Bulk Handling Today January 2017 by Promech Publishing

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

T O D A Y

January 2017

A ‘SUPERTUBE’ OR ‘CASCADE’ APPROACH LOCAL - THE BEST WAY TO GO BULK HANDLING TODAY

January 2017

BULK HANDLING TODAY

January 2017

BULK

HANDLING

BULK HANDLING TODAY

T O D A Y

January 2017

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

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

January February2017 2012

Jay Pillay

BULK HANDLING TODAY

January 2017

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 SAIMHâ&#x20AC;&#x2122;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 January 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

BULK HANDLING TODAY

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

January 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

BULK HANDLING TODAY

January 2017

BULK HANDLING TODAY

January 2017

BULK HANDLING TODAY

January 2017

FLSmidth SA

Metso South Africa

Osborn Engineered Products SA

Total Number of Employees

717

780

275 (SA)

Employees with tertiary qualifications Number of years operating in SA

70% ± 20

71% 91 +

91 +

ISO Accredited

Yes

Subsidiary of Overseas Principal

Name of company

Ownership CAD/FEA and/or CAM facilities BEE rating

Yes

Yes Public / Subsidiary of Overseas Principal Yes

BEE ownership compliant

Type of crushers handled ▪ Jaw

▪ Cone

▪ Mineral sizers

▪ Gyratory

▪ Impact Crushers

— Horizontal Shaft

— Vertical Shaft

— Hammer mill Primary area of expertise: ▪ Design ▪ Manufacture/assembly ▪ Import ▪ Export ▪ Installation and commissioning ▪ Turnkey Contract to supply and install ancillary items such as: ▪ Structures ▪ Screens ▪ Chutes and feeders ▪ Pit civils and front-ends ▪ Grizzly screens ▪ Cyclones ▪ Separators ▪ Liners

ü ü ü ü ü ü ü

ü ü ü

ü ü ü ü ü

ü ü ü ü

ü ü ü ü ü

ü ü ü ü

ü ü ü ü ü ü ü -

ü ü ü ü ü ü ü R11.3 m ±18

ü ü ü ü ü ü ü -

R74 m

1 500 tons

600 tons

±60% of orders

Yes

Constructional Engineering Association SA

Yes

Service support: ▪ Manufacture and delivery to site ▪ Assembly on site ▪ Commissioning ▪ On-site supervision ▪ Personnel training ▪ On-site annual shutdown service ▪ Maintenance contracts Total value of last two contracts Number of projects completed in 2016 Value of largest contract completed in past 5 years Size of largest contract in terms of tons conveyed per hour Number of export orders over past 5 years Professional affiliations

BULK HANDLING TODAY

January 2017

Pilot Crushtec

Sandvik Mining & Rock Technology

Weir Minerals

Wirtgen SA

Total Number of Employees

100

1800

1200

Employees with tertiary qualifications Number of years operating in SA

80% 25

106

ISO Accredited

Yes

Private

Subsidiary of Overseas Principal

CAD/FEA and/or CAM facilities

Yes

BEE rating

Name of company

Ownership

Type of crushers handled ▪ Jaw

▪ Cone

▪ Mineral sizers

▪ Gyratory

▪ Impact Crushers

— Horizontal Shaft

— Vertical Shaft — Hammer mill Primary area of expertise: ▪ Design ▪ Manufacture/assembly ▪ Import ▪ Export ▪ Installation and commissioning ▪ Turnkey Contract to supply and install ancillary items such as: ▪ Structures ▪ Screens ▪ Chutes and feeders ▪ Pit civils and front-ends ▪ Grizzly screens ▪ Cyclones ▪ Separators ▪ Liners

ü ü

ü ü ü ü ü ü

ü ü

ü ü ü

ü ü ü ü

ü ü ü

ü -

ü ü ü ü ü ü ü -

ü ü ü ü ü ü ü R55 m -

ü ü ü ü ü ü ü -

R45 m

400 tons

Yes

SAIMM, SACPS, IQSA

ü ü ü ü ü ü

ü ü ü ü

BULK HANDLING TODAY

January 2017

At the stage where the yellow becomes visible, the operators or mine personnel have a period of time in which to undertake the liner changeout

Shift supervisor, Richard Marum and shift operator, Lodwin Ngubeni examining the liner.

BULK HANDLING TODAY

January 2017

The liner is supplied with an integral yellow rubber compound which acts as a visual aid specifically for condition monitoring purposes

Matthew Fitzsimons, technical manager at Multotec Rubber

DUNLOP INDUSTRIAL PRODUCTS

Are you sure you have the best possible solution for your belt conveying system?

A belt conveyor comprises of many components; while the belt itself is arguably the most important – how does it perform? �e Rema Tip Top and Dunlop organization has developed tools to measure conveyor belt performance and condition – that's how conﬁdent we are that our belting will outperform your expectations. Tools that can quantify expectations in terms of rate of wear and predicting when exactly replacement should be scheduled. Tools that can be used to optimise components and operation strategy. Resources and tools needed to monitor and maintain every aspect of operation. Strategies that quantify beneﬁts that

could have or have been realised. Choose Rema Tip Top and Dunlop – �e only brand that has the conﬁdence to measure performance and compare with expectations. �ousands of Rands saved on initial outlay may evaporate in a short period if the product does not perform to expectation. Manufacturing high quality conveyor belting in South Africa for the world since 1929, it is Rema Tip Top and Dunlop Strategy to partner with customers with the objective of optimising plant availability. Tel: 011 741 2500 Email: marketing@rematiptop.co.za Website: www.rema-tiptop.co.za

Conveyor Belting Advert Thursday, August 25, 2016 3:10:23 PM

Physical Address: 22-24 Lincoln Road, Industrial Site, Benoni

BULK HANDLING TODAY

January 2017

BULK HANDLING TODAY

January 2017

The system is not an alternative to conventional chute systems

BULK HANDLING TODAY

January 2017

Paul Nel, global product manager for M 3

BULK HANDLING TODAY

Hannes Wakeford, RTT Technologies technical director

January 2017

Keith Rice, a director of RTT Technologies

havas 14530/E

RARE IS REWARDING The Narina Trogon - One of Africaâ&#x20AC;&#x2122;s most elusive birds. A rare breed indeed. Rather like graduate professionals. Contact your PPS-accredited financial adviser or visit pps.co.za to see if you qualify.

PPS is an authorised Financial Services Provider.

BULK HANDLING TODAY

January 2017

The company delivers complete turnkey manufacturing and solutions at its Johannesburg factory

BULK HANDLING TODAY

January 2017

A comprehensive design system is upgraded annually, allowing the company to deliver bespoke solutions to its clients

Colin Fairweather in the companyâ&#x20AC;&#x2122;s Johannesburg factory

BULK HANDLING TODAY

January 2017

Gizelle McIntyre

BULK HANDLING TODAY

January 2017

Coralynne & Associates +27 (011) 849 3142

ABSOLUTE MATERIAL FLOW CONTROL

• Optimum material flow • Up to 80% decrease in material degradation • Reduced dust and noise levels • Virtually maintenance free • Greatly reduced spillage • Significant reduction in belt damage

SOUTH AFRICA

Phone: +27 (0) 11 827 9372 Email: info@webachutes.com

BULK HANDLING TODAY

January 2017

BULK HANDLING TODAY

January 2017

This unique shaft sinking methodology is engineered to deliver optimal safe working conditions

Man and material loading is handled on one side of the gantry with waste rock being dumped from the other side

BULK HANDLING TODAY

January 2017

Yijun Zhang, Conveyor Dynamics, Inc

Figure 1. Equivalent (von Mises) strain in the belt bottom cover of a steel cord belt from finite element modeling

BULK HANDLING TODAY

January 2017

Michael Thompson, Conveyor Dynamics, Inc

Figure 2. Idler junction cover failure

Figure 3. Belt contacting idler edge

BULK HANDLING TODAY

January 2017

Figure 4. Finite element modeling of belt deformation with Idler Junction Pressure Index (IJPI). Top graphs: cut plane of a belt near the idler junction area. Bottom graphs: the belt bottom cover (looking from beneath the belt bottom cover)

Figure 5. Idler Junction Pressure Index (IJPI) vs idler spacing, belt thickness, trough angle and tonnage. Belt width is 1 200mm in all cases

BULK HANDLING TODAY

January 2017

Figure 6. Project examples of Idler Junction Pressure Index

The IJPI can increase very quickly with a normal three-roll trough even with reduced idler spacing

Project Name

IJPI

Zisco

0.33

Yandi

0.84

Impumelelo

1.12

Curragh

1.17

Ingwe

1.49

Los Pelambres Escondida CV102

0.95 0.65

Tonnage (T/H) 500 Iron Ore 4000 Iron Ore 2400 Coal 2500 Coal 1800 Coal 11000 Copper Ore Copper Ore

Belt Speed (m/s)

Belt Width (mm)

Belt Thickness (mm)

Trough Angle

Idler Spacing (m)

Conveyor Length (km)

4.5

750

25°

15.6

5.5

1200

2.5

6.5

1200

4.5

7.5

1200

45°

1050

45°

4.5

8.9

1800

40°

1.5

12.8

6.1

1600

35°

1.5

3.8

2800

35°

1~3

20000 3.15 Overburden Table 1. Selected system details for IJPI calculation Overburden

1.56

BULK HANDLING TODAY

January 2017

Figure7. Bottom cover damage at high contact pressure area

Figure 8. Belt cover wear due to idler forward tilt

BULK HANDLING TODAY

January 2017

Figure 9. Belt cover wear from sharp ceramic lagging tile. The lagged pulley surface is shown in the upper left corner

Figure 10. Comparision of contact stress between two ceramic lagging tile designs

BULK HANDLING TODAY

January 2017

Figure 11. Bottom cover wear from ceramic lagging

Tel no. +27 (0)10 210 4000 • flsm-za@flsmidth.com • www.flsmidth.com

BULK HANDLING TODAY

January 2017

MARKET FORUM

Rio-Carb director, Martin Maine

The Trio TP cone crusher is used in secondary and tertiary stage crushing

BULK HANDLING TODAY

January 2017

MARKET FORUM

BULK HANDLING TODAY

January 2017

MARKET FORUM

BULK HANDLING TODAY

January 2017

BULK HANDLING TODAY

January 2017

Your boutique business destination Surrounded by lush gardens in the hub of Johannesburgâ&#x20AC;&#x2122;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, and an onsite Hair & Beauty Boutique, 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

MARKET FORUM

Key representatives from the various businesses that form part of the InServe Group

BULK HANDLING TODAY

January 2017

MARKET FORUM

MOBILE MATERIALS HANDLING

Improved Efficiency and Productivity ELB Equipment, the sub-Sahara Africa distributor of a complete range of Telestack radial telescopic conveyors is dedicated to offering the most cost-efficient and effective way of stockpiling material on the market. In today’s competitive environment, you need high quality equipment backed by an outstanding support network. Our sales and aftermarket teams are trained to provide customers with outstanding stockpiling solutions backed by product warranty and 24/7 technical support and parts service. Contact us to see how you can increase your stockpile capacity by up to 30% on the same footprint.

Distribution and Product Support by:

H/OFFICE: 14 Atlas Road, Anderbolt, Boksburg Tel: (011) 306-0700 • Fax: (011) 918-7208 e-mail: Elb@elbquip.co.za Website: www.elbequipment.com BRANCHES & DEALERS – SOUTH AFRICA: BRITS: (012) 250-1565 • CAPE TOWN: (021) 933-2383 DURBAN: (031) 464-6522 • EAST LONDON: (043) 740-4530 GEORGE: (044) 878-0874 • KIMBERLEY & KATHU : (053) 841-0040 MIDDELBURG: (013) 246-2312 • POLOKWANE: (082) 334-1564 SUBSIDIARY: ELB EAST AFRICA: NAIROBI, KENYA: (00254) (0) 20 807-0728 DEALERS – SOUTHERN AFRICA: BOTSWANA: (00267) 390-9972 • LESOTHO: (00266) 2831-3926 MOZAMBIQUE: (00258) 219-00469 • NAMIBIA: (00264) 61-234-052 SWAZILAND: (00268) 518-5348 • ZAMBIA: (00260) 212-210-642 ZIMBABWE: (00263) (4) 448-990-3

BULK HANDLING TODAY

January 2017

► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l Skills on Site

Septmeber 2012