo Group.

“The WeighTUBE is not only notable for its minimal maintenance requirements and wearresistant construction, but also for its automatic onlinerecalibration during operation.”

ABHR What are some of the challenges that cement and related companies face in achieving

fulfil the following three requirements in order to guarantee a successful operation: (i) accuracy, (ii)

accurate dosing? Dominik Aufderheide (DA) The cement manufacturing process and all related transport and logistic systems are driven by strict requirements regarding the accurate proportioning of bulk materials from various sources. Analysing the complete supply chain from quarry to final product – in bags or as bulk cement – it is obvious that the applied dosing equipment needs to be able to handle a great variety of different types of bulk materials in terms of their general appearance (powdery, granular, flaky, fibrous), their followability (free-flowing, cohesive), their granularity (size of smallest and biggest 2D or 3D particles) and their general bulk material properties (e.g. density, humidity). Furthermore, it is also often the case that any inaccuracies of the dosing operation would have a direct influence on either the quality of the final product or the overall efficiency of the process in terms of energy consumption and/or utilisation of raw materials. Therefore the selection of adequate dosing equipment is also essential to maintain a sustainable operation. In this context, it is also important to mention that environmental aspects of the cement manufacturing process are gaining importance due to the development of stricter regulations regarding CO2 emissions all over the world. This has led to a situation where many dosing operations are nowadays also part of legislative frameworks (e.g. for the dosing of

stability and (iii) availability. Most classical dosing systems, such as dosing belt weigh feeders, suffer from typical disturbances such as impurities, spillage, leakages and varying bulk material characteristics. Therefore, accuracy demands are typically met only for a relative short period of time after commissioning. The long-term stability of those systems cannot be guaranteed and it is often necessary to execute manual calibration routines in order readjust the inner parameters of the system. However, such online calibrations require the system to be turned off for a maintenance period, since the calibration can only be done manually by service technicians offline. Consequently, availability of the dosing system and associated installation is reduced.

fuels) where the plants need to guarantee a certain accuracy of the dosing operation.

used today for the exact dosing of all kinds of bulk material across several industries in applications worldwide. Associated with the ODM-GravitAS control system, the WeighTUBE has become a stateof-the-art gravimetric dosing device for all kinds of bulk materials.

ABHR What are the limitations of traditional systems? DA Typically each and every dosing system should

68 І Australian Bulk Handling Review: May/June 2018

ABHR When was the ODM-WeighTUBE invented? DA Di Matteo is a family-run business that was founded in Germany in 1968 by Orlando Di Matteo. The company’s products are introduced by an acronym of his name – ODM. The first generation of the ODM-WeighTUBE was introduced into the market in 2011. It was the first comprehensive dosing system especially designed for the exact gravimetric dosing of “green fuels” such as household garbage, industrial waste, or biomass. The success of this concept, which won awards in Germany for its precision, led to the successful introduction of a second generation model which is

ABHR Briefly, how does it operate and what are its advantages? DA The main element of the operation is the exact weighing of the bulk material within the tube section of the machine. This is the basis for an adaptive control of the included screw conveyor by the GravitAS control system, in order to deliver at all times constant massflow of material according to the needs of the associated process. Changes within the bulk material, such as its bulk density, are immediately measured and the control system guarantees a high accuracy of the dosing operation. The WeighTUBE is not only notable for its minimal maintenance requirements and wearresistant construction, but also for its automatic online-recalibration during operation. An integrated intermediate material buffer is used in order to perform an online calibration routine, which measures the current dosing performance of the system with a second independent weighing circuit. The GravitAS control system is able to evaluate the current accuracy of the system and adapts itself automatically in order to maintain longterm stability without the need of any manual intervention. The system remains in operation as the online calibration routine is operating. Furthermore, the fully enclosed design

prevents excessive formation of dust and facilitates environmentally friendly working conditions when working with fuels. Due to its low overhead clearance, the WeighTUBE can easily be incorporated into existing facilities.

ABOVE: Di Matteoâ&#x20AC;&#x2122;s WeighTUBE, a dosing system designed for precise gravimetric dosing.

ABHR Does Di Matteo have an Australian presence and Australian customers? Or is this something now being advanced? DA Currently the Di Matteo Group works closely together with Silveranne Pty Ltd, located in Brisbane, to bring our products from Europe to our Australian clients. The Di Matteo Group has already expanded its activities from our German base to markets in America, Africa and Asia. We are eager to advance our activities in Australia in coming years.

Phone: 08 8118 6466 Email: sales@flowforce.com.au 10 Peekarra Street, Regency Park SA 5010 Web: www.flowforce.com.au

SPIRAL CONVEYORS

Aussie-made flight forming technology The TruHelix™ Flight Forming System was developed, designed and built in Australia, by a company with more than 50-years’ experience in the manufacture and use of sectional spiral flights, augurs and spiral conveyors. ORIGINALLY DESIGNED TO OVERCOME THE

How does it work?

numerous problems associated with production of helical sectional spiral flights, Advanced Spiral Technology’s (AST) first flight forming systems where purely built for in-house use. They are now exported around the world. Until the advent of TruHelix Flight Forming System, helical screw “pitch” dependent cast dies where primarily used in various ad-hoc presses to form/bend flights into a reasonable spiral shape. The accuracy and consistency of the helical form was largely a function of the die pitches, the experience of the press operator and the accuracy of the cut annulus from which the helix was formed. AST’s TruHelix Flight Forming System eliminates any and all of the constraints and limitations associated with the ‘Black Art’ of sectional screw flight manufacture. The company believes it has revolutionised the process, with a system that is able to consistently produce accurate sectional screw flights with the best quality in the world at efficiency rates two to four times better than any other system. It is also the only flight forming system that incorporates guarding to protect the operator, earning it CE approval and an EC certificate of conformity. The company has more than 50 systems already installed, or scheduled for installation throughout Europe, North America, South America and Asia. AST has won several prestigious export and technology awards in the past couple of years, testifying to the quality and ingenuity of the system. Many manufacturing companies that once purchased their sectional screw flight requirements from a self-professed expert flight manufacturer are now realising the savings and flow on benefits that manufacturing themselves, in-house, can provide. Plus, they proving to be a superior product, which further saves them time and money and reduces the need for stocking. They can produce exactly what they need, when they need it.

AST’s TruHelix system is fully adjustable with interchangeable TruForm™ Forming Tool Packs that can be utilised for both right-hand and lefthand forming. Each tool set is ambidextrous. And additional tooling packs can be fully retrofittable at any time. The specialised durable design virtually eliminates wear and the need for constant maintenance. Whereas, the old style ‘Black Art’ utilises restrictive pitch dependent forming dies that require numerous sets of right hand tools and the equivalent sets of left hand tools, constantly wears and requires regular maintenance. Unlike the industry standard bulky pitch dependent dies, AST’s TruForm tooling technology requires minimal storage space. Tooling set up is done in minutes by hand, virtually no maintenance is needed and minimal experience necessary to set up and run. It is technology driven, requiring no previous experience.

70 І Australian Bulk Handling Review: May/June 2018

RIGHT: Advanced Spiral Technology’s TruHelix Flight Forming System is able to consistently produce accurate sectional screw flights with the best quality in the world at efficiency rates two to four times better than any other system.

“One day in the future there will be an easier, more accurate way to make these!”

SmartQB – Condition Monitoring made easy. All the TruHelix Flight Forming SuperTyro™ press machines utilise a PLC that runs the machine setup programme. The programme calculates and controls all the forming constraints. It sets the machine’s forming parameters and pressure, specific to the flight combination, to ensure uniform indexing and identical pressing of every helix consistently. The process begins with the TruHelix Flight Blank Designer program, which accurately calculates and draws the flight blank development, regardless of the combination or complexity. The TruHelix Machine Configuration Tool (Virtual Tool Setter) incorporates a scientific calculation of the flight material’s proportional limits by utilising Yield Stress and Young’s Modulus to correctly predict the best tool set and then provide a machine/tool set up that will form the flight very accurately in the first pass. The integrated Flight Fit Adjustment feature of the programme can easily accommodate any variations in material characteristics. All standard materials are preprogrammed and new or exotic materials can be easily added at any time in the future. This is an improvement on conventional methods where you have to take an educated guess and then keep resetting, manipulating and reworking until you achieve a result that resembles something satisfactory. The safety aspect of TruHelix has not been overlooked as people are always our most precious asset. The machines are all approved to some of the strictest safety regulations in the world and fully guarded to protect the operator.

With Schaeffler’s SmartQB condition monitoring system, rotating equipment such as motors, gearboxes, pumps, compressors and vibrating screens – as well as their components such as bearings, fan blades, and pump vanes – can now be diagnosed for mechanical and electrical faults and reported via a touch panel in clear plain text. Industries that will benefit from this intuitive condition monitoring system: • Mining • Bulk Handling • Water Treatment • Steel • Cement • Paper • Sugar

Discover more: +61 2 8977 1000 info.au@schaeffler.com www.schaeffler.com.au

CONVEYORS

Hydraulic pump and lifter for efficient conveyor belt lifts Maintenance tooling specialist, Techmine has developed a new lightweight hydraulic belt lifter that utilises an Enerpac XC-Series cordless portable hydraulic pump to provide the hydraulic pressure of 700 bar or 10,000 PSI required to lift belt sections of up to 2,000kgs. “THE NEW BELT LIFTER EFFORTLESSLY RAISES

Solving a sore point for the Mining industry

the belt in 20 to 25 seconds without requiring complex input from the user,” explained Justen Wright, principal engineer, Techmine, and inventor of the new technology. “An 1800mm belt lifter, comprised of three main parts, weighs only 29.5 kilograms once assembled. The main 13.7 kilogram lifting beam is ergonomic and easily portable.” Western Australia-based Techmine says it has more than 75 years of experience working both on brownfield and greenfield projects across all mining sectors and their maintenance processes. The company was founded on the principle of bringing safe, efficient and reliable conveyor maintenance solutions to the mining industry. “The Enerpac XC-Series cordless hydraulic pumps were the logical choice solution to power our belt lifters,” said Wright. “Enerpac’s tools are high quality, reliable, easy to use, extremely versatile and adaptable for use with our products. The portable XC pump fits in perfectly alongside our lifters and when not being used for belt maintenance, the pump can be used on-site for any other of its normal tasks. They are a much smarter way to get the job done.”

The Techmine team identified a fundamental safety risk in existing conveyor maintenance practices, and used its experience to develop a solution. “We discovered that when it came to conveyor lifting, equipment that wasn’t specifically designed for that purpose was being used simply because it was the only thing available – but there could be inherent safety and performance risks,” said Wright. “Mine sites should not be lifting anything without knowing the weight first, because if the weight is above the lifting device’s capacity, this can cause all sorts of problems. Our new belt lifter clearly displays the belt’s weight as the lift progresses, meaning it cannot be overloaded. “Currently, it is too easy for mining operations to perform maintenance on thousands of metres of conveyor belts without knowing the load on their belt lifters. All it takes is one failure resulting in an injury or incident that may change a worker’s life forever as well as significant downtime and additional repair costs. “So we developed a lightweight portable system that could be easily stored at a shift crew workshop, for example. This means that the belt lifter is charged

ABOVE: The Enerpac XC-Series cordless hydraulic pump is intrinsic to the design of a new lightweight Techmine belt lifter designed to improve the efficiency of conveyor maintenance.

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CONVEYORS

and ready to lift any conveyor on the mine site safely and correctly, whether it’s for general shutdown maintenance or an unscheduled breakdown.” Enerpac WA territory manager David Capper is delighted to see the belt lifter innovation come to fruition and says that the Techmine team has been working hard for many years to reach this point. “This application has been a sore point for the mining industry for a long time, with many companies past and present working to produce a solution. The Techmine team has delivered a refined and ingenious solution, which will draw interest from mine sites across the country,” he said. Techmine has already had successes in trials with major mining companies, with others specifically seeking them out for a solution to this entrenched problem.

Enerpac XC-Series cordless hydraulic pumps 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’s cordless pumps eliminate venting and offer leak-free operation in any orientation. Plus, the overall

EFFECTIVE

507 Enerpac Techmine.indd 73

RELIABLE

body, handle and trigger have been ergonomically engineered to maximise ease-of-use and portability. The pumps deliver oil flow of 2.05 liters (125 cubic inches) per minute at its low-pressure setting and .25 litres (15 cubic inches) per minute when operating at full pressure, up to 700bar (10,000 psi). The pumps promote operator safety by removing trip hazards associated with traditional powered pumps. Safety features include overload protection circuitry, which safeguards both the pump and the operator from excessive amp draw or temperatures, and a trigger lock-off mechanism that protects against unintended operation during transport. The XC-Series cordless pump has a bladder reservoir capacity of 2 litres, weigh 11kg and comes with a shoulder strap. There are single and double acting models, which both come with two batteries and chargers. In terms of applications they can be used for lifting, pushing, pulling and cutting. They can mobilise heavy equipment, pull gears, and lift rail cars.

ABOVE: Techmine’s new lightweight hydraulic belt lifters, featuring Enerpac XC-Series cordless hydraulic pumps (shown front).

ECONOMICAL

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AD INDEX

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Special features for 2018 July/Aug

Weighing & level measurement,

Software Development and Applications,

Grain handling

Sept/Oct

Engineering services â&#x20AC;&#x201C; design & consultancy

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Special features for 2019 JAN/FEB Gears, motor & drives; Instruments; Electrical engineering Mar/Apr

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Maintenance & Service

Be a part of these features! Send news and stories to ABHR editor: Paula Wallace at email: paula.wallace@mohimedia.com Or call her to discuss on 0404 088 501

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