Bulk Handling Today February 2017

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

MANOEUVRING CANAL GATES GEAR UNITS TO COAL TERMINAL

PART OF THE MATERIALS HANDLING PROCESS

T O D A Y

February 2017

BULK

HANDLING

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February 2017

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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 500 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

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LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SOUTH AFRICA Head Office: 8 Boris Road, Bordeaux, Randburg, Johannesburg P.O.Box 2348, Pinegowrie. 2123, Republic of South Africa Tel: 074 900 8378 • www.leeasa.co.za Secretary: Arni Sommer • email: arni@leeasa.co.za

BULK BULK HANDLING HANDLING TODAY TODAY

February February 2017 2012

Jay Pillay

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This splicing system can also be used inserting new belting into old conveyor belt systems

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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 February 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

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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

February 2017 www.saimh.co.za

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

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Francois Smit

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The Materials Management module utilises mine data to provide a real-time stockpile balances throughout the mining operation

The Shift Planner module allows for planned work to be divided into tasks or activities and rescheduled or reallocated in real-time during the shift

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The Controlled Areas module monitors access to hazardous or restricted areas and alerts supervisors when the authorised duration within those areas is exceeded

Altra

®

Industrial Motion

South Africa (Pty) Ltd

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BULK HANDLING TODAY

February 2017

Svendborg Brakes

David Kruyer

We are transporting sugar into Mozambique and are negotiating the logistics of getting steel to Tanzania

Lifting Solutions That Work.

TorreLifting_657_adv_BulkHandlingToday_180x30.indd 1

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Even though South Africa currently permits some of the largest vehicle combinations in the world for general freight haulage, at a maximum general vehicle mass of 56 tonnes, moving heavy-lift cargo remains a challenge as each province requires different permits and a police escort

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It’s one of the most corrosive environments imaginable, only one material can tough it out

With stainless steel’s strength, versatility and over 200 grades, these are some of the reasons we call it the only man-made noble metal.

Stainless Steel. It’s Simply Brilliant.

Call 011 883 0119 or see sassda.co.za. Your complete stainless information source.

Image courtesy of www.72andrising.com

MSC 1611-001MechChem

Stephan Roos

Figure 1. Bulk density results for Platreef material at 2% moisture content

Figure 2. Internal friction angles determined for the Platreef material at 2% moisture content

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Figure 3. Internal friction angles determined for the Platreef material at 2% moisture content

Figure 4. Wall friction angle results per liner, for the Platreef material at 2% moisture content

Figure 5. Flow functions obtained with the Jenike shear tester for Platreef material at 2% moisture content

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BULK HANDLING TODAY

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Sample MC BC (m) BS (m) BP (m) ϴc/ϴs (°) ϴp (°) Platreef 2% 0.909 0.721 0.436 17 24 Platreef 2% 0.856 0.682 0.447 11 18 Platreef 8% 1.145 0.925 0.583 12 19 Platreef 8% 1.082 0.878 0.595 8 14 Table 1. Platreef material at 2% and 8% moisture contents – mass flow –instantaneous minimum requirements

Liner CB 8000 VRN-500 CB 8000 VRN-500

Sample MC BC (m) BS (m) BP (m) ϴc/ϴs (°) ϴp (°) Platreef 2% 1.321 1.012 0.630 17 25 Platreef 2% 1.236 0.954 0.655 11 18 Platreef 8% 1.860 1.430 0.940 17 25 Platreef 8% 1.751 1.357 0.982 10 20 Table 2. Platreef material at 2% and 8% moisture contents – mass flow – 48 hours time storage minimum requirement

Liner CB 8000 VRN-500 CB 8000 VRN-500

Figure 6. Critical rathole dimensions – Platreef at 2% moisture content Instantaneous Df (m) Effective Head (m) 1.75 N/A 3.34 2.5 5.79 5 8.12 7.5 10.25 10 12.20 12.5 14.05 15 15.50 17.5 16.86 20 Table 3. Tabulated instantaneous critical rathole dimensions – Platreef at 2% moisture content

Time Storage - 48 hours Df (m) Effective Head (m) 2.45 N/A 4.25 2.5 7.12 5 9.75 7.5 12.10 10 14.31 12.5 16.16 15 17.96 17.5 19.42 20 Table. 4. Tabulated time storage critical rathole dimensions – Platreef at 2% moisture content

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Figure 7. A mass flow bin containing platinum material

Figure 9. An expanded flow flat bottom silo containing platinum material

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BULK HANDLING TODAY

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Figure 8. A funnel flow bin for run-of-mine platinum ore

Figure 10. An expanded flow stockpile containing platinum material

(a) Conical

(b) Pyramid

(c) Flat bottom

(d) Flat bottom with slot (e) Eccentric discharge Figure 11. Examples of mass flow bins

(a) Transition hopper

(b) Chisel-shaped hopper

Gussets

Valley angle Plan view showing gussets (c) Pyramid hopper Figure 12. Examples of funnel flow bins

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Funnel flow

Flow zone (dilated condition)

Mass flow

Dead material

(a) Single outlet Figure 13. Examples of expanded flow bins

Figure 14. Flow-no flow condition for mass flow design

havas 14530/E

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A rare breed indeed. Rather like graduate professionals.

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PPS is an authorised Financial Services Provider.

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BULK HANDLING TODAY

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(b) Multiple outlets

Figure 15. A vibrating feeder at the bottom of a bin

Figure 18. Existing stockpile – underground ore – angle of repose = 34° for 5% moisture content

Figure 16. A belt feeder at the bottom of a stockpile

Figure 19. Temporary stockpile – underground ore – angle of repose = 45° for 10% moisture content

Figure 17. An apron feeder

Sample UG2 Ore UG2 Ore UG2 Ore UG2 Ore

MC 5% 5% 10% 10%

BC (m) 0.600 0.760 0.890 1.180

BS (m) 0.560 0.690 0.780 1.050

BP (m) 0.300 0.380 0.470 0.570

ϴc/ϴs (°) 13 14 14 16

ϴp (°) 23 24 24 26

Liner VRN-500 VRN-500 VRN-500 VRN-500

Storage 0 Hrs 48 Hrs 0 Hrs 48 Hrs

Table 5. Run-of-mine UG2 material at 5% and 10% moisture contents – mass flow – instantaneous and time storage requirements

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Option

Height (mm)

Live Volume (m3)

Live Capacity (tons)

No. of Feeders

Operational Time (hrs)

Material Moisture (%)

Stored Time (hrs)

Existing

11591

908.71

2180

2

1

11591

416.55

999

2

5.74

5

48

2.63

10

2

11591

805.89

1934

48

4

5.08

10

3

11591

559.12

1341

48

2

3.53

10

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Table 6. Comparison between design options – stockpile height at 12 m (level controlled) EXISTING 5% MC UG2 MATERIAL

EXISTING

OPTION 1

WITHDRAWAL TO δ c = 10°

KEEPING EXISTING MASS FLOW CHUTES NEW 10% MC UG2 MATERIAL

INTRODUCING 2 NEW FEEDERS NEW 10% MC UG2 MATERIAL

RATHOLING

WITHDRAWAL TO δ c = 10°

REQUIRES BRATTICE WALLS

OPTION 2 MODIFYING MASS FLOW CHUTES TO PREVENT ARCHING NEW 10% MC UG2 MATERIAL

LIVE WITH RATHOLING

OPTION 3

Figure 20. Stockpile functional design comparisons for different options

• Possible improvements and modifications • Cost • Bulk materials testing and flowability

Stockpile Properties

The following material and stockpile properties were used in conjunction with the mass flow test work results: Material Required live capacity Expected moisture content Maximum lump size Maximum diagonal lump Minimum material density at 0 kPa (Discharge) Minimum material density at 60 kPa (Volume) Minimum material density at 120 kPa (Load)

UG2 2 000 tons 5% – 10% 300 mm x 500 mm 583 mm 2 000 kg/m 3 2 200 kg/m 3 2 400 kg/m 3

The material properties and design parameters obtained from test work for the 5% and 10% moisture content material were compared. This was used to predict the difference in flowability of the UG2 ore. It was evident that the 10% moisture content material was more cohesive.

The existing mass flow chute properties onto vibrating feeders were as follows: • Square opening width = ± 900 mm • Hopper angle with the vertical for VRN-500 = 14° Since material could be stored for periods longer than 48 hours,

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Figure 21. Option 1 – Existing mass flow chutes and feeder interface

Figure 22. Improved mass flow chutes with wider feeders

Figure 23. Discharge mass flow chutes with visible hammer rash to promote flow for 10% moisture content material

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MARKET FORUM

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MARKET FORUM

Allan Widlake

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