Bulk Handling Today April 2018

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

FEEDING WILD HORSES FROM THE BOTTOM-UP REBUILDS

T O D A Y

April 2018

S15197

A trusted industry leader For more than 90 years, Scaw, a South African industry leader, has been a preferred supplier to the lifting and rigging industry.

From wire & strand products, Haggie® Steel Wire Rope, chain products as well as fittings and attachments, Scaw continues to design and deliver the highest quality products to customer specifications.

Highly qualified teams with extensive experience in all aspects of the application of our products are on call to advise and support the selection, handling, installation and maintenance of products vital to driving safety, productivity and profit in the lifting and rigging industry.

www.scaw.co.za

More than steel.

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

BULK

T O D A Y

HANDLING

April 2018

T O D A Y

April 2018

Contents

FEEDING WILD HORSES FROM THE BOTTOM-UP REBUILDS

On the cover: Demag Cranes South Africa, Tel: (011) 898-3500 richard.roughly@demagcranes.com www.demagcranes.co.za

SAIMH 5 CMA News Cover Story

Beltcon 2017

4

6

22 A Finite Element Analysis on the Troughed Belt Turnover

Construction Machinery

Quadruples Lifting Capacity

29 A Global Service

LEEASA News The Ultimate Delivery 8 9

Reborn Equipment

32 A New Lease on Life

Companies Come Together to Save Wild Horses

Lifting

10 Feature-rich Hoists for Wide Cranes

34

Market Forum

Endorsing Bodies •

CMA (Conveyor Manufacturers Association)

•

LEEASA (Lifting Equipment Engineering Association of South Africa)

•

Multi Product Pipeline

SAIMechE (SA Institution of Mechanical Engineering)

•

Iron Ore Operation

•

SAIMH (SA Institute of Materials Handling) also mailed to members of the RFA (Road Freight Association)

Materials Handling System

13 Tailings Disposal System for Fast Track Contract

Boiler Deck

15 Aircraft Fuselage Re-homed 17 A Remarkable Achievement 18 Longevity and Low Operating Costs

Copyright

The monthly circulation is 3 673

All rights reserved. No editorial matter published in “Bulk Handling Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Our e-mail address is bulkhandling@promech.co.za Visit our website on www.bulkhandlingtoday.co.za

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Chief Editor: Lara de Matos Advertising Sales: Linda Patricio DTP: Anne Rotteglia Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas.

Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)

BULK HANDLING TODAY

April 2018

3

The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.

Company Affliates as at May 2017 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

4 BULK TODAY 2018 Tel: (011)HANDLING 867-0902  Fax:April (011) 867-0036  Email: saimh@global.co.za  www.saimh.co.za

CONVEYOR MANUFACTURERS ASSOCIATION

From The Chairman’s Desk

I

t was a proud day when the concept of the Uni-Directional Roller rig was proved last month and signaled the start of collecting data. The CMA had responded to an industry requirement for quantifying resistive forces on stationery rollers by building a test rig, which is housed at Dunlop’s premises in Boksburg.

The rig has been designed to test rollers with steel, nylon and HDPE shells, 127 and 152 diameters, using 900mm, 1200mm and 1500mm belt widths of fabric carcass, PVC and steel cord belting. The 12m long rig can be raised from the horizontal to 5, 10 and 15 degrees.

Jay Pillay

Bryan Moore is a WITS student who is operating the rig to quantify the friction factors for the practical side of his master’s degree. Terry Frangakis is the WITS supervisor for the degree.

On a different rig, built for the purpose of conducting research on stresses and deformation local to the idler junction on belt carcass, Carl van der Linde of Flexco has been conducting tests using In-line, SANS 1313 Off-set and extremely Off-set (Belt friendly) idlers. Various belt classes of multi-ply fabric reinforced belting are used.

Jay Pillay, Chairman

Membership at April 2018 All members subscribe to the CMA Code of Ethics ABB Industry Acrow Limited Actom Afripp Projects Altra Industrial Motion South Africa (Pty) Ltd Bauer Bearings International Belt Brokers Belting Supply Services BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CedoTech cc Closeal Manufacturing Collisen Engineering ContiTech South Africa (Pty) Ltd Conveyor & Engineering Equipment CPM Engineering CT Systems David Brown Gear Industries DRA Projects SA (Pty) Ltd

Dunlop Belting Products Dymot Engineering Company ELB Engineering Services Fenner Conveyor Belting (South Africa) Flexco SA (Pty) Ltd FLSmidth Roymec Habasit South Africa (Pty) Ltd Hägglunds Drives South Africa Hatch Africa (Pty) Ltd Hosch - Fördertechnik (SA) International Belting & Marketing (Pty) Ltd Iptron Technology KevConBelt (Pty) Ltd Lesa Mining Equipment and Conveyor Belt Lorbrand Martin Engineering Megaroller Melco Conveyor Equipment Moret Mining Nepean Conveyors OE Bearings Oriental Rubber Industries SA Osborn Engineered Products

Pegasus Industrial Services cc Protea Conveyors Regal Beloit South Africa Rema Tip Top South Africa Ringspann South Africa Rossi Gearmotors (Pty) Ltd Rula Bulk Materials Handling Schaeffler South Africa SENET SEW Eurodrive Shaft Engineering (Pty) Ltd SKF South Africa Tenova Takraf ThyssenKrupp Industrial Solutions South Africa (Pty) Ltd Timken South Africa (Pty) Ltd Transvaal Rubber Company Voith Turbo Weba South Africa (Pty) Ltd WorleyParsons RSA Zest Electric Motors

BULK HANDLING TODAY

April 2018

5

QUADRUPLES LIFTING CAPACITY Demag, one of the oldest crane manufacturers in the world established almost 200 years ago, has developed a new Double V-Girder crane which is capable of a 50T lifting capacity – four times that of the Single Girder.

T

he double-girder overhead travelling cranes offer exceptional load capacity for a low deadweight.

Their outstanding crane geometry also provides for extremely good travel characteristics, which minimises wear on the end carriages and crane runway.

The load hook can be raised between the two crane girders, which allows for large lifting heights to be achieved.

The crane offers high long and cross-travel speeds thanks to thehigh-performance double-girder design. The girders can be adapted to building structure requirements and has minimum approach dimensions thanks to the compact travelling hoist design.

Reduces oscillation frequency by 30%, cuts its weight by an average of 17% and doubles its service life to as many as 500 000 changes of load Significantly improved efficiency

“Since the launch of the V-girder in 2016, 60% of all our single girder cranes produced locally are now V-girders”, says Richard Roughly, Senior Manager: Sales & Marketing at Demag South Africa. “They have revolutionised load handling”.

Their innovative design featuring tapered diaphragm joints reduces oscillation frequency by 30%, cuts its weight by an average of 17% and doubles its service life to as many as 500 000 changes of load.

The V-girder has significantly improved efficiency for handling loads and higher handling rates than conventional box-section girders.

Safety

The revolutionary design enables sensitive loads to be positioned more precisely, carefully and also speeds up the process. It allows for particularly precise and careful

6

BULK HANDLING TODAY

April 2018

COVER STORY

positioning of sensitive and heavy loads.

It improves efficiency and simplifies installation thanks to more lifting points. From a safety point of view, the V-girder’s surface area exposed to wind is reduced by up to 55%. It also offers a much improved view for the operator.

“Our eco-friendly utilisation of resources is reflected by the use of less material, reduced drive output requirements, blast cleaning of metal parts with dry ice and the use

of water-based paints,” Richard concludes. “The possibility of energy recovery completes the concept.

“These are just a few of the revolutionary features the V-girder crane offers”.

Demag Cranes South Africa, Tel: (011) 898-3500, Email: richard.roughly@demagcranes.com www.demagcranes.co.za

It allows for particularly precise and careful positioning of sensitive and heavy loads

BULK HANDLING TODAY

April 2018

7

ENDORSER OF “BULK HANDLING TODAY”

LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA

• A recognised ECSA Voluntary Association (VA) •

LEEASA is a fully-fledged association devoted to the lifting industry across Southern Africa. Members hale from the crane, forklift, mobile elevated work platform, aerial and suspended access platform, chain hoists, rigging and lifting tackle arenas, etc. Primarily devoted to the LMI’s (Lifting Machinery Inspectors), and LME’s (Lifting Machinery Entities), the association considers safety paramount. As such it serves in an advisory capacity to the SABS, the Department of Labour, various training bodies and the industry at large. LEEASA is recognised by ECSA as a voluntary association.

What’s in it for you:

As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year).

and other training courses accredited by the association attract ECSA CPD points.

ECSA registered LEEASA members are awarded one Continuing Professional Development (CPD) credit each year. CPD is an ECSA requirement to retain registration.

Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry.

Members obtain a discount on LEEASA seminars. Both these

LEEASA has some 650 members (Individuals and Companies).

• • •

LEEASA Occupational Health & Safety Act and Regulations LEEASA Mine Health & Safety Act and Regulations LEEASA Lifting Equipment Inspection & Legal Compliance Register

Available for purchase online at www.leeasa.co.za

81

LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SOUTH AFRICA Head Office: 8 Boris Road, Bordeaux, Randburg, Johannesburg Tel: 074 900 8378 • www.leeasa.co.za Secretary: Arni Sommer • email: arni@leeasa.co.za

BULK HANDLING TODAY

February April 2018 2012

THE ULTIMATE DELIVERY

Companies come together to save wild horses The plight of wild horses in drought-stricken Namibia has resulted in three Industrial Services Holdings (InServe) companies stepping up to the plate to assist in delivering 112 teff bales for the Namibia Wild Horses Foundation.

A

ccording to the foundation, the wild horses have been in the region for over 100 years. However, due to the severe drought affecting the area for the last five years, the population has drastically declined from 120 in September 2015, to about 75 at present.

Sightings of these human-shy animals are rare. But such was their hunger, they immediately approached the teff bales that were loaded from the trucks onto bakkies, and began feeding straightaway InServe companies Concord AngloV3, Concord Namibia, and Afrit combined their resources to deliver 112 bales of teff, each 1.2m long, which had been donated by a generous individual donor from South Africa.

Team effort Concord Namibia CEO, Francois Smith explains that the company had deployed its mobile cranes at the Neckartal Dam site, about 40km west of Keetmanshoop, when he was alerted to the plight of the starving wild horses. The company coordinated all the logistics in terms of obtaining the teff from the South African donor, and its ultimate delivery to Namibia.

Anglo-V3 Crane Hire provided trucks from Rusten-

Francois Smith, CEO, Concord Namibia

burg to collect the teff from its location in Brits, about 73km away. Afrit, in turn, supplied waterproof tarpaulins and netting to cover the teff to ensure it remained dry during transit.

“Initially the plan was to just drop the teff off in Keetmanshoop, and let the foundation transfer it 200km to Aus, where the horses are found. However, we decided to transport all the bales directly to the feeding ground in Aus,” Francois explains.

Two super-link trailer trucks, with 6m and 12m long trailers, were used.

Sightings of these human-shy animals are rare. But such was their hunger, they immediately approached the teff bales that were loaded from the trucks onto bakkies, and began feeding straightaway – in the presence of their human helpers.

Namibia Wild Horses Foundation Ambassador, Jan Van Blerk, expressed his deep gratitude to the InServe companies who had banded together. “As InServe companies, we are proud to have been able to assist with this critical conservation project.

We make an urgent appeal to other companies to assist the Namibia Wild Horses Foundation in any manner that they can, especially as the drought in the Aus region is ongoing,” Francois concludes. www.wild-horses-namibia.com

BULK HANDLING TODAY

April 2018

9

LIFTING

Feature-rich hoists for wide cranes Crane and oist manufacturer, Condra supplied feature-rich lifting equipment for ongoing expansion at Aberdare Cables’ Port Elizabeth facility.

T

he modernisation and expansion programme called for two 23-metre-span overhead travelling factory cranes, with capacities of 30 tons and 15 tons, and one 20-ton all weather portal crane with a span of 26 metres.

An order worth R5.5 million was placed early in December for all three machines to be designed, manufactured and delivered by end February.

European crane manufacturers are only now beginning to introduce V-belt drives, whereas Condra has offered the reliability and lower maintenance costs afforded by this type of drive for more than five years.

Robust usage

The cranes, which will be used to handle newly filled power cable drums, are both robust and feature-rich, sporting handheld remote controls for operation from factory floor, control cabins for alternative operation from elevated vantage points (open cabins on the factory cranes; closed on the portal machine), variable frequency V belt drives on the hoists, and load cells to protect design limits and warn operators via LED lights when these limits are being approached.

The portal crane also features Condra’s patented storm brake.

Three companies competed for the order.

Though prices were similar, lower overall operating costs achieved through rapid spare parts delivery and an effective and efficient maintenance service tipped the scales in Condra’s favour.

The company holds substantial stocks of locally manufactured spares, routinely

10

BULK HANDLING TODAY

April 2018

delivering these parts to any point in South Africa within 24 hours. By contrast, European companies with local representation need several weeks to ship spare parts to South Africa.

First-hand experience

Aberdare Cables has experience of Condra’s service through Load Mass Crane Services, the Port Elizabeth-based company behind the operation of an initial Condra crane installed some years ago, and the company which also installed, commissioned and maintains the three new machines.

Two of these cranes will lift completed cable drums coming off the production lines into a covered storage area. Outside, a portal crane will manage the open air storage facility.

The remaining two machines, a 15ton crane of identical span and similar configuration, and a 20-ton double-girder portal crane with a wider span of 26 metres, are at an advanced stage of manufacture.

In terms of incorporated technology, there are variable frequency drives on all hoists, adapted and set to allow lifting speeds that can be altered at will from very slow to very fast, maximising productivity by minimising handling time.

European crane manufacturers are only now beginning to introduce V-belt drives such as those incorporated in the Aberdare Cables hoists, whereas Condra has offered the reliability and lower maintenance costs afforded by this type of drive for more than five years.

The company is tipped to secure further orders resulting from the Aberdare Cables expansion programme, when open ground is converted into additional factory space.

Condra Tel: (011) 776-6000 Email: sales@condra.co.za

LIFTING

Collage of Aberdare Cables’ double girder crane, with insert of cabin under manufacture for a portal crane for the same company

BULK HANDLING TODAY

April 2018

11

C16092

THE GLOBAL STANDARD IN CRANES AND HOISTS DESIGN • MANUFACTURE • SERVICE • SALES As a global manufacturer and provider of cranes in varying industries, Condra provides high quality engineering, flexible inhouse design and an impressive range of products to mining, shipping, steel, fabrication, robotics, railways and ports.

Since 1966, Condra has mastered the engineering, manufacturing and installation of cranes all over the world to large, medium and small industries. We are constantly innovating to provide manual, electric and combo cranes that provide solution to lifting, hooks, grabbing, magnets, ladles, buckets or stacking duties.

Overhead travelling cranes Wire rope hoists Portal or semi-portal cranes and bridge cranes Cantilever cranes (pillar, jib and wall)

Tel: +27 11 776 6000 | 0861 CONDRA (266372) | 24hr Mobile: +27 82 491 7525 | Email: sales@condra.co.za

www.condra.co.za South Africa | Africa | Middle East | Europe | Russia | Australia | South America | North America

MATERIALS HANDLING SYSTEM

Tailings Disposal System for Fast Track Contract Demcotech Engineering designed and supervised the construction and commissioning of a materials handling system for the disposal of dry tailings at Liqhobong Diamond Mine in Lesotho in less than a year.

T

he contract was awarded to Demcotech by Turnkey Civil Lesotho, on behalf of diamondproducer, Firestone Diamonds. The brief called for a system to dispose of between three and four million tons per year of dry tailings, which also had to be capable of withstanding the extreme weather and rugged mountainous conditions in Lesotho. At the same time, it had to be completely re-routable or extendable.

Advanced features were designed into the operation, including a belt storage system, enabling the entire arrangement to be extended by 60m within a 24-hour time period.

conveyor inclusive of the belt storage system, and a slewable 15m mobile stacker that is 4-wheel driven. This allows the machine to be self-propelled.

The 450m-long extendable storage system’s ability to extend the conveyor by 60m increments reduces the number of belt splices, thereby reducing the standing time when the head station, also mounted on a pontoon, is pulled for repositioning using mobile equipment, such as a front end loader.

The head of the conveyor feeds onto a mobile, self-propelling slewable stacker, mounted on rubber tyres and equipped with hydraulic drives, which can be repositioned by remote control.

Proven track record The first route comprised of a downhill conveyor, transfer house and mobile slewable stacker, which became operational in November 2016 - just eight months after the contract was awarded. The second, main route was operational by February 2017. These tight contract deadlines were met despite the challenges posed by access to, and working in, the high altitude location of Liqhobong (2 600 m above sea level), which required special engineering solutions.

Demcotech has a well-established track record in Southern Africa, working in similarly challenging, high altitude environments such as Letšeng Diamond Mine, also in Lesotho. First contracted in 2008 for the taillings disposal system at the mine, the company has continued to service the mine’s expansion initiatives, with its most recent work focused on upgrading part of the mine tailings materials handling capability.

Advanced features were designed into the operation, including a belt storage system, enabling the entire arrangement to be extended by 60m within a 24-hour time period. The tailings disposal system consists of a fixed downhill conveyor rated at 700tph, which is equipped with a regenerative electric-hydraulic braking system to prevent the conveyor from running away.

While it is a South African based operation, the company has also seen considerable success internationally. It was recently awarded the contract for a sulphur handling system in Malaysia, following the successful completion of other offshore work, which included the detailed design for an import terminal at Port of Ploce in Croatia, handling both iron ore and coal, through to the contract for the multimillion-dollar iron-ore import/export facility in Lumut, Malaysia.

In addition, a 20m mobile slewable emergency boom is part of the standby route, while other components of the system include a 120m-long retractable conveyor, a 450m-long extendable

DemcoTech Tel: (011) 608-4355 Email: info@demcoTECH.com www.demoTECH.com

Advanced features

The fixed downhill conveyor is equipped with a low speed regenerative electric-hydraulic braking system to prevent the conveyor from running away.

BULK HANDLING TODAY

April 2018

13

BOILER DECK

Aircraft Fuselage Re-homed With the help of a 2-axle Scheuerle UltralightCombi, the last chapter in the history of the Boeing 737 ‘Landshut’ has been written. Hijacked by terrorists in 1977, the Lufthansa plane has gone down in history as part of the infamous ‘Deutscher Herbst‘ (German Autumn).

W

hile attempting to free the imprisoned first generation of the Red Army Faction (RAF) from prison, the kidnappers first forced the aircraft to an intermediate landing in Rome and then directed the plane to head for Dubai via Cyprus and finally to Mogadishu. There, on 18 October 1977, a few minutes after midnight, the German special unit GSG 9 overwhelmed the hostage-takers.

Years later, this famous Lufthansa airplane could be found rotting at an aircraft cemetery in Fortaleza, Brazil. An untenable condition for the Dornier Museum which arranged the return of the plane to Germany for it to be restored and subsequently put on permanent display.

Firstly, the fuselage was transported out of Fortaleza on board an Antonov AN 124 while the wings followed in an Iljushin 76. In order to safely move the valuable cargo from Lake Constance Airport to the Dornier Museum, Logistics Plus brought in Spedition Kübler from Michelfeld/Erlin. Their long years of experience in aircraft transport along with

the proven Scheuerle UltralightCombi ensured a problem-free assignment.

"With the new Scheuerle boiler deck, we were able to drive to Friedrichshafen without requiring an empty-run approval and, once there, were able to extend the vehicle to the required length through the addition of beams," explains Heinz Rössler, Spedition Kübler MD. The UltralightCombi is available as a reliable combination vehicle complete with a 12-tonne axle load, 2.55m width, 650mm axle compensation and 60° steering angle throughout Europe and, in addition, can be coupled with the InterCombi and EuroCombi models as well as their accessories.

It is often purchased as a weight-optimised vehicle for expanding existing fleets. With a 250mm total height, high loads can also be moved without difficulty on the flat bed deck. Furthermore, with a 12-tonne axle load at 80km/h and a 2.55m width, the UltralightCombi complies with current EU guidelines and registration is problem-free.

Tii-Group, www.tii-group.com

BULK HANDLING TODAY

April 2018

15

Piecing together your success.

12415/E

We understand that you’ve been building your career piece by piece, and that all those hours, projects and plans allow you to live the lifestyle you deserve.

Partner with PPS, and let us help you ensure your success is more than the sum of its parts.

Proud sponsor of the SAICE Young Engineer of the Year.

Visit pps.co.za to find out more about our financial solutions for graduate professionals.

PPS is an authorised Financial Services Provider.

MULTI PRODUCT PIPELINE

A Remarkable Achievement A 24 inch multiproduct pipeline is now in multiproduct mode and currently holds ULP 93, ULP 95, Diesel 50 and Diesel 500. The terminal at Jameson Park, Heidelberg, is ready to go onstream.

T

ransnet Multi Product Pipeline (NMPP) is one of South Africa’s most ambitious engineering and construction projects to date, and is one of the biggest and most complex multi-product pipelines in Africa.

The pipeline runs underground over 555km from its start point in the south of Durban to the Jameson Park Inland Terminal in Heidelberg. The project also includes 160km of 16inch diameter steel inland pipelines, three inland pumping stations and two accumulator terminals (with over 3 000 000 litres of storage capacity). Just one tank at the terminal in Jameson Park can hold 20 million litres.

The logistics were challenging as the pipeline runs through towns and cities, under highways and open countryside. The construction involved 49 main river crossings, 95 kms of major wetland crossings and 169 trenchless crossings.

It also involved new drilling technology, Horizontal Drilling Technology, the longest HDD drill used in South Africa. A distance of approximately 1,5km was drilled under one of Gauteng’s busy highways, Uncle Charlie’s at a depth of approximately 18m.

The achievement

The NMPP is managed jointly by Transnet Capital Projects and Transnet Pipelines.

Top facts: • The MPP can transport 1 million litres of fuel per hour and with future investments this can increase to 3 million litres per hour.

• It has sophisticated security monitoring and security access control systems.

• The Coastal Terminal at Island View in Durban and the Inland Terminal at Heidelberg have a combined capacity of over 3 000 000 litres and give the pipeline full multi product pipeline handling capability and the ability to operate at optimal flow-rates.

• The MPP ransports four different types of fuel simultaneously. The high pressure within the MPP ensures the products do not mix except at the point where they touch, this intermixture is then refined.

• The NMPP will enable the economic growth of South Africa while reducing road congestion and lowering carbon emissions associated with transporting petroleum products. Without the MPP, there would be 1 000 additional road tankers on the roads every single day.

About Transnet Pipelines

Since 1965 Transnet Pipelines has owned, operated and maintained a 3 800km network of high pressure underground pipelines which transport crude oil, diesel, petrol, jet fuel and methane gas.

Clients include all the major multinationals and a number of South African independent petroleum distributors for the pipeline transportation of crude and refined products (Shell, BP, Chevron, Engen, Total SA, Sasol, PetroSA, AfricOil, Vuyo Petroleum).

The pipelines currently supply 71% of all refined products required for the inland market and 100% of the jet fuel for OR Tambo as well as all the crude for the Natref refinery in Sasolburg.

Transnet Pipelines, www.transnetpipelines.net

12415/E

IRON ORE OPERATION

Longevity and low operating costs Jan Schoepflin, general manager sales and service at Kwatani.

“Being cost competitive is not just about the capital purchase price, it is actually about the owning and operating costs of equipment,” says Jan Schoepflin, General Manager: Sales and Service at Kwatani.

T

he company has gained a reputation as a vibrating equipment solutions provider and not just an equipment supplier. Jan explains that the company’s technical team offers a depth of expertise and experience that is largely unmatched in the mining sector.

The vibrating equipment replacement programme saw 100 Kwatani screens installed across the plant in recent years.

“Our modus operandi is to spend time with the customer so that we understand specific plant conditions and application requirements. This investment is essential, as it also allows for the flexibility needed to provide a vibrating screening solution that takes both the capital outlay, as well as the operating cost into account,” he explains.

This is one of the primary reasons why an iron ore operation in the Northern Cape placed an additional order on the company for 24 of its vibrating screens.

18

BULK HANDLING TODAY

April 2018

Kwatani has a strong relationship with this customer, built on the back of the successful operation of its vibrating screens on the plant for decades. The vibrating equipment replacement programme saw 100 Kwatani screens installed across the plant in recent years.

The order for the 24 new vibrating screens will complete the plant upgrade. The first two orders were for a combination of double and single deck machines, while the latter was entirely for single deck screens. All screens are 2,4 metres wide with a length of 4,8 metres.

Existing sub-frames

Retrofitting vibrating screens does require a dynamic approach. Jan says that in this instance, the company engineered a solution whereby the bottom sections of the previous existing screens were used as counter balance frames.

This will reduce the dynamic loads into the existing structure where these replacement screens will be installed. In addition, costs were saved as

Majority of the vibrating screens operate in very wet conditions with high humidity, which makes a mechanical driven system such as a gearbox the preferred option.

A Kwatani scalper screen being installed for an iron ore application

there was no need to manufacture new counter balance frames.

“The existing sub frames were closely inspected for structural integrity to ensure that they would be able to handle the load, which is all part of our overall approach when working closely with customers on retrofit projects such as this,” he adds.

All the vibrating screens being supplied are exciter driven, and a significant aspect of this turnkey project was that the customer specifically requested Kwatani gearboxes.

Very wet conditions

Derrick Alston, director at Kwatani, says that the majority of the vibrating screens operate in very wet conditions with high humidity, which makes a mechanical driven system such as a gearbox the preferred option.

The locally-manufactured gearboxes are known for their robust construction and reliable performance, even under the harshest operating conditions. These components are produced at Kwatani’s facility in Spartan under stringent quality control conditions. The company is ISO 9001 accredited.

Kwatani (Pty) Ltd, Tel: (011) 923-9000 www.kwatani.co.za

A scalper screen being installed for an iron ore application.

BULK HANDLING TODAY

April 2018

19

TRACE Inte is a globa anti-br or leading pr party risk

TRACE due diligence solutions are based on internationally accepted best practices and our experience and familiarity with the compliance needs of multinational companies. Services range from a denied parties screening to enhanced due diligence, including TRACE Certified Due Diligence.

20

BULK HANDLING TODAY

April 2018

International, Inc. globally recognized ti-bribery business organization and g provider of third risk management solutions.

BULK HANDLING TODAY

April 2018

21

BELTCON 19

A Finite Element Analysis on the Troughed Belt Turnover A belt turnover is an effective way to reduce material carry-back on the return side. It has the ability to reduce environmental contamination and maintenance work, and improves return idler roll life. Flat turnover has been the dominant belt turnover method to date. For extra wide and high strength belts, the concern is that the flat turnover requires long length, large space, and causes high sag and stress in the belt.

Yijun Zhang

A

troughed belt turnover, pioneered by the Mordstein turnover, is introduced to address these concerns, where the belt is folded into a troughed or semicircular shape by guide rollers along the turnover.

However, there isn’t a clear and effective design method on the troughed turnover due to its complexity. There is a wide range of mechanical designs to induce the troughed belt turnover without a clear understanding of their effectiveness. This study uses the finite element method to analyse a troughed belt turnover. The purpose is to establish an analysis tool and propose an optimised troughed turnover design.

A troughed belt conveyor is an ubiquitous bulk materials handling system. It is very efficient and reliable in transporting millions of tonnes of bulk material, year after year. A typical arrangement has the material riding on a carry belt located at the top level of the conveyor structure. After the material has been discharged, a return belt travels in the reverse direction at the lower level of the conveyor structure, beneath the carry belt.

This arrangement simplifies the mechanical arrangement for material loading and unloading. But the work side, or the dirty side of the carry belt, faces down during the return and

is in constant contact with return rolls. Residual material sticking to the dirty side of the belt easily comes off and is deposited on the ground or conveyor structure. This is called material carry-back.

Modern, advanced belt cleaning systems can do a very good job of cleaning the belt surface and minimising material carry-back. However, because a huge amount of material is being transported, even a tiny percentage of material carryback poses a serious problem over time. For example, if a conveyor transports 10 million tonnes of material in a year, a 0.001% material carry-back, a tiny percentage, amounts to 100 tonnes in a year.

Cleaning the 100 tonnes from and underneath the conveyor is a difficult and expensive job. Without diligent cleaning, the material keeps piling up on the conveyor structure, reducing structural safety, and contaminates the bearings of rotating parts. The material also permeates into the environment, creates dust and affects human health.

The problem of dirty side facing down on the return belt, can be solved by adding a belt turnover. Typical belt turnover system uses pulleys or large rolls to guide the belt to rotate 180 degrees, so that the dirty side is now facing upward

Figure 1. Mordstein turnover schematic Belt Width

2000 mm

Steel Cord Pitch

19.5 mm

Belt Strength

ST-5200

Cover Thickness

10×8

Cord Diameter

11 mm

Belt Weight

109 kg/m

Steel Cord Break Tension

104kN

Number of Steel Cords

100

Steel Cord Ultimate Stress

1094 MPa

Belt Modulus

372537 kN/m

Flat Turnover Length

48 m (24 × Belt Width)

Belt Tension at Turnover

Belt Safety Factor 25 (416 kN)

Troughed Turnover Length

36 m (18 × Belt Width)

Table 1. Parameters of the belt and turnover in this study

22

BULK HANDLING TODAY

April 2018

BELTCON 19

Figure 2. Flat turnover model showing the tensile stress in steel cords

after the turnover. The conveyor belt can be arranged in a way that the return belt sits on the top and the carry belt sits on the bottom. As a result, the material carry-back deposits onto the carry belt. But it involves a complicated mechanical arrangement for material loading and unloading, which makes this solution uncompetitive.

Flat turnover – A brief review

In the flat turnover, the belt maintains more or less a straight line width-wise, while making a helical turn of 180° lengthwise. A flat turnover typically uses three or five sets of long rolls as guide rolls to maintain the straight belt cross-section.

There is one set of rolls or snub pulleys at the entrance of the belt turnover and one set at the exit. In the three-set arrangement, there is a vertical roll set in the middle of the turnover. For the five-set arrangement, there is one additional support roll at 45° or quarter-length position, and one at 135° or three-quarter-length position.

A flat turnover has been studied in detail. Both numerical and analytical tools have been developed to calculate: 1. Stress and belt safety factors across the belt width, along the length of the turnover 2. Belt sag along the length of turnover.

the allowable belt safety factor. The low centre stress can even go into compressive condition and cause the belt to buckle.

This may affect the service life of steel cords as they can only accommodate very limited amounts of compressive stress.

Excessive belt sag is undesirable because the belt edge may scrape over the ground or the structure and be damaged. The maximum belt sag always occurs at the middle point of the belt turnover. Belt sag increases with lower belt tension and vice versa. A guide roll can be placed below the belt to limit any excessive sag during a momentary, dynamic low tension condition. But it is a design goal to ensure that there is no excessive belt sag during steady state running.

For a belt width less than 2 000 mm and belt rating less than St5000 N/mm, flat turnover usually is considered by the system designer. But for wider and higher strength belts, there is a concern that including the turnover would incur significant risk for the belt. Probably due to this reason, many high tonnage and high tension conveyor systems don’t include turnovers, even though the material carry-back from the high tonnage is more significant than low tonnage conveyors.

These calculations are done with predefined belt rating, mass, tension and turnover length. The belt rating governs the belt modulus. Calculation tools that analyse flat belt turnovers are now part of competent conveyor design software. The designer can calculate the proper turnover length and arrangement.

Another drawback of the flat turnover is the space requirement. At the centre of the turnover, the belt is vertically flat.

Additional space is needed for the vertical turnover rolls and clearance. In underground mining, space is expensive to create. If an underground conveyor uses a wide belt, there just isn’t enough space to accommodate the flat turnover of a wide belt.

In flat turnovers, the stress in belt edge is always higher than the stress in the centre. This is because the belt edge travels a longer path than the centre, which causes higher strain in the edge. The high edge stress needs to be checked against

On the other hand, cleaning material carry-back is also more important but also more difficult for underground conveyors.

As a result, if underground conveyors are to use belt turnover, a design with a smaller profile is imperative.

BULK HANDLING TODAY

April 2018

23

BELTCON 19

Figure 3. Tensile stress in flat turnover at the centre of the flat turnover

Roughed belt turnover

Troughed belt turnover means the belt is not straight widthwise, but being formed into a troughed or semi-circular shape by guide rollers during the turnover. The belt still makes the 180° helical turn length-wise.

The perceived benefits of the troughed turnover, compared to the conventional flat turnover, include: 1. Reduced turnover length 2. Less stress in the belt edge and less possibility of belt buckling in the centre 3. Less space requirement, suitable for underground application.

Walter Mordstein pioneered the concept of troughed belt turnover in 1960s. Figure 1Error! Reference source not found. shows the schematic of the Mordstein turnover in the related US patent. The Mordstein turnover uses a series of sphereshaped guide rolls that are positioned around a centre axis to guide and support the belt. The axial position, the angle and the arm length of each guide roller can be adjusted. The intention is to give maximal flexibility so that the Mordstein turnover can accommodate a wide variety of belts and tension conditions.

In reality, conveyor operators are often confounded by the vast degree of freedom of the adjustment. It is difficult to find an optimal roll arrangement, especially if the belt tension has large fluctuations during operation.

It was noticed there had been a wide range of design approaches to the troughed turnover. Different practitioners have different philosophies on the guide roll design, arrangement and turnover length. Analyses, design tools and literature are very rare.

24

BULK HANDLING TODAY

April 2018

Troughed belt turnover analysis In this study, an optimised troughed turnover is proposed.

The turnover design is based on a steel cord belt with the parameters shown in Table 1. It was felt that this was a typical scenario where system designers start to have concerns about implementing a flat belt turnover system.

Finite element analysis (FEA) in Ansys software is done on a flat turnover and a troughed turnover, with the same belt specification and belt tension. The turnover length is different in two models. The finite element model of the belt includes individual steel cords and cover rubber instead of using homogeneous shell elements for the whole belt. This approach increases the model size and calculation time but improves accuracy. Belt sag, stress in steel cords and the overall belt shape are compared between the flat turnover and the troughed turnover.

The flat turnover is mainly used as the benchmark to evaluate against the troughed turnover. Figure 2 shows the flat turnover and the tensile stress in the steel cords. The turnover length is 24 Ă— (belt width) or 48 m. Figure 3 shows the centre of the flat turnover. The cover rubber is not shown in the two figures. The tensile stress is higher along the belt bottom edge than the belt top edge, due to the belt sag by gravity. The maximal stress is around 190 MPa, or 5.64 belt safety factor.

Multiple troughed turnover arrangements were attempted during the study, and the arrangement presented in this paper has the best results. Figure 4 and Figure 5 show the troughed turnover model and tensile stress in steel cords.

The turnover length is 18 Ă— (belt width) or 36 m, shorter than the comparable flat turnover. This turnover design has the following advantages:

BELTCON 19

Figure 4. Troughed turnover model showing the tensile stress in steel cords

1. Uses trough rolls as guide rolls, instead of finger rolls or spherical rolls, to minimise cover wear 2. Minimal adjustment is needed after installation; turnover arrangement is analysed and optimised during the design phase 3. Belt is in trough shape at one end of the turnover and in flat shape at the other end, reducing the turnover length

and simplifying pulley arrangement 4. Turnover profile and length are reduced compared to flat turnover 5. Stress in belt is improved compared to the flat turnover.

Consideration of guide rolls There are many types and arrangements of guide rolls for

Figure 5. Troughed turnover model showing the tensile stress in steel cords, viewed from a different direction

BULK HANDLING TODAY

April 2018

25

BELTCON 19

Figure 6. Vertical displacement of the troughed turnover, viewed from the belt centre line

troughed turnovers. The purpose of guide rolls is to support the belt turnover and limit uncontrolled belt displacement.

The Mordstein turnover uses spherical rolls as guide rolls.

Finger rolls with spherical heads are also used. The spherical roll rotates around a single axis; every point on the roll surface rotates around the axis at the same angular velocity.

Because the radius from the surface to the axis varies, the line velocity at the surface is not constant.

As a result, when the spherical guide rolls contact the belt surface, there is sliding contact because the belt moves only at a single line velocity. The sliding contact between steel and rubber causes excessive wear in the cover rubber, and should be minimised.

In the proposed troughed turnover design, ordinary cylindrical rolls are used as guide rolls. The line velocity on the cylindrical surface is constant, so rolling contact with the belt is maximised and sliding contact is minimised. Cylindrical idler rolls are also less expensive and more readily available. The cylindrical guide rolls support the belt from the pulley cover or bottom cover of the belt.

Only two finger rolls with spherical heads are used, and the spherical heads are normally not in contact with the belt.

One finger roll is placed after a snub pulley to support the belt and reduce belt sag. A second finger roll is a hold-down roll positioned above the belt to prevent belt lift.

Consideration of adjustments

Flat turnover is popular because it is simple, straightforward and requires no adjustment. One problem of the troughed turnover has been that there is too big a degree of freedom for guide roll adjustment. The proposed turnover design needs minimal adjustment. Only the finger roll after the snub pulley

26

BULK HANDLING TODAY

April 2018

may need small adjustments to prevent the spherical head from being in constant contact with the belt.

The optimal guide roll location and shape are analysed in the design phase using FEA to achieve an optimal arrangement.

This approach simplifies the maintenance and ease of use of the troughed turnover.

Belt shape at the ends of the turnover

In the proposed design, the belt is in troughed shape at one end of the turnover and in flat shape at the other end. This approach reduces the turnover length and snub pulleys. If the turnover is located at the discharging or head end of the conveyor, the belt enters the turnover in flat shape, after leaving the bend or drive pulleys.

The belt curls into a semi-circular shape before the mid-point of the turnover, lands onto trough roll sets, and then moves onto to regular return V or trough rolls. No additional belt transition is necessary after the turnover.

If the turnover is located at the loading or tail end of the conveyor, the belt enters the turnover in troughed shape, after leaving the return trough or V rolls. At the exit of the turnover, the belt goes over a snub pulley that enforces the flat belt shape, and then goes into tail pulleys.

Small turnover profile and shorter length

The vertical turnover profile is significantly reduced compared to the flat turnover. The 2 m wide belt in a flat turnover stands at 2 m vertically at the centre of turnover. Figure 6 shows the vertical displacement of the troughed turnover of the same 2 m- wide belt. Here the vertical profile is only 1 130 mm (258 mm+872 mm), almost half the space compared to the flat turnover. It is reasonable to expect that for belts with different specifications, troughed belt turnover can achieve

BELTCON 19

Figure 7. Tensile stress in steel cords in troughed turnover, after the snub pulley region

a vertical profile around half of the belt width, excluding the clearance for guide rolls and structures.

Another advantage of the troughed turnover in reducing the vertical profile is that the belt centre line can be lowered during the turnover, so that the top edge of the belt sits at a lower position. This further reduces space requirements and helps the turnover arrangement in underground applications.

Lowering the belt centre line is more difficult to do in the flat turnover, because the lower belt edge will have much higher increases in stress.

The troughed turnover is shorter in length. In the current analysis, the turnover is 18 Ă— Belt Width, compared to the flat turnover of the same belt over a distance of 24 Ă— Belt Width.

The reduction in turnover length is 25%. Shorter turnover length is always welcomed by conveyor system designers, helping to achieve a more economic design.

Stress in the belt

During the troughed turnover, the travel length of the belt edge is reduced, thus reducing the belt edge stress. The travel length of the centre increases, thus reducing the compressive stress in the belt centre. Comparing Figure 3 with Figure 7, the maximum belt edge stress in the troughed turnover is 16.7% lower than that in the flat turnover, even with the troughed turnover being 25% shorter than the flat turnover.

it was found that the troughed turnover can have lower belt edge stress and higher belt centre stress, while the troughed turnover is 25% shorter. The troughed turnover needs smaller vertical space as well. The belt in troughed turnover is 56% in height compared to the flat turnover.

This troughed turnover is accomplished by using multiple trough roll sets as guide rolls, with minimal finger rolls, so that belt cover wear is minimised. The guide rolls require almost no adjustment during operation. The belt is in troughed shape at one end of the turnover and in flat shape at the other end. This simplifies idler and pulley arrangements. This numerical tool based on finite element analysis can also be used to analyse and improve other troughed turnover designs.

This paper was first presented at the Beltcon Conference in 2017.

Copyright is vested with IMHC. www.beltcon.org.za Dr Yijun Zhang Conveyor Dynamics, Inc. Email: zhang@conveyor-dynamics.com

The stress in the belt centre, which tends to go compressive, is higher in the troughed turnover than the flat turnover. This helps prevent belt buckling.

Conclusion

By comparing a flat turnover and troughed turnover using the same 2 m wide ST-5200 belt under the same tension, BULK HANDLING TODAY

April 2018

27

Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine well-appointed and equipped business suites.

Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages.

Secure parking, business centre, fibre optic broadband AV, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 1401 41 St. Albans Ave, Craighall Park

CONSTRUCTION MACHINERY

A Global Service New Agreement Expands Hitachi Construction Machinery’s Remote Construction Machinery Management Business and Grows Iridium’s Heavy Equipment Partner Network.

I

ridium Communication has announced a new longterm agreement, which brings the truly global coverage and reliability of their network to Hitachi Construction Machinery Co. By integrating Iridium connectivity, Hitachi will now be able to expand to regions and markets previously not possible.

Hitachi’s Global e-Service construction machinery management system provides customers with robust maintenance information to help companies control CO2 emissions, minimise idling times

Through this new agreement, e-Service customers will be able to easily access and transfer critical data, which conveys key operational information and monitor fuel consumption. Through this new agreement, e-Service customers will be able to easily access and transfer critical data, which conveys key operational information including, but not limited to, daily operation hours, temperatures and pressures, says Toru Kurenuma of Hitachi, adding, “Iridium’s network will afford us a new level of global connectivity that will help us grow our telematics business and expand our worldwide footprint.”

Moving satellites

Their network is uniquely qualified for mobile telematics and serving the Internet of Things (IoT) beyond the reach of terrestrial networks, due to the inherent advantages it boasts. Iridium operates the only 100-percent global network comprised of interconnected LEO satellites.

Due to its proximity to earth in LEO, Iridium’s network delivers low-latency and reliable connectivity supporting critical business functions, like remote asset tracking, vehicle management and preventative maintenance.

With constantly moving satellites that can communicate with each other, end-users have access to enhanced reliability and connectivity, even in the most remote locations.

To date, Iridium IoT services are used by eight of the top 20 original heavy equipment manufacturers, and includes five of the top 10. As the satellite IoT market continues to grow through the increased adoption of satellite-enabled telematics solutions, the need for global and reliable solutions will increase, further establishing the company's position as a leader in this space.

Iridium Communications Inc www.iridium.com Hitachi Construction Machinery www.hitachicm.com/global

BULK HANDLING TODAY

April 2018

29

“THE LINK FOR AFRICAN TRADING”

30

BULK HANDLING TODAY

April 2018

TRANSNET FREIGHT RAIL

www.transnetfreightrail-tfr.net

BULK HANDLING TODAY

April 2018

31

REBORN EQUIPMENT

New Lease on Life An unprecedented number of mines are opting for from-the-bottom-up rebuilds of equipment rather than more traditional selective rebuilding and repairs.

S

andvik Mining and Rock Technology’s Jet Park rebuild workshop is a hive of activity as a significant number of machines cross the floor to get a new lease of life. The company’s strategy to rebuild machines, including all-new components from the frame up, has been a revelation and at approximately 65% of the cost of a new machine, represents an offer that simply cannot be ignored.

Customers are aware that tighter standards are being applied and as a result they are mitigating the risk of liability arising from accidents involving non-compliant equipment The “Reborn” strategy means that used Sandvik equipment is stripped to the frame and rebuilt with all new components before being delivered to the customer with the same warranty as a new machine. What’s more, each piece of equipment is brought up-to-date with the latest specifications, including operational, safety and comfort features found on new models.

New legislation

According to Sandvik operations manager, Andre van der Heever, this is part of the reason why reborn equipment makes sense as it brings the equipment in line with new health, safety and environmental legislation.

Equally important, the productivity, efficiency and operational performance is also brought up to the same specification as equivalent new equipment.

32

BULK HANDLING TODAY

April 2018

“Customers are aware that tighter standards are being applied and as a result they are mitigating the risk of liability arising from accidents involving non-compliant equipment. They are opting rather for genuine OEM services instead of supposedly ‘cheaper’ options.”

Timeous

Apart from these benefits, a reborn service saves time and is less complex as it cuts out the need to strip and evaluate each machine, obtain quotes for repairs or replacement and then reassemble it.

Reborn’s are simply stripped, the frame repaired if necessary and a complete kit is purchased to undertake the repairs including new cabs, motors, transmissions, harnesses and everything else that is required.

With all the parts at hand the machine is simply reassembled, tested and made ready for delivery.

Where traditional rebuilds take an average of six-months to complete, the reborn route allows customers to implement it as a scheduled maintenance intervention and halves the time a machine is out for repairs.

Warranty

Sandvik rebuild workshop manager, Stephan Joubert, says that because the machines are issued with a new machine warranty, all work is carried out with the utmost professionalism by highly OEM trained workmen. They work to the strictest standards and rebuild each piece of equipment to the original specifications as indicated by its serial number.

REBORN EQUIPMENT

This takes a high degree of expertise and commitment to do things right and is something that our Sandvik team has in spadesful,” says Stephan.

The team also undertakes careful root cause analyses of failed components to provide customers with findings that may help them to implement improvements to prevent damage in future,” he adds.

Rebuild specialist, Cedric Chiloane, says that reborn services are available for any Sandvik underground hard rock equipment. “It is advisable to speak to one of our advisors to ensure the reborn programme can be undertaken as a planned intervention.”

Far shorter lead times

The fact that the reborn is a planned intervention with adequate lead times means that all parts can be manufactured and sourced globally and delivered in kit form to Jet Park in the most cost-effective manner, hence the unbeatable price positioning.

This is considerably cheaper than buying individual parts for a selective rebuild. It is also quicker than conventional rebuilding. In some instances the turnaround time on a reborn machine may even be quicker than buying and waiting for delivery of a new machine.

“We think that it addresses every need usually associated with buying a new machine in terms of quality, safety, reliability and increased availability. Considering it is significantly cheaper and has a far shorter lead time than a new machine, it is definitely a good offer.

In some instances the turnaround time on a reborn machine may even be quicker than buying and waiting for delivery of a new machine “In comparison with conventional rebuilds where the machine is only as good as its weakest part, reborns have no such limitation as they make use of all new parts all around,” Cedric concludes.

Sandvik Mining, Tel: (011) 929-5300 www.mining.sandvik.com

PALIFENCE NEW

WELD FREE PALISADE WELDED MESH •Save on transport •Ease of assembly •Save on storage •Follows surface contours •Installed, DIY, Trade

•Good viewing visibility •Complete system •Longevity – Zincalu or Zincalu and plastic coated •Secure and discrete POOL

FENCING

High Security Welded Mesh Palisade Gates Gate Automation Electric Fencing and more…

MARK: 083 454 6488

HEIDI: 083 334 4835

www.palifence.co.za BULK HANDLING TODAY

April 2018

33

MARKET FORUM

InfoLink Launched in South Africa Materials Handling Equipment (MHE) solutions provider, Goscor Lift Truck Company, has launched InfoLink in South Africa, a wireless operator and fleet management solution that puts the power of accurate, up-to-date business metrics right at management’s fingertips.

First Local Mobile RopeHandling System Tech Edge’s Winches and Winders Division has successfully manufactured and installed South Africa’s first locally designed and built mobile rope-handling system for the Bakubung Mine.

In 2013 InfoLink received the International Forklift of the Year Award in the “Forklift Truck Solutions” category, for revolutionising materials handling technology for UK office supplies wholesaler, Spicers, by reducing maintenance and repair costs by 90%.

Tech Edge won the tender issued by Worley Parsons in April 2016, based on the company’s reputation in the winder industry, extensive design capabilities and competitive pricing.

In essence, InfoLink helps customers monitor and manage the efficient use of their forklift fleet and total operations, by delivering actionable data through content-rich, interactive dashboards that help fleet managers focus on real opportunities and avoid wasted time deciphering mounds of data.

The equipment was specifically designed to install head and tail ropes onto a four-rope headgearmounted Koepe friction winder at the mine in the North West Province.

Apart from impact monitoring and history, thanks to its user-friendly interface, it provides management fleet-wide visibility into an array of other operator and fleet information, such as battery usage, truck utilisation, service needs and more.

Goscor Lift Truck Company Tel: (011) 230-2600 Email: lifttrucks@goscor.co.za www.goscor.co.za

SKF Explorer tapered roller bearings

The key deliverables consisted of four rope reelers, a large two-drum friction winch, a compression beam with deflection sheaves, and four messenger winches, complete with a sophisticated, integrated, electrical control system.

The performance of the rope handling equipment has exceeded the design requirements, including all electrical and safety systems. This gives the client complete control of the ropes, fully satisfying the project objectives.

Tech Edge, Bannister Erasmus or Vanessa Rabie Tel: (0)11 976-3063 Email: techedge@techedge.co.za

Fit the right part at the right time, every time Getting a replacement tapered roller bearing can sometimes be a challenge, especially if it’s needed in a remote location. Machines can be out of action.

Productivity can slow and costs quickly escalate.

With SKF you’ll get the right support and the best tapered roller bearing solution for your needs, wherever the application. With 17 000 distribution locations in over 130 countries around the globe and a continually extending range of standard metric and imperial sizes, we’ll get the part to you, no matter what.

SKF South Africa (Pty) Limited Tel: +27 11 821 3591, Fax: +27 86 677 7876 Email: sales.za@skf.com, Web: www.skf.co.za ® SKF is a registered trademark of the SKF Group. | © SKF Group 2018

34

BULK HANDLING TODAY

April 2018

MARKET FORUM

Two Working Days

Metso is addressing the growing demand for mobile track-mounted crushing plants by commissioning a new, faster assembly line at the Tampere factory in Finland. The assembly of a 50-tonne, track-mounted crushing plant now takes two working days.

The serial production line operates in two shifts and increases Metso's mobile crushing plant production capacity by 25 percent.

"Demand for mobile Lokotrack crushers for aggregates took an upward turn 18 months ago, so the timing

Operating in two shifts, the new assembly line can complete more than two trackmounted crushing plants in one day.

of our investment in capacity growth was right. We want to ensure that our production capacity can meet customers' growing needs," says Markku Simula, President: Aggregates Equipment business area at Metso.

will begin later this year. The first Lokotrack model rolled off the new assembly line in the second week of January. Based on the current plan, the assembly line will complete about 200 crushing plants before mid-year.

The new high-speed assembly line has six assembly stations instead of the previous five, thus improving the line's flexibility and shortening the overall assembly time. Currently, the line is used for assembling the most popular crusher models. Assembly of heavier and more complex models

Metso is a Finish industrial company, offering equipment and services for the sustainable processing and flow of natural resources in the mining, aggregates, recycling and process industries. www.metso.com

New Assembly Plant Completed Northmec’s new assembly plant in Camperdown, KwaZulu-Natal, has recently been completed by Macwin Construction and is now fully operational.

“The Capital Equipment Group (CEG) has made a R59-million investment in the construction of this new plant, which is now home to the Group’s extensive range of agricultural and construction equipment, as well as forklift trucks,” says Tony Sinclair, CEO, Capital Equipment Group, a subsidiary of Invicta Holdings Limited.

He adds, “This investment confirms the Group’s pledge to support local industries – particularly agricultural and construction sectors – by continuing to expand the product range to meet exact market demand, improve accessibility to equipment and spares and to provide a dependable repair and maintenance service.”

The new 5 500 m3 building rests on 14 hectares of land just off the N3 highway, between Durban and Pietermaritzburg. It is strategically positioned to ensure swifter delivery times. Machinery that arrives at the Durban harbour from abroad will be transported directly to the conveniently situated plant, for assembly and efficient distribution throughout Africa.

Full workshop facilities are equipped with state of the art tooling and machinery to ensure quick assembly and premium quality, according to stringent international standards.

www.capitalequipmentgroup.co.za www.invictaholdings.co.za

BULK HANDLING TODAY

April 2018

35

MARKET FORUM

Disaster Prevention fluid micro concrete repair product, durarep FMC. According to Jasper Allardice, KZN Regional Manager, a harbour tippler (heavy equipment used for offloading coal onto conveyor belts running into coal-carrying ships) had collapsed, due to the failure of its supporting concrete columns and base.

Emergency around-the-clock repair work in progress on the coal tippler’s concrete supports.

a.b.e. Construction Chemicals recently prevented the economically-important operations of Portnet’s Richard Bay Coal Terminal from being severely disrupted when a key tippler collapsed. This was thanks to the supply of their special

“This was a potentially disastrous setback for the coal terminal, which immediately lost 50% of its loading capacity.

If the tippler could not be operational within a couple of days, trains and ships would be backed-up resulting in substantial knock-on costs as well as a logistics nightmare for Portnet,” Jasper explains.

FMC (fluid micro concrete) allows for faster repairs, while still delivering the

required tensile strength of 30 MPa in three days. Epidermix 344 wet-to-dry epoxy was used as a bonding agent and their Chryso Cure WB (wax-based) curing compound was applied to speed up the curing process.

It was recommended that the other tippler, with concrete supports still intact, also be reinforced with similar repair treatment, to ensure no further mishaps. a.b.e.’s durarep FMC is a cement-based, non-shrink concrete reinstatement grout, which is applied by pouring or pumping.

The product is supplied in ready-to-use form requiring only the addition of small amounts of water for easy mixing and fluid consistency.

It can also be used for the repair of potable water retaining structures such as dams, water cooling towers and silos as well as concrete structures in general.

a.b.e. Construction Chemicals Tel: (011) 306 -9000 www.abe.co.za

voith.com

Intelligent Driving of Belt Conveyor Systems The New TurboBelt 500 TPXL This new fluid coupling combines the proven reliability of hydrodynamic power transmission with digital control technology. The integrated controller assures optimised coupling and conveyor performance in every operating mode. The intelligent logic protects all conveyor components, providing a longer lifetime of utilisation.

Your Benefits: Intelligent speed & torque control • Self-diagnosis & remote services • Easy plant control integration • Up to 98.5 % efficiency • Unrivaled Total Cost of Ownership •

Join us at Electra Mining Africa 2018, Hall 6 Stand: F06

36

BULK HANDLING TODAY

April 2018

MARKET FORUM

Putting the Brakes on Chute Wear

New Machines for Coal Facility Two Redler chain elevators ordered from equipment supplier, Takraf Africa, by the Willowton Group in Pietermaritzburg, KwaZulu-Natal, brings the number of machines supplied to this plant to more than 40, in a business relationship stretching back some four decades.

In addition, the supplier has provided more than 100 Redler machines to Willowton Group in Isando. The machines include both Redler en-masse chain conveyors and chain elevators.

The latest two elevators replace existing machinery at the coal intake facility, which feed the boiler house.

The new machines are almost identical, except for drive modifications, as the original gearboxes are no longer available. Machines are today manufactured from laser cut plates, which eliminates boilermaker tolerances and ensures a perfect site fit.

The Redler Chain Elevators are 10.7m and 5.2m in horizontal length, with a vertical height of 19.6m and 11.4m, respectively. Their conveying capacity is 15tph of coal.

While chute design tends to be ubiquitous, the fact that minerals-processing plants cater for a diverse array of commodities means that there are equally diverse requirements in terms of wear solutions.

In order to overcome this challenge, Rio-Carb aims to become involved in projects at a much earlier stage, preferably at plant design. “This affords us the opportunity to provide input about the use of various wear materials, their correct application, and their behaviour from an operational point of view,” explains director, Sias Suurd.

Redler machines convey a wide range of solids, including coal, wood chips, sand, lime, cement, fly-ash, sunflower seeds, maize, wheat, flour, grain and many more. These low maintenance systems ensure minimal product degradation, while the dust tight casings protect the conveyed material and the environment from mutual contamination.

Takraf Tenova Takraf www.takraf.com Willowton Group www.willowtongroup.com

Older minerals-processing plants have often been designed with a specific type of wear material in mind, without due consideration given to wear characteristics.

“The flow rate of the material in question through a chute or over a screen invariably alters over time as wear accelerates. The best option to deal with this long-term issue is CrC,” he states.

Sias argues that project houses have traditionally focused on cost, which does not always equate to the best solution. “While CrC is a much more expensive material than quenched and tempered steel, for example, it has ten to 12 times more wear resistance.

Therefore it is a far superior product.

“Our main challenge is to explain the role that CrC can play in reducing the total cost of ownership. Mineralsprocessing plant operators have to ensure maximum productivity for the greatest period. This means that utilisation and availability are critical factors, which is where our total wear-solutions approach offers the greatest value proposition for our clients,” he concludes.

Rio-Carb www.riocarb.com

BULK HANDLING TODAY

April 2018

37

MARKET FORUM

Logistics Support ‘Business as Usual’ Precision control of the boom, arm, and bucket is critical in harsh operating environments such as Africa. It is for this reason that Bobcat Equipment South Africa is punting the Bobcat E55 compact excavator as the toughest and most efficient machine on the market today.

With a maximum digging depth of 3.923mm, the excavator is used mainly in the mining, construction, and plant-hire sectors, and even diverse applications such as the fruitfarming industry. Various clamp-ready arm configurations are available. The standard power arm offers maximum arm breakout force, while the optional long arm allows for added reach and dig depth.

Selectable auxiliary hydraulics allow for three flow rates to optimise the response of hydraulic attachments, such as tilting buckets, clamps, grapples,

hydraulic breakers and augers. Low flow is ideal for precise control and accurate angles, medium flow for placing and handling materials and maximum flow for peak hydraulic attachment performance.

“The excavator controls allow operators to make fine, accurate movements with minimum effort and maximum comfort, which translates into precise results in less time and with less fatigue,” stresses Bobcat Equipment South Africa Product Specialist, Jan Stansfield. A rocker-style thumb switch on the left joystick gives superior boom-swing control with better metering than foot pedals.

Other features that boost productivity are two-speed travel, while the Dual Direction Detent system provides

for continuous flow for attachments in either direction. This means that attachments can be operated continually without having to press a button.

Additional features include ‘auto idle’, which reduces fuel consumption when the operator needs to take a break or pause the operation. The ‘auto shift’ travel function moves the excavator out of high range and back automatically, allowing for optimal travel performance without the need to downshift manually.

Goscor Group Debby Marx Tel: (011) 230-2600 Email: dmarx@goscor.co.za www.goscor.co.za

C

M

Y

CM

MY

CY

CMY

K

Precision Control Boosts Productivity Due to Africa’s economic reliance on the extraction of natural resources, logistics operators are often required to facilitate the movement of large machinery and parts, often transporting goods from South African ports to remote locations beyond our borders.

For Dachser South Africa this is ‘business as usual’. However, when the company was called upon to provide logistics support for a supply chain facilitating the manufacture of mega machinery between South Africa and

38

BULK HANDLING TODAY

China, all their skill, knowledge and systems were put to the test.

Detlev Duve, Managing Director of Dachser South Africa, says that the project took a full 12 months from start to finish, and necessitated intensive coordination and highly specialist knowledge.

“The client required the replacement of two stacker re-claimers and two ship loaders to be fabricated in China using raw materials from South Africa.

We were involved in collection of the

April 2018

raw materials, transporting these to the Durban port, ensuring customs clearance and correctly loading the cargo onto the waiting ships. Once the machinery was manufactured some months later, it was shipped back to South Africa, cleared through customs, offloaded and delivered,” he concludes.

Dachser South Africa www.dachser.com

We drive Industry

C

M

Y

CM

MY

CY

CMY

K

Quality. Innovation. Efficiency.

Gear units and motors from SEW-EURODRIVE have always set the trend and established new standards in drive technology. For this reason, the quality label “made by SEW� has become a hallmark of quality in the drive industry. Market-orientated products developed and manufactured in-house, as well as uncompromising quality, are the cornerstones of our success.

SEW-EURODRIVE - Driving the world

DEMAG V-GIRDER CRANES – NOW AVAILABLE UP TO 50 TON LIFTING CAPACITY.

Visit us at CAMINEX 2018 05 – 07 June 2018 Stand C02

+27 11 898 3500 www.demagcranes.co.za