BULK
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH
T O D A Y
July 2018
New focus on belt scrapers Just-in-time crushing
BULK
HANDLING
T O D A Y
July 2018
Contents On the cover: Rema Tip Top www.rema-tiptop.co.za www.dunlopbelting.com
Safety
SAIMH 5 CMA News Cover Story 4
25 Proximity Detection Systems
Processing Equipment
6 Tips for Optimising Conveyor Performance
30 Small and Nifty
Mining
33 The Influence of Steel Cord Conveyor Belt Dimensions on Indentation Rolling Resistance Performance
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Beltcon 19
Unlocking Latent Mineral Wealth
Conveying
Market Forum
10 Clips and Cleaners
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12 Unique Strategy to Control Dust Emissions
Endorsing Bodies
Lifting
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CMA (Conveyor Manufacturers Association)
27 Belgium Port Worker Training Centre
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LEEASA (Lifting Equipment Engineering Association of South Africa)
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Trenchless
SAIMechE (SA Institution of Mechanical Engineering)
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Integrated Solutions Provider
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SAIMH (SA Institute of Materials Handling) also mailed to members of the RFA (Road Freight Association)
17 Safer and More Efficient
Transportation 18 Theft, Fraud, Corruption Up to Second Place 21 Hydro-transportation Solutions 23 End-to-End Solutions
Copyright
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
The monthly circulation is 3 673
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 DTP: Anne Rotteglia Advertising Sales: Linda Patricio Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R643,00 (excl postage and VAT) per year; R1 600,00 per year for Africa/Overseas. Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)
BULK HANDLING TODAY
July 2018
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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 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
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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 2012
CONVEYOR MANUFACTURERS ASSOCIATION
From The Chairman’s Desk
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t was a proud day when the concept of the UniDirectional Roller rig was proved earlier this year 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. Jay Pillay Chairman
Jay Pillay Terry Frangakis
Bryan Moore and Simon Curry
Membership at July 2018 All members subscribe to the CMA Code of Ethics 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 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 Giza Technologies (Pty) Ltd Habasit South Africa (Pty) Ltd Hägglunds Drives South Africa Hatch Africa (Pty) Ltd Hosch - Fördertechnik (SA) International Belting & Marketing (Pty) Ltd KevConBelt (Pty) Ltd Lesa Mining Equipment and Conveyor Belt Lorbrand Martin Engineering Megaroller Melco Conveyor Equipment Moret Mining Nautilus Projects (Pty) Ltd Nepean Conveyors OE Bearings
Oriental Rubber Industries SA Osborn Engineered Products Pegasus Industrial Services cc Regal Beloit South Africa Rema Tip Top South Africa Ringspann South Africa Rossi Gearmotors (Pty) Ltd Rula Bulk Materials Handling 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
July 2018
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COVER STORY
Tips for Optimising Conveyor Performance Belt conveyors require regular inspection of the condition of all components. The frequency of these inspections will change over the life of the system. Initially, while everything is new, less frequent inspections, merely to confirm correct operation, will be required. As the components age, more frequent inspection will be required. Using a standardised check list helps ensure that every component is properly monitored.
Dave Pitcher Global Product Manager: Conveyor Belting
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he check list should include checks of free rotation of all the idler rollers, unhindered movement of the belt under all conditions of loading and free flowing loading and discharge of the material without spillage. Furthermore the correct adjustment and state of wear of scrapers, ploughs and skirt seals must be checked regularly. At the beginning of each operating shift an experienced operative must carry out the inspection of the conveyor system and while doing so verify that all is in order by completing a check list.
The conveyor belt condition is a very good indicator of the health of the conveyor system The check list used at every inspection should be retained so that a history of component performance can be established. Trends stemming from the inspection history will dictate future inspection frequency. A strict maintenance regime linked to the conveyor inspection is required. The conveyor belt condition is a very good indicator of the health of the conveyor system. In particular sudden changes to the belt condition require immediate investigation into the cause.
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BULK HANDLING TODAY
July 2018
Poor or incorrect design, poor quality of the belt, poor quality splices, lack of maintenance on the conveyors and lack of accurate sizing of material and typically failing to pay attention to the conveyor are typically the most likely causes of conveyor belt failures.
Be reasonable!
Look after the equipment, or outsource to an organisation able to provide expert maintenance and management services. Note that no conveyor belt will just break, as there are safety factors built into the designs. Typically these machines will provide adequate warning before failing. Spilled material, particularly large lumps of material that are carried back into pulleys are a major cause for concern. Spilled material accumulates on and/ or below the conveyor structure and if this is not rectified the belt will eventually slide continuously over the material causing cuts, gouges and rips in the belt. Lumps of material passing around a pulley, trapped between the belt and pulley face puncture the rubber cover or fracture the carcass. Material spillage is often a cause of misalignment of the belt that can result in damage to the belt edges. Rema Tip Top have developed systems to continuously and automatically monitor belt condition. These include rip detection systems, belt thickness monitoring, splice condition monitoring and belt tracking monitors. We have teams of experienced conveyor inspectors who are used to identify root cause of conveyor
COVER STORY
system malfunction, identify risks to continuous operation and check condition of all components. These teams provide fast feedback on system condition with a prioritised listing of corrective action to maintain uninterrupted operation of each conveyor. The common goal that a partnership with the operation aims to achieve is 100% conveyor availability since this represents the least amount of downtime and maximises production potential. Our offering is to make a team available to the mines to review their conveyors and identify issues, and then maintain on behalf of the mines, increasing the life of their belts and minimising operational risk. Our goal is to maximise predictive maintenance, which will lead to preventative maintenance, thereby minimising the requirement for reactive maintenance. We are able to provide a seamless, reliable, professional service, from ordering the belt to commissioning and operation of a conveyor system, including reliable splicing, after sales service, maintenance and management of conveyor systems.
Energy saving product
Belt conveyor systems are very efficient machines. But this does not mean that efficiencies cannot be improved. Energy usage can be reduced by making use of the latest technology in conveyor belt design, namely aramid reinforced straight warp construction conveyor belting. This product which Dunlop have introduced into the range under the name FlexTech Powamax, allows the user to select a conveyor belt
of the same strength that is considerably lighter than say a steel cord reinforced counterpart. Due to its reduced mass it is easier to transport, easier to install and the conveyor power demand will reduce. Should one be able to reduce belt mass by say 5kg/m, over a conveyor 1 000m long, the total reduction in mass that has to be turned by the conveyor is 10 tons. Not only will this save power, but will reduce the required belt class, resulting in significant Opex savings.
These teams provide fast feedback on system condition with a prioritised listing of corrective action to maintain uninterrupted operation of each conveyor Belt conveyors are the most energy efficient means of moving materials. Proper free-running of the system ensures that energy consumption is as low as possible. Product enhancements that reduce already low resistances receive high priority at Dunlop. Such enhancements include reduction of belt mass through use of high strength low mass reinforcement, and low rolling resistance rubber formulations that also have high wear life.
www.rema-tiptop.co.za www.dunlopbelting.com
BULK HANDLING TODAY
July 2018
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MINING
Unlocking Latent Mineral Wealth Privately-owned Mauritanian mining and exploration company Suricate Minerals is engaging with international financial and technical service partners to develop its quartz, barite, lithium, copper and gold prospects located throughout the country.
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uricate executive director, Ahmed Hertani, who has extensive business experience in Europe and Africa, says that while the company is still in the early stages of developing its prospects, it has already undertaken considerable geophysical and geochemistry testing at its various sites, with positive results verified by German materials testing and analysis company, Dorfner Anzaplan. Suricate plans to start mining at its high-purity quartz deposits in Tasiast, in north-west Mauritania, about 130km from the Port of Nouadhibou, containing around 99% silicon, before the end of 2018. The company envisages that the project will produce both quartz lumps and sands. “This high-purity quartz is well-suited to the production of photovoltaic- and electronic-grade silica, as well as for quartz engineering slabs and silicone metals, and many others industrial applications, all of which are vitally important elements for environment-friendly renewable energy technologies, Ahmed explains.
As the project has substantial potential to be a lowcost producer, this ideally places the project to take advantage of rising demand, particularly from the Chinese market Lithium
These deposits also have considerable pegmatite reserves, which contain ultra-high purity quartz and rare earth minerals. Pegmatite is also the primary source of lithium, either as spodumene, lithiophilite or lepidolite.
in north-west Mauritania containing an alkaline intrusion with large mafic and ultramafic rocks, which are indicators of metals including copper, wolframite, molybdenum, tin and gold.
Diversified metals
“We are very excited about this discovery, as the medium-to-long term forecast for these diversified metals remains strong. As the project has substantial potential to be a low-cost producer, this ideally places the project to take advantage of rising demand, particularly from the Chinese market.” Furthermore, the mine contains a large hydrothermal deposit of pure barite. This is significant, as the resources of the largest producers of barite worldwide, namely China and India, are being depleted rapidly. The analysis of rock collected on surface indicates a barium sulphate content of 78.9%. This surface barite is enriched with silica, comparable in quality to the Bou Ouzzal deposit in neighbouring Morocco, which is the third-largest exporter of barite in the world, producing around a million tons a year.
An anomaly
Moreover, Ahmed highlights that the company is continuing exploration on another deposit in the north of the country that contains a felsic-alkaline intrusion. Geochemistry work on the deposit has uncovered a large gold anomaly. “It is certainly a good target for exploration for a high-grade gold deposit that, according to our initial studies, could be fairly large,” he notes.
Suricate is optimistic about the prospects for the lithium sector, as plug-in hybrid electric vehicles and all-electric vehicles currently use lithium-ion batteries. This is bolstered further by technology giants Tesla’s $5 billion Gigafactory in Nevada in the US, which aims to meet the needs of lithiumion battery packs for emerging energy-storage technology trends.
Straddling the Arab Maghreb and Western SubSaharan Africa, Mauritania’s massive mineral resource wealth makes it an attractive prospect for resource investors. According to geological survey organisation USGS, Mauritania is an established producer of crude oil, copper, gold, and iron ore. As recently as 2013, Mauritania was reportedly the second-largest exporter and producer of iron ore in Africa after South Africa.
Ahmed adds that the company has another permit
Suricate Minerals, www.suricateminerals.com
BULK HANDLING TODAY
July 2018
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CONVEYING
CLIPS and CLEANERS “Bulk Handling Today” set off to Spartan, Johannesburg to meet with Benjamin Sibanda, the General Manager of Mato. Benjamin was appointed as GM in 2015 and understands the in’s and out’s of the business intimately as he worked his way up from a sales administrator answering phones and preparing quotes etc, to his current position.
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Benjamin Sibanda, GM of Mato he management of Mato reports into the Multotec group, a well-known above ground minerals processing and beneficiation the only manufacturers in Africa and in fact have concern. In fact, it was their specialisation in the only Mato clip manufacturing machine outside all things minerals that first made the retired CEO of Germany. We dominate the industry with signifiand ex-Chairman, EJ Holtz, reluctant to take on cant market share. You might find some product Mato’s business of supplying clips for mechanical here and there from the US and France with the splicing of textile conveyor belting. odd box or two from China.” But he was finally persuaded by a business coun- Mato supplies direct with the exception of KZN terpart in the then Rhodesia to take over the busi- where Benjamin tells us they have formed a relaness, as it had grown too large for him to handle. tionship with Inmins Conway Johnson to look after Consignment stock was duly sent out from Germany the region including their largest client in the area, and Mato South Africa sprang into life. Zululand Anthracite Colliery.
To this day, we are the only manufacturers in Africa and in fact have the only Mato clip manufacturing machine outside of Germany All went well for a while but skip a few years and Mato’s biggest client, Sasol, let it be known that they no longer wished to import and would place their orders in future with the first local concern to manufacture on home ground. Mato obliged and a clip machine, which later came to be known as the ‘green monster’, was installed. “At that time, Sasol represented around 85 percent of our business and they remains a major consumer of around 50 to 55 percent of our stock currently,” Benjamin explains. “We still retain the majority of Sasol’s business and haven’t lost ground here but have expanded our net to include many other customers. To this day, we are
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BULK HANDLING TODAY
July 2018
Quality
With belt clips as their main line, the company supplies all the accessories for the lacing systems including clamps, cutters, skiving machines, grips and wire rope winches. Mato lays claim to having the only belt clamp certified in the world to 3X the rated capacity and, with the upgraded belt grip,
CONVEYING
monster’. “Having worked like mad for over 28 years, our clip machine was behaving badly to say the least. So we put in a two-shift system to ensure supply and imported some stock from Germany. The monster was dismantled and sent off to Germany for a comprehensive overhaul,” he adds. thet are to export to six other countries around the world. Although clips are primarily sent out to maintenance crews on the mines, the company does undertake some splicing on their premises if specialised work has to be undertaken such as on very long, thick or very thin belts. Says Benjamin, “When it comes to these jobs, it’s best they are carried out here as, together, we have extensive experience on these out-of-theordinary tasks.”
Reliability
This experience was also called upon when it came time to do a major refurbishment of the ‘green
“Hydraulics, pneumatics, electrical, digital electronics and an upgrade from a 180 to a 360 ton press now allows us to manufacture a clip in 14 seconds and enables us to do the whole range from 5 to 20mm, if necessary. Most significantly, one of our technicians, Tebogo Motene, led the team in Germany where he spent a good few weeks assisting with the refurb. Tebogo has since received his mechanical engineering diploma through Unisa and we certainly have big respect for this gent.” With their product tried and tested in coal, Mato has sold the lacing system to Debswana Orapa for breakdown purposes and to mines in the DRC but the intention is to enter other markets. In addition, the company is focusing on its belt cleaner range, having recently appointed a sales engineer to drive this business as it sees potential in plant applications.
Conveyor belt cleaners/scrapers
Their primary cleaner is a 100 percent locally manufactured with a solid blade and a spring tensioning system so it is constantly in contact with the belt. 75 percent of the carryback is removed. The secondary cleaners have been designed by a sister company in Australia with a slide on M-track system. A feature of this product is the fact that if a blade needs to be changed, the end stop is simply removed, the blade knocked out and a replacement blade installed quickly and easily. Diagonal cleaners complete the line-up. There is much afoot at Mato as there is for Benjamin. He concludes, “Mato has been very good to me. Maybe I should thank my lucky stars that my parents made it clear that I was on my own when I dropped out of studying electrical engineering which was not for me. “A business coach within Multotec mapped out a career plan for me and with Multotec’s development plan, I have completed various management and leadership development courses at Gibs, and at Wits Business school and through our own regular leadership forums. I see only good things ahead.” Multotec Benjamin Sibanda Tel (011) 928-4163, Email: benjamin@multotec.com, www.multotec.com, www.mato.de Machine Operator, Jeremia Moshabane, has been with the company over 40 years and is particularly proud of the good marks he achieved while undergoing training in the UK and Germany
BULK HANDLING TODAY
July 2018
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UNIQUE STRATEGY to Control Dust Emissions A global conveyor technology company has helped mitigate dust emissions at the underground limestone mine of a cement production plant by implementing an innovative transfer point solution.
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sing a specially-designed dust control unit (DCU) to spray a surfactant onto both sides of the cargo stream during transfer onto the main conveyor, Martin Engineering was able to help Continental Cement Company, LLC, suppress fugitive dust both along the underground belt path and during discharge at the outdoor storage yard. The result is a significant reduction in dust emissions, creating a safer workplace and offering a measurable return on investment.
To control costs, the VFD-driven pump regulates chemical flow by releasing chemical only when material is detected on the conveyors Efficient process
Continental Cement has been in operation since 1903. Over more than a century, the company has continued to improve and increase operations to reach a current cement production capacity of 1.2 million short tons of clinker annually. A 106m underground mine now provides the primary source of limestone, which makes up 75% of the raw material required to produce the meal in the company’s Type I/II, and Type III Portland cement. Yielding 1.6 million short tons of limestone annually, the extracted material is transported via truck and high-speed conveyors in order to move it to the surface, where it is held in a 100 000 ton outdoor storage pile, then processed through a four-stage preheater/precalciner dry process cement kiln.
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BULK HANDLING TODAY
July 2018
Fifty-ton trucks dump 544-589 mt/h of extracted limestone into an underground hopper that feeds an impact crusher, which reduces the rocks to 101mm minus. The aggregate is then loaded onto Conveyor 0, a 1 524 mm wide belt traveling approximately 3.5m/s for 122 m. The rock is discharged through a transfer chute onto Conveyor 1, travelling up the 400m inclined belt to the surface and dropping 6m onto the outdoor storage pile. “The two main areas we identified as having unacceptable dust emissions were at the underground crusher hopper and outdoors where the material was discharged onto the stockpile,” explains environmental manager, Leonard Rosenkrans.
Solutions
The original dust control equipment followed a traditional approach, with a goal of wetting the surface of the cargo. However, operators learned that limestone dust was not being adequately controlled by the water alone. Martin Engineering representatives visited the site with a trailer containing a fully functional Dust Control Unit (DCU), allowing a full demonstration of the unit’s capabilities. Conducting an end-to-end walkthrough of the cargo flow, technicians were able to determine the best course of action. “After inspection, we devised a plan that optimised the dust control at both locations, while using as much common equipment as possible,” says Brian Nance, product engineer at Martin Engineering.
Better work environment
A 6-nozzle cradle-mount system was installed to
CONVEYING
provide serviceability at the Conveyor 1 discharge, and a manifold system was placed to address the issues at the dump pocket. Material monitoring sensors were employed at both locations to ensure application only when needed. The pumps in the DCU are powered by variable frequency drive (VFD), allowing independent control over the flow of water and chemicals for each pump. The proprietary Martin MEL-101 chemical binder additive is dosed at the proper ratio to suit the operating conditions. The entire system is integrated with the plant’s control system, so that it can be monitored remotely. With an approximate 300:1 water-to-additive ratio, the MEL-101 supports the water’s role in providing dust suppression using economically concentrated volumes. To control costs, the VFD-driven pump regulates chemical flow by releasing chemical only when material is detected on the conveyors. Nozzles were placed at the hopper mouth, so the DCU could spray treated moisture inward toward the impact zone. By keeping the particles within the material flow, the new dust control system helps minimise health and safety issues, reduces wear and tear on equipment and creates a better work environment.
Results
After some fine-tuning to obtain the optimal chemical-to-water ratio, as well as proper sprayer placement for best coverage of the cargo flow, the system has eliminated most visual signs of dust emissions and has drastically improved air quality in and out of the mine. “It’s almost like a light switch,” says Brian. “Turn the DCU on and the dust is no longer present at either of the emission points. Turn it off and within a few minutes, the dust returns.”
There are 22 employees on the mine. The cost of cement industry dust to society and workers has been studied in depth by the EPA to justify dust regulations. The cost of the installation was about $50 000 and the annual maintenance and chemical costs are about $35 000 per year. The 5 year Net Present Value (NPV) of the costs plus the investment is about $200 000. Using the data from the EPA report, the benefit to society created by Continental from being proactive in the mine is about $375 000.
The right thing
The intuitive decision to be proactive in protecting the workers and surrounding neighborhoods was a wise choice. There are many ways to look at the direct benefit to the company, including reduced health and safety issues as well as increased equipment life. Sometimes it just pays to do the right thing.
The system has eliminated most visual signs of dust emissions and has drastically improved air quality in and out of the mine “The Martin team has gone above and beyond to make sure everything is operational and efficient,” Brian concludes. “We are currently considering a service contract for the new dust system, and potentially including the company’s onsite belt cleaner blade replacement service as well. From our first encounter, we’ve had a positive experience throughout the entire process and we’re very satisfied with the result.”
Martin Engineering Email: info@martin-eng.com, www.martin-eng.com
BULK HANDLING TODAY
July 2018
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“THE LINK FOR AFRICAN TRADING”
TRANSNET FREIGHT RAIL
www.transnetfreightrail-tfr.net
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
LIFTING
SAFER AND MORE EFFICIENT Osborn product development manager Andre van Tonder says, “When our customers asked us to investigate alternative ways to lift jaw crusher liners in and out of our machines, we listened and responded. After detailed investigations, and having conducted on-site tests, we are rolling out liner lifting features that cater for specific customer requirements,” he explains.
Vinesh Surajlall, sales and marketing director
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sborn’s designs use standard lifting equipment, not special lifting tools, which have been thoroughly evaluated on several mines and quarries.
This innovation will deliver exceptional benefits to customers. Andre elaborates, “With our new jaw crusher liner lifting points, there is no need for customers to employ special lifting devices that require additional certification. There is no need to weld lifting lugs onto the manganese liners. We have also eliminated the need for coded welders and non-destructive tests on welds.
"Our enhanced manganese liners will save our customers time and money. They will optimise safety and efficiency in lifting liners in and out of machines,” he concludes.
Osborn Engineered Products, Tel: (011) 820-7600 www.osborn.co.za, www.astecindustries.com
Quick change-out
“The primary advantage for end users is the quicker changeout of liners, which means less downtime,” he stresses. Osborn’s new liner lifting points have been designed and evaluated by the company’s professionally registered engineers. Andre notes that a minimum safety factor of five was applied to all designs. The points allow for the use of standard D-shackles for lifting. Older crushers only require minimum on-site rework to allow for the hooking of liners without moving them.
The points allow for the use of standard D-shackles for lifting BULK HANDLING TODAY
July 2018
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TRANSPORTATION
Theft, Fraud, Corruption Up to Second Place The Allianz Risk Barometer 2018 reveals that business interruption is a top concern for the transportation industry with 37% of responses from a record 1 911 risk experts from 80 countries.
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AGCS Africa CEO, Thusang Mahlangu
heft, fraud, corruption with 32% of responses is in at no.2, up from no.3 in 2017. Cyber incidents (29%) and natural catastrophes (25%) are new emerging threats. Changes in legislation and regulation are at 24%(no.5) and have moved down from no.4 in 2017. The interruption of business operations by various factors such as fire and natural disasters, has a tremendous effect on revenue in transportation. In South Africa, this is often caused by high road and rail accidents.
If hackers were able to take control of a large container ship on a strategically important route they could block transits for a long period of time, causing significant economic damage
If hackers were able to take control of a large container ship on a strategically important route they could block transits for a long period of time, causing significant economic damage
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South African roads are known to be high risk, especially over the festive and holiday periods. Although the 2017/2018 festive period deaths toll figures have decreased by 11% to 1527, the number is still very high, consequentially making the roads unsafe and transportation very risky. The complexity of ‘getting back to business’, is often underestimated by companies, and bottlenecks can also affect their emergency plans.
Rail networks
The Railway Safety Regulator that is heavily involved in investigating rail accidents reports that a majority of their accidents emerge from collisions and derailments. The regulator also points to the accidents as consequences of operational risks such as human error and disruption of operations but
TRANSPORTATION nonetheless cost the operator millions of Rands in operational losses. Vandalism has also become a common problem in the rail and road networks. The maritime sector is no exception to risks associated with the disruption of operations. Last year saw a further decrease in the number of piracy incidents recorded as only 191 incidents were reported globally, down from 246 in 2015. This is the lowest total recorded since 1998, and reflects the successful measures taken to contain the threat of Somali pirates in the Gulf of Aden and the Indian Ocean. However, other risk challenges remain, such as the rise in crew kidnappings in parts of West Africa.
Hijacking a ship
Theft, fraud, corruption is a huge challenge across many sectors, however due to the large amounts of money circulating in transportation it makes it more susceptible to this risk. The threat of cyber-attacks continues to be significant. Most attacks to date have been aimed at breaching corporate security rather than taking control of a vessel. “The shipping sector doesn’t have a particularly heightened risk awareness when it comes to cyber. As no major incident due to a cyber-attack has taken place yet, many in the industry are still complacent about the risks,” says Captain Rahul Khanna, Head of Marine Risk Consulting at AGCS. As many as 80 percent of offshore security breaches are estimated to be down to human error. “IT secu-
rity should not be put on the backburner. If hackers were able to take control of a large container ship on a strategically important route they could block transits for a long period of time, causing significant economic damage.”
Costing millions
In South Africa, changes in legislation and regulation may cause uncertainty for many industries particularly the airline industry that is comparatively the most regulated. The airline industry contributes over R150 billion towards the South African economy. A slight discontinuation of cargo flights due to non-compliance could cost the sector millions in a few hours. Such interruptions may also translate to increased costs of food in the same way that increased fuel levies and road tolls impact the cost of goods and services. “Modern supply chains and multimodal distribution pose truly global challenges. It is important for businesses in transportation to have operational risk management support through risk consulting network, advice on worldwide infrastructure transport logistics (including delay in start-up), engineering, supply chain and logistics risk, as well as cargo security, packaging and industry best practices as part of their risk management plan,” concludes AGCS Africa CEO, Thusang Mahlangu. Allianz, Lesiba Sethoga, Tel: (011) 214-7948 Email: lesiba.sethoga@allianz.com
voith.com
Your service and solution Driveline expertise Our products and services include: • TurboBelt Drive Package • TurboBelt Controller with Intelligent Logic
• •
Onsite Service and Maintenance Condition Monitoring
Join us at Electra Mining Africa 2018, Hall 6, Stand F06
BULK HANDLING TODAY
July 2018
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THESE BRANDS SUPPORT RESPONSIBLE RECYCLING OF USED OIL
Support brands that care for the environment Use ROSE approved collectors and recyclers to dispose of your used oil. 021 448 7492 • usedoil@iafrica.com • www.rosefoundation.org.za
TRENCHLESS
Hydro-transportation Solutions Hydro-transportation is becoming an increasingly important consideration for the mining industry which is under ever greater pressure to conserve the environment. When solids are carried in a closed pipe, environmental concerns such as dust, spillage and noise are eliminated.
I
n addition, hydro-transportation, which is now being widely used throughout the world, is proving to be more cost-effective than other bulk transportation systems such as conveyor belts, long haul road or rail transportation. “An important factor here is that hydro-transportation pipelines require less maintenance than comparable bulk transportation systems,” says Aegion SA General Manager, Johann Scholtz.
The specialised wear-resistant polymer provides excellent flow characteristics that in some cases improve the overall system performance. This factor releases significant savings when hydro-transporting over extended distances.
Much of Africa is chronically short of water. Hydrotransportation also presents a viable alternative to conventional tailings deposition. “In arid water-scarce regions, the pumping of ‘paste’ tailings cuts water usage and losses dramatically,” Johann adds.
“At Aegion SA, we are fortunate to be able to tap into this experience and expertise,” says Johann, adding that the company is also cooperating with South African consulting engineers and globallyrenowned hydro-transportation specialists.
Proving to be more cost-effective than other bulk transportation systems such as conveyor belts, long haul road or rail transportation
The transportation of corrosive or abrasive slurry materials in the oil, gas, mining, industrial and municipal markets will lead to rapid failure if the correct solution is not implemented from the outset.
In Southern Africa currently, Aegion South Africa has been supplying hydro-transportation solutions to several of the major mining houses in South Africa, Zimbabwe and Zambia, and the company completed hydro-transportation projects for a number of Southern African platinum, gold and copper mines. Aegion’s proprietary pipeline technology the Tite Liner system – as well as its Steel Polypipe spool solution – are used in both new and rehabilitation solutions for hydro-transportation.
Rehabilitation
Complete replacement of pipelines is costly and time-consuming, but Aegion sister company United Pipeline Systems developed and provides the world’s leading in-situ polyethylene pipe lining systems for the rehabilitation of existing installations. This solution has proven to be a major improvement over replacement options, especially in pipelines that are in a poor condition.
Aegion South African shareholder, Robor’s Pipe Systems division, manufactures and supplies a range of steel pipe and customised conveyance pipe solutions and products.
Twenty years
The HDPE-lined steel polypipe system combines the inherent strength of steel with the visco-elastic properties of HDPE to deliver high-pressure capability, structural integrity, resistance to mechanical damage and chemical and abrasion resistance, properties well suited for use in hydro-transportation projects for more than 20 years. Mining the world over is under pressure as the grades of available new orebody discoveries decline. The answer is in larger volume mining and more effective and economical minerals processing. “Africa is the world’s last relatively unexplored mining frontier, and we look forward to providing our advanced and cost-effective hydro-transportation solutions to both new and existing mining operations,” Johann concludes. Aegion SA www.aegion.com
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Mobile Bulk Material Handling Solutions 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 accompanied by an outstanding support network. Our sales and aftermarket teams are trained to provide customers with outstanding stockpiling solutions accompanied 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% Distribution and Product Support by:
BUILT TO LAST
Website: www.elbequipment.co.za
nt.com
ELB EQUIPMENT - HEAD OFFICE:
14 Atlas Road, Anderbolt, Boksburg • Tel: +27 (0)11 306 0700• Fax: +27(0)918 7208 • e-mail: Elb@elbquip.co.za
BRANCHES & DEALERS – SOUTH AFRICA:
BRITS: +27 (0)12 250 1565 • CAPE TOWN: +27 (0)21 933 2383 • DURBAN: +27 (0)31 464 6522 • EAST LONDON: +27 (0)31 464 6522 • GEORGE: +27 (0)21 933 2383 • KIMBERLEY: +27 (0)53 841 0040 • MIDDELBURG: +27 (0)13 246 2312 • POLOKWANE: +27 (0)11 306 0700
SUBSIDIARY: ELB EAST AFRICA: NAIROBI, KENYA: +254 (0)20 807 0728
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BOTSWANA: +267 (0)390 9972 • LESOTHO: +266 (0)28 313 926 • MOZAMBIQUE: +268 (0)76 022 8488 • NAMIBIA: +26 (0)46 123 4052 • SWAZILAND: +268 (0)518 5348 / 518 5602 • ZAMBIA: +26 (0)21 221 0642 • ZIMBABWE: +263 (0)77 236 2596
INTEGRATED SOLUTIONS PROVIDER Cavex DMS hydrocyclone
Warman MCR slurry pump
ENDTO-END SOLUTIONS Visitors to this year’s Electra Mining Africa exhibition at Nasrec will be in for a feast of technology at the Weir Minerals Africa stand; particularly hard to miss will be their 7 metre high crushing station featuring a high performance Trio cone crusher.
“
We are reminding visitors and customers that Weir Minerals Africa – well known for our pump technology, has transformed into an integrated solutions provider in minerals processing,” says Hoosen Essack, Process Manager at Weir Minerals Africa. “With our extensive footprint across Africa, we are adding even more value through this growing range of offerings. Underpinning our service levels is our process expertise that equips us to partner closely with customers in finding answers to their daily challenges.”
Staffed with experts who work closely with customers on efficiency and other issues, whether on a particular item of equipment or an entire comminution circuit Skilled input
Among the other items on display will be a large Cavex hydrocyclone with a substantial 1 500 mm diameter and weighing five tonnes. With the company’s leading position in pumping equipment, the stand will also display the impressive Waman 450MCR pump, measuring 2,5 metres in diameter. Hoosen highlights the strategic importance of the company’s process department, which is staffed
with experts who work closely with customers on efficiency and other issues, whether on a particular item of equipment or an entire comminution circuit. “This capacity allows us to provide enhanced support to customers on their plants, taking our role well beyond just supplying product,” he says. “This centralised team of experts are available to all of our branches, so customers can always be assured of skilled input on challenging problems and equipment choices.”
Experience and focus
He emphasises the value of specialised tools employed by Weir Minerals, such as the JKSimMet software to simulate comminution and classification circuits, in helping customers select the appropriate solutions for their mineral processing plants. “To consolidate our continuous improvement efforts and stay at the leading edge of the technology curve, research and development is a strong focus for us,” he says. “Weir Minerals, as a leading global player also has centres of excellence around the world each focusing on a particular field. While South Africa focuses on screen performance, for instance, the United States focuses on comminution equipment and centrifugal pumps.” Weir Minerals Africa Rajen Govender, Tel: (011) 929-2701 Email: rajen.govender@mail.weir, www.minerals.weir
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The Local Manufacturing Expo Aims to:
21 – 23 MAY 2019
Promote local manufacturing
EXPO CENTRE, NASREC,
Demonstrate Southern Africa’s export potential
JOHANNESBURG, SOUTH AFRICA
Provide access to global markets
A Showcase of Southern Africa’s Manufacturing Capabilities Who Will Exhibit?
Networking opportunities Develop public / private partnerships Public / private sector collaborations Identify industry challenges and opportunities for growth
Manufacturers across a variety of sectors, including:
Agriprocessing
Automotive
Business Process Outsourcing
Capital Equipment
Chemicals
Construction
Engineering
Food and Beverage
Furniture
ICT and Electronics
Metals
Mining
Plastics
Textiles/ Clothing/ Footwear
Transport
www.localmanufacturingexpo.co.za In association with:
Endorsed by:
Implemented by:
Brought to you by:
SAFETY
Proximity Detection Systems Becker Mining South Africa has provided turnkey proximity detection systems (PDS), tagging and tracking and related communication systems, which comply with stringent mining health and safety regulations, for nearly 20 years.
“
The company’s latest patented tri-technology PDS solutions which range from a simple, lowcost single technology system, to integrated multi-technological solutions, encompass all aspects of the most advanced mining communications and technology,” states Andrew Trentelman, senior general manager: Electronics, Becker Mining South Africa.
ous alert mechanisms for operators. These include cabin lighting and alert tones which are selected to suit exact requirements. This system consists of a customisable caution zone, warning zone and critical zone. Detection zone threshold distances are set according to specific requirements, covering small and large vehicles. The company’s advanced solutions prevent electromagnetic interference, by transmitting data packets across the generated H field. Data received is recognised as a system tag and not an environmentally generated signal that could cause unnecessary warnings. The tri-technology tag, which supports accident investigation and multi mode operation, is compatible with Becker’s tagging systems and communications networks. This tri-axis electromagnetic receiver ensures reliable detection by the system, regardless of the tag or miners’ position. Vehicle tags are self-powered RF devices that ensure the presence of a vehicle continues to be broadcast, even if the ignition has been turned off or the battery has been isolated. Control tags transmit specific commands to PDS controllers and miner tags, also providing alerts when entering a restricted or hazardous area.
“Our patented tri-technology point of detection system is the only system available globally that combines three technologies: UHF, Radar and Electromagnetic, into one scalable system.”
Data received is recognised as a system tag and not an environmentally generated signal that could cause unnecessary warnings Bi-directional notification and early warning messaging alerts vehicle operators and personnel to the presence of each other and to stationary or moving vehicles in close proximity, enhancing safety in arduous conditions.
Alert mechanisms
The latest PDS controller, which is the interface between the vehicle operator and multiple detection sensors mounted around the vehicle, provides vari-
Immediate warning
Advanced self-diagnostic functionality provides continuous monitoring of all peripherals connected to the system, to ensure equipment is functioning correctly. The operator is immediately warned if a device stops responding to the PDS controller. High performance, fit for purpose solutions for underground and surface mining installations include Leaky Feeder, Wi-Fi, tagging and tracking, as well as environmental monitoring PDS solutions. In addition to communications solutions, the company offers IS and flameproof underground electrical reticulation products, as well as fluid transfer, rigging and rope attachment systems. An important feature of these systems is they are designed to facilitate future upgrades. Becker Mining South Africa, Andrew Trentelman Tel: (011) 617-6300 Email: info@za.becker-mining.com www.za.becker-mining.com
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LIFTING
Belgium Port Worker Training Centre The Belgium port worker training centre Ocha recently received a new Liebherr mobile harbour crane type LHM 120. The machine will be used for practice-based training of crane operators.
L
ocated in the heart of the Port of Antwerp, Ocha offers various training options for port workers, specialising in practical crane training. Crane operators can hone their driving skills in a realistic environment and get down to business with state-of-the-art material. Ocha has been established by Cepa, a cooperative organisation of private port operators. The first crane Liebherr provided to Ocha was a fixed cargo crane FCC 230, which was delivered in 2007, followed by a Liebherr LiSIM simulator in 2015. A major benefit of simulator training is the ability to simulate harsh environmental conditions when required. This allows trainees to gain valuable experience operating under challenging conditions in a safe environment.
Professional knowledge
Earlier this year, Liebherr delivered a new mobile harbour crane type LHM120 to the training centre. The LHM 120 has a maximum lifting capacity of up to 42 tonnes and a maximum outreach of 30 metres. The machine is the smallest machine out of the Liebherr mobile harbour crane product range but it will help Ocha training participants to acquire professional knowledge about the safe handling of a mobile harbour crane. The operators learn how to handle loads and material correctly in order to prevent damages. Manager of the training centre, Ann Baats comments, “The new LHM 120 allows us to combine training in a high-tech simulator with intensive training on the crane. This method of training enhances the learning curve significantly with high returns on productivity, safety and quality for our clients.” Liebherr, www. liebherr.com LHM 120 will be used for training purposes
Liebherr’s maritime Managing Director Sales, Leopold Berthold, did the official handover to the Managing Director of CEPA, Paul Valkeniers
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TRACE In is a glo antio leading party ri
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.
nternational, Inc. obally recognized bribery business organization and provider of third isk management solutions.
Small and Nifty
Martin Conway, international sales manager for EvoQuip and Janita Grobbelaar of ELB Equipment
Distributed by ELB Equipment, the EvoQuip range is part of the Terex brand and extends from 3- to 19-ton screens, complemented by crushers that range from 3.5- to 29-tons. With the emphasis on mobility, the concept is to bring efficient crushing and screening operations to wherever they are needed.
A
ccording to Martin Conway, Terex international sales manager for EvoQuip, the company was established, and machines developed within the space of the last decade making them compliant with emerging trends in numerous industries. “For example, in the existing processing market the trend is for crushing operations to become smaller and operate on a just-in-time (JIT) principal where just enough is produced for immediate needs rather than stockpiling materials for future use. All too often big crushers and screens stand idle waiting for materials with obvious negative cost implications
Less expensive to buy and to operate making many lower-yield types of operations feasible by considerably bringing down operating costs “By comparison the small EvoQuip machines are less expensive to buy and to operate making many lower-yield types of operations feasible by
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considerably bringing down operating costs. That means it can give old operations a new lease of life or may even be feasible to be brought onto quarries to produce saleable products from by-products,” says Martin.
Onsite processing
Perhaps the most exciting opportunity, however, is to take processing plants to customer’s sites. Whether it be processing of rocks at the site of road construction projects, the processing of demolition waste for reuse, or processing of manure, compost, fertilizers or soils for agriculture In addition, the relatively low overall cost of the equipment significantly lowers the entry level into a host of new industries and makes these more feasible for startups to process smaller quantities of materials profitably. Here examples could include waste concrete recycling at precast and readymix concrete yards, processing of illegally dumped building materials on behalf of municipalities, supporting construction operations in remote areas using available resources etc.
PROCESSING EQUIPMENT they can be used to open new avenues of business for hire companies. “Imagine all the land that is wasted underneath piles of building rubble that can be accessed and opened with this type of machinery? Or the types of building projects that can be undertaken in rural areas where dams, mast-footings, roads and other necessary infrastructure can be accessed by 4x4 trucks or even hitched to an excavator and towed to remote sites where the available natural materials can be used - the possibilities are endless,” Martin adds. He concludes that EvoQuip crushers and screens are designed to be rugged and durable enough for overland transportation and tough remote-site operations. A wide range is available for different applications from soft materials to soils and rubble with special apparatus for the removal of rebar and metals. EvoQuip machines comply with rigorous safety and environmental requirements.
Typically, in Europe and elsewhere abroad, EvoQuip’s innovative machines are being used in just this type of application. They have established a foothold among small-scale aggregate producers, recyclers of materials at dumpsites, demolition experts, agricultural co-ops and building contractors who make use of onsite spoils to produce building materials.
Plant hire
Martin continues that they are particularly useful in shared-type applications where a co-op of farmers or rural municipalities may purchase a machine and share it among themselves. This also makes the machines ideal for the plant hire industry where
Imagine all the land that is wasted underneath piles of building rubble that can be accessed and opened with this type of machinery
ELB Equipment Janita Grobbelaar Tel: (011) 306 0700 Email: janitag@elbquip.co.za www.elbequipment.co.za
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Conveying Excellence with High-End Conveyor Belts Every conveyor belt, every climate zone and every topography calls for perfect conveyor belt technology. ContiTech provides knowledge, experience, a globally encompassing and competent network and a broad product range to give your conveyor belt applications a technological lead. More than 140 years of rubber expertise make us a strong partner, enabling our customers to benefit from the synergies within the Continental corporation. We implement innovative conveyor belt technology reliably, sustainably and safely from development to commissioning and after-sales service.
conveying excellence
+27 (0) 11 248 9300 www.contitech.co.za
BELTCON 19
The Influence of Steel Cord Conveyor Belt Dimensions on Indentation Rolling Resistance Performance Figure 0.1: A view of a three dimensional indentation rolling resistance model
Paul Munzenberger
Craig Wheeler
For some time, long conveyors have utilised conveyor belts with low rolling resistance bottom covers; the low rolling resistance cover properties help to lower the conveyor’s overall system resistance which is a key benefit that allows a conveyor designer to modify the conveyor’s specifications to achieve a more profitable design. Low rolling resistance conveyor belts obviously reduce the drive requirements of a given conveyor, as well as the power consumption, but they can also be used to reduce the belt strength requirements, increase the throughput for a given power input or each benefit may be traded off against the others to achieve any particular balance that is required for a proposed design.
M
uch effort has been expended to develop new cover compounds for use in Low rolling resistance conveyor belts. Other ideas like the effects of secondary reinforcements on reducing indentation rolling resistance have also been experimentally investigated, but one area of steel cord conveyor belt design that has not been considered for exploitation to achieve more gains in indentation rolling resistance performance, is the dimensions of the conveyor belt’s elements. To say that no elements of a conveyor belt have been considered is not true: extensive work of both
Figure 0.2: The model from Figure 0.1 shown with strain contours superimposed on the elements Rating:
ST1250
Bottom Cover Compound:
Low Rolling Resistance
Top Cover Compound:
DIN-X
Bottom Cover Thickness:
6.5 mm
Top Cover Thickness:
7.5 mm
Cord Diameter:
4.0 mm
Cord Pitch:
15.0 mm
Table 1: Low rolling resistance conveyor belt details Temperature:
20 °C
Speed:
4 m/s
Idler Diameter:
6” (152 mm)
Belt Sag:
0.50, 0.75, 1.00 and 1.25 %
Belt Load Range:
1.0 – 5.0 kN/m
Table 2: Indentation rolling resistance test parameters
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BELTCON 19
a theoretical and experimental nature has been conducted to determine the effect of bottom cover thickness on indentation rolling resistance and it is widely known that thinner bottom covers are conducive to good indentation rolling resistance performance. However, previous efforts have been limited to determining the influence of the bottom cover’s thickness on indentation rolling resistance as, up until now, no model has existed that could be used to assess the influence of other elements of the conveyor belt; and, experimentally, it is costly to produce the required number of steel cord conveyor belts and the machinery that is large enough to measure the indentation rolling resistance of steel cord conveyor belt is rare.
Figure 0.3: The University of Newcastle’s large indentation rolling resistance test
But, what of the other elements of machine inside its temperature controlled room the conveyor belt? How does a wider cord spacing or thicker steel cords affect indentation rolling The latest indentation rolling resistance model is the three resistance? Or, what influence does the thickness of the top dimensional model, it incorporates many of the features of cover have? the two previous indentation rolling resistance models but A recent advancement in the field of theoretical analysis of adds the third dimension and a new element type known as conveyor belt indentation rolling resistance is the develop- a trilinear brick which is the three dimensional equivalent of ment, by the author, of a true three dimensional finite element the bilinear rectangle. analysis model of the indentation rolling resistance problem that can be used to directly study the effects of the size of various elements of a steel cord conveyor belt. This paper aims to show the results of an investigation into how the indentation rolling resistance is changed by modifying the size and location of individual conveyor belt components.
The three dimensional finite element analysis indentation rolling resistance model
The three dimensional finite element analysis indentation rolling resistance model is the latest iteration of a family of indentation rolling resistance models that begins with Wheeler’s two dimensional model, which was a modified version of the model published by Lynch; Munzenberger further modified Figure 0.4: A comparison of low rolling resistance conveyor belt 0% sag experimental and three dimensional simulation results the method by taking Wheeler’s model and adjusting the viscoelastic calculations so that commercial finite element analysis software could be used to carry out the solving of the model’s stiffness matrix. This change had the advantage of being fast to generate results with efficient commercial solvers, and of being able to view the model’s solution in the software’s post processing environment where the deformed shape could be viewed and other information like contact length and rubber strains could be easily measured. Following on, a new two dimensional indentation rolling resistance model was programmed that was similar to the previous iteration but replaced the poorly performing constant strain triangle finite elements – that were used in all previous models – with the more realistically performing bilinear rectangle element. The new element type improved the accuracy of the indentation rolling resistance predictions but at the expense of longer solution times that were a result of the mathematical complexities of the new element type.
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6.5mm Cord Height 8.5mm Cord Height
10.5mm Cord Height
Figure 0.5: Model cross sections for different cord centre height
BELTCON 19
A view of the three dimensional indentation rolling resistance model is shown in Figure 0.1. The model is shown with twice the calculated deformations applied, which makes the contact area more visible, and with each element shown in its component colours so that the cord and the bottom and top covers are distinguishable. In making use of the commercial finite element analysis software’s post processing environment, the same model is shown in Figure 0.2 with vertical strain contours applied.
A three dimensional indentation rolling resistance simulation is slow to run, and because of this, only the minimum possible amount of conveyor belt is modelled. In Figure 0.1 it can be seen that, while the full thickness of the conveyor belt is modelled, only a section beginning at the cord centre line and finishing at the midpoint of the space between the cords is included. Modelling this small amount of conveyor belt reduces the solution time for one data point of a small conveyor belt model (something like an ST1000) to around eight hours. The length of the model is defined by the user, with longer models being preferred; however, to avoid significant increases to the solution times, only enough of the model is represented to capture the extent of the strained areas introduced by the contact deformations and model lengths of around 120mm are normal. At the beginning of a simulation, each un-deformed element represents a cube with a side length of 0.5mm.
Figure 0.6: Indentation rolling resistance simulation results for different cord centre heights versus vertical load
Two simplifications of the belt model can also be seen in Figure 0.1: it will be noted that the cord insulation rubber is not modelled by a separate group of elements and that the cord cross section is represented by an arrangement of cubes which only approximates the round shape of a cord. There is no insulation rubber represented in the model primarily because there are usually no material properties available for entry into the model; instead, the region of the insulation rubber is divided into two sections with the lower half using the same material properties as the bottom cover rubber while the upper half uses the same material properties as the top cover.
The unusual cross section shape of the cord is necessary to avoid the need for odd shaped rubber elements around the cable, which would require individual mathematical calculations to be programmed for them, and is further justified by the fact that the cords used in conveyor belt do not, in reality, have a round cross section. Further to this, no attempt has been made to bestow the cord elements with similar properties to steel cord, and Figure 0.7: Rearranged indentation rolling resistance simulation results the cord is instead modelled as being made from versus different cord centre heights solid steel; this approximation is reasonable since the cord is not required to be flexible in the model, as the conveyor belt is modelled as always being flat, and the cross sectional properties of an actual cord are not to dissimilar to solid steel in that they are both significantly stiffer than rubber. The three dimensional indentation rolling resistance model can be programmed with any desired cross section (to a tolerance of 0.5mm) and allows the user to specify the cord diameter and pitch, the top and bottom cover thicknesses and also the idler diameter.
Comparison of simulation predictions and experimental results
3.0mm Cord Diameter
4.0mm Cord Diameter
5.0mm Cord Diameter
Figure 0.8: Model cross sections for different cord diameters and constant cord area
The need to prove that the three dimensional indentation rolling resistance model is accurate could be avoided by presenting the various predictions as a percentage change from a reference conveyor belt design; however, this paper will be presenting its predictions in terms of the expected, or absolute, indentation rolling resistance performance of a BULK HANDLING TODAY
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BELTCON 19
conveyor belt manufactured with the same dimensions as the reference model. In order to prove that the presented predictions bear some resemblance to reality, it is necessary to prove that some of the model predictions match a related set of experimental results. Experimental measurements for the indentation rolling resistance of a low rolling resistance conveyor belt were conducted at the University of Newcastle’s large indentation rolling resistance test facility which is shown in Figure 0.3. The relevant belt details and test parameters are given in Table 1 and Table 2 respectively. The indentation rolling resistance test machine uses the belt flex method devised by Spaans (Spaans, 1978) to apply the vertical load (FV) to the test idler and, as such, the measurements that are obtained from the machine are the sum of the test belt’s indentation rolling resistance and its flexure resistance. Since, for the experiment and simulation comparison, only the indentation rolling resistance (FIRR) results are of interest, they must be extracted from the combined results. Separation of indentation rolling resistance and belt flexure measurements can be achieved with the conservative method outlined in Australian Standard AS1334.13 (Conveyor and Elevator Belting Commitee RU-002, 2017), however, for the comparison shown here an alternative method, which yields slightly more accurate results at the expense of a large increase in the amount of experimental and analytical work required (Munzenberger, 2017), was used.
sag while the 2% refers to the strain percentage of the finite element analysis material property inputs and is not related to the 0% value in any way. In Figure 0.4 and throughout this paper, indentation rolling resistance (FIRR) results are presented in a graphical form against the vertical load (FV); the vertical load is simply the force that is applied to the test idler while the indentation rolling resistance result is being measured.
Figure 0.9: Actual area of the conveyor belt model – per metre, marked by the line, and the actual areas achieved for each cord diameter modelled marked by the points. The two vertical axes scales are equivalent and relate to all graphed data
Essentially, what is a rather complex procedure, can be explained as follows: at the required belt speed and loads, belt resistance testing is carried out with the experimental setup adjusted so that the test belt is bent around the test idler by a large, though still realistic, amount; when the measurements are complete the belt flexure angle is reduced and more measurements are taken; this process is repeated until there is a set of measurements taken for four or more belt flexure angles. The belt flexure angles should approach zero degrees, but since testing at zero degrees is impossible – as the test belt tension cannot apply any additional vertical load to the test idler – the indentation rolling resistance results for zero degrees of belt flexure are calculated by extrapolating the measurements, collected at higher belt flexure angles, to zero degrees. In this way, indentation rolling resistance results that are free of any belt flexure resistance are obtained. To complete the comparison of the experimental and simulation results, the test belt dimensions are entered into the three dimensional indentation rolling resistance model and, after several days, a set of predictions are obtained. A comparison of the extrapolated, zero degree belt flexure indentation rolling resistance results (labelled as “0 % Sag”) and the theoretical results (labelled as “FEA 2 %”) are given in Figure 0.4 where it can be seen that there is reasonable agreement between the experimental results and the theoretical predictions. Note that here the 0% refers to the amount of simulated belt
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Figure 0.10: Indentation rolling resistance simulation results for different cord diameters and constant cord area versus vertical load
Figure 0.11: Indentation rolling resistance results versus cord diameters for constant cord area models
BELTCON 19
With the model – and its material properties – shown to be suitably accurate, it can now be used as the reference model for a series of indentation rolling resistance simulations that are designed to show the effects that different sized steel cord conveyor belt elements can have on the indentation rolling resistance performance. The model and results that were just presented will act as the reference model and will be included in every group of results that follows.
Indentation rolling results for conveyor belts with different dimensions
Now that the reliability of the three dimensional model is
confirmed, it becomes possible to use it to make indentation rolling resistance predictions for conveyor belts manufactured using the same materials but with different element dimensions. In the following, indentation rolling resistance results for new models that are based on the reference model – presented in the previous section, but with modified dimensions, will be presented. Each model uses the same material properties as the reference model and simulates the same test conditions as listed in Table 2. For each element variation, a series of model cross sections will be shown that are intended to depict the dimension changes that are being modelled; the indentation rolling resistance results will then be given in two graphical forms: one being the results from the simulation and the second being the same set of results rearranged to clearly show the effect of the dimensional change on indentation rolling resistance predictions.
Cord height
4.0 mm Cord Pitch
11.0 mm Cord Pitch 19.0 mm Cord Pitch
Figure 0.12: Model cross sections for different cord pitches
The first dimension that was studied for its effects on indentation rolling resistance was the position of the steel cord within the belt. Figure 0.5 shows how the finite element analysis model was varied to predict the effects of cord position; as shown by the three models, the cord position is modified while the overall model thickness is kept constant. This series of models acts similarly to models with changing bottom cover thickness, however, this is investigated later and only changing the cover thickness results in a thinner model. Here, the only dimension that is modified is the vertical location of the cord within the model hence the “cord centre height” labels rather than any reference to the cover thickness. The simulation results are shown in Figure 0.6 and are rearranged in Figure 0.7 to show the effect of the cord centre height dimension change more clearly. Unsurprisingly, the results given in Figure 0.7 show the predicted indentation rolling resistance is proportional to the vertical position of the cord, as is the thickness of the bottom cover which is probably responsible for a large part of the increase. The middle model shown in Figure 0.5 is the reference model that was used to produce the simulation results for the comparison in the previous section.
Cord diameter Figure 0.13: Indentation rolling resistance simulation results for different cord pitches versus vertical load
Figure 0.14: Indentation rolling resistance results versus different cord pitch
In this series of simulations, the effect of different cord diameters on indentation rolling resistance predictions was investigated. Figure 0.8 shows the series of models used to study different cord diameters; the models show that the cord diameter is changing from left to right but they also show that the models are getting wider as the cord diameter increases. The increased model width is replicating the increasing cord pitch that would be needed to maintain the same belt strength, or cord area – based on the circular area rather than the modelled area – when using different diameter cords. Due to the resolution of the finite element analysis model, the desired model pitch to cord diameter ratio could not be maintained exactly and Figure 0.9 shows the per-metre width area achieved for each cord diameter investigated against the actual cord area of the original model. Although there is some error in the model dimensions they are considered to be adequate for their intended purpose. BULK HANDLING TODAY
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BELTCON 19 Figure 0.10 shows the simulation results and Figure 0.11 gives the same results to make the effect of different cord dimensions on indentation rolling resistance predictions clear. The results predict that indentation rolling resistance will rise for conveyor belts that use fewer large diameter cords to achieve their strength rating. This is possibly caused by the ability of the wider section of rubber between the thicker cables to deform more for a given load than the narrow section of rubber between the more numerous smaller diameter cables, thus allowing more rubber to become active in the generation of indentation rolling resistance.
return belt of a belt conveyor but rather the effect of the top cover thickness on the indentation rolling resistance of the conveyor belt in its upright orientation, rolling on its bottom cover. The simulation results are shown in Figure 0.19 and are rearranged in Figure 0.20 to more clearly show the effect of top cover thickness on indentation rolling resistance. The predictions show that for top cover thicknesses in the normal range above 5mm there should be little difference in indenta-
Cord pitch Some of the models used to study the effect of cord pitch on indentation rolling resistance are shown in Figure 0.12. Cord pitches from the minimum possible pitch – with the cords touching each other – up to 19mm were investigated. The simulations are similar to the models used to study the cord diameter, however, here, only the pitch is varied while the cord diameter is held constant so the strength of the conveyor belt being modelled is inversely proportional to the cord pitch. The indentation rolling resistance simulation results for the varying cord pitches are given in Figure 0.13 and the rearranged predictions are shown in Figure 0.14. The results here are similar to those in Figure 0.11 and predict that for larger cord pitches the indentation rolling resistance will rise.
Bottom cover thickness
Some of the models used to investigate the effects of bottom cover thickness on indentation rolling resistance are shown in Figure 0.15; the models show that as the bottom cover thickness is modified no other dimensions are changed, resulting in the overall model thickness changing by the same amount as the cover thickness. The bottom cover thickness indentation rolling resistance simulation results are shown in Figure 0.16, and Figure 0.17 shows the rearranged results which presents the effect of different bottom cover thicknesses more clearly. As with the results from Figure 0.7, the predictions are proportional to the cover thickness but here the trend is stronger, most likely due to the overall thickness of the belt model changing as well. The simulation showed that for a bottom cover thickness of 0mm there would be zero indentation rolling resistance regardless of the applied load: this result was expected as the entire load is carried through the cord part of the model which has no viscoelastic properties. The data for the 0.5mm and 1.0mm bottom cover thicknesses is incomplete because of inaccurate predictions that were caused by the lack of element layers between the cord and the bottom of the model which led to large strain gradients in those elements and, from there, a failure of the solution to converge.
0.0mm Bottom Cover
4.5mm Bottom Cover
8.5mm Bottom Cover
Figure 0.15: Model cross sections for different bottom cover thicknesses
Figure 0.16 Indentation rolling resistance predictions for different bottom cover thicknesses versus vertical load
Top cover thickness The final set of indentation rolling resistance simulation models is shown in Figure 0.18. They were used to study the effect of different top cover thicknesses on indentation rolling resistance. Care must be taken here to note that the effect of different top cover thicknesses does not refer to the indentation rolling resistance performance of the conveyor belt if its orientation was inverted – as it could be on the
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Figure 0.17: Indentation rolling resistance results versus different bottom cover thickness
BELTCON 19 tion rolling resistance performance; while at lower thicknesses the indentation rolling resistance can be expected to rise. The rise in the indentation rolling resistance of thin top covers seems to stem from the lack of sufficient top cover material to stabilize the rubber in the areas between the cords thus permitting more movement there. Unlike what was experienced with the bottom cover thickness simulations, these models experienced no difficulties with thin top covers as this section of the model is an area of low strain and small numbers of elements could easily cope with the small strain gradients found there.
Conclusion
0.0mm Top Cover
5.5mm Top Cover
9.5mm Top Cover
Figure 0.18: Model cross sections for different top cover thicknesses
A true three dimensional indentation rolling resistance model for the prediction of conveyor belt indentation rolling resistance has been produced and has been shown to make good predictions by way of comparison with experimental results. The model has then been used to show the effect that each element of a steel cord conveyor belt has on its indentation rolling resistance performance. The predictions shown agree with the previously proven property that thinner conveyor belt bottom covers tend to improve indentation rolling resistance properties but they have also shown that the size of the gap between the steel cords is an important consideration when designing low rolling resistance conveyor belts.
Figure 0.19: Indentation rolling resistance simulation results for different top cover thicknesses versus vertical load
The three dimensional model has also predicted that the top cover has an influence on the indentation rolling resistance of the conveyor belt (which is rolling on its bottom cover) with thinner top covers predicted to increase the overall indentation rolling resistance performance. Hopefully in the future, conveyor belt designers will be able to take this information, build upon it, and create a new generation of low rolling resistance conveyor belts based not only on high performance rubbers but also by incorporating smart design as well.
This paper was first presented at the Beltcon Conference in 2017. Copyright is vested with IMHC. www.beltcon.org.za Paul Munzenberger University of Newcastle, Australia Email: Paul.Munzenberger@newcastle.edu.au Craig Wheeler University of Newcastle, Australia Email: Craig.Wheeler@newcastle.edu.au Figure 0.20: Indentation rolling resistance results versus different top cover thicknesses
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MARKET FORUM
rubber crawler track impresses technological properties result in a longer overall service life. Armorlug technology makes the tracks last up to 23 percent longer than comparable lugs, for example.
The technology company Continental was honoured with a total of eight prizes for its innovative products at the recent German Innovation Awards. The Trackman XP rubber crawler track impressed the panel with its innovative properties and user benefits.
Special anti-vibration technology combined with optimised tread design reduces vibrations by as much as 70 percent compared with conventional tracks, therefore enhancing ride comfort, particularly for applications with a high tractive force. Special additional
Rubber crawler tracks with integrated sensor technology also feature among the company’s future technological innovations. This technology measures and monitors the temperature of the carcass when the vehicle is in operation. Targeted monitoring helps operators of agricultural vehicles, for example, to improve the service life and efficiency of the components and Trackman XP rubber track costs. to avoid crawler breakdown www.contitech.de
Mine Winder Manufacture So well regarded is Parnis Manufacturing’s reputation in manufacturing and refurbishing mine winders, that the company recently delivered a 23 tonne, 3 metre single drum winder to a gold mining company in Canada. The unit will be used as a man winder and service hoist, and will be used to reach a depth of 2 000 metres. Manufacturing the winder using material that is safety critical, Parnis Manufacturing’s contribution was to profile and roll, fabricate and weld, inspect, machine and paint – among other specialist services.
brake discs, as well as a shaft, gear box, couplings, bearings and bearing bases,” he adds. Brian highlights the depth of expertise in mine winder fabrication and refurbishment which continues to reside in South Africa, and emphasises the value of close communication with the customers during construction, to ensure that
“We work from drawings supplied by our customers, first inspecting the material to ensure that it complies with the specifications, and then preparing it for welding. This is essential to ensure an optimum quality result,” says Brian Berry, works manager at Parnis Manufacturing. “A critical element in the fabrication of the winder drum is our specialised welding and boilermaking skills. “Winder manufacture is certainly a complex engineering task, with the final product comprising a drum, two brake carriers and two
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the final quality product is perfectly to specification. Parnis Manufacturing tackles not only new winders, but also has an established track record for the repair and complete refurbishment of mine winders. Parnis Manufacturing, Mario Guerini Tel: (011) 613 3801 www.parnismanufacturing.co.za
MARKET FORUM least Performance Level c and Category 2 to EN ISO 13849-1.
Series Hoist Unit
Apart from safety, service is of major importance. The generously dimensioned slipping clutch and gearbox, which is maintenance-free for up to 10 years, as well as fast and simple maintenance of individual components thanks to its modular design, help to make the Demag LDC-Q quadro chain hoist easy to service. These are all important aspects that minimise downtimes and extend the unit’s service life for improved productivity.
Fitted with four load hooks, the Demag LDC-Q quadro chain hoist allows different load handling attachments to be lifted and transported at the same time. The available LDC-Q sizes enable loads weighing up to 3.2 t to be handled safely and efficiently.
For control of the Demag LDC-Q quadro chain hoist, operators also benefit from DSC/DSE control pendants with their low-fatigue actuation force for improved ergonomics. To meet specific ergonomics needs, operators can choose between radio controls or cable-connected control pendants that can be integrated into stationary control units.
offers benefits for safe and efficient lifting. Operation of the control unit with low voltage (24 V contactor control) as well as smooth starting and braking for low load sway are also significant factors. Further safety-related functions satisfy at
And ultimately, 2D and 3D geometry models in the Demag Designer tool give owners the opportunity to view a potential solution and its precise arrangement in their existing building and machinery infrastructure already at the pre-planning stage. Demag, www.demagcranes.com
Equipped with four load hooks, LDC-Q units can handle and transport customerspecific load handling attachments or flat components and feed materials to the relevant workstations. The basis for this broad range of applications is the technology offered by the LDC-D double chain hoist and some dedicated characteristics. For example, these include a design that combines two double chain hoists which have only one drive, which is a special technical feature. This means that only one chain hoist motor transfers power to the other three chain lead-offs of the Demag LDC-Q quadro unit via corresponding connections. Mechanically synchronised hook lead-offs provide for uniform and precise load handling. This arrangement enables loads with an asymmetrical weight distribution up to a ratio of 70:30 to be picked up without any problems. ProHub integrated variable speed control, which is a feature unique to Demag chain hoists, also permits rated speeds of up to 90% higher in the partial load range.Operators can utilise sizes DC 10 and DC 25 for handling loads weighing up to 3.2 t. The Demag LDC-Q quadro chain hoist
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Drone Combo
Car rier Network
Skyriders has carried out routine inspections of two smokestacks and one cooling tower using a highly successfully combination of rope access and Remotely-Piloted Air System (RPAS) drones for client Dundee Precious Metals at the Tsumeb Namibia mining operation.
Inttra, the largest neutral network, software and information provider at the centre of the ocean shipping industry, has announced an expansion of its rapidly growing carrier network with the addition of Salam Pacific Indonesia Lines (SPIL), its first carrier in Indonesia.
The drones completed a general internal visual inspection, followed by detailed visual inspection and core sampling by a six-person rope-access team. “The deliverable was a comprehensive report, with recommendations signed off by our consulting engineers,” Skyriders Marketing Manager Mike Zinn explains. The deployment of drones makes for rapid and safe visual inspections. “This allows decision-makers such as engineers and plant owners to formulate a more focused inspection plan, honing in on the areas of concern picked up during the drone inspection,” Mike elaborates. Introduced by Skyriders in 2015, the
SPIL provides services to all Indonesian routes, with 32 offices strategically located across the Indonesian archipelago. SPIL will offer its customers a range of services through Inttra’s network, including booking requests, shipping instructions, Track and Trace, and Ocean Schedules. use of drones has become an integral element of the company’s turnkey service offering. This comprises visual inspection using drones, detailed inspection by means of rope access, repairs undertaken by rope access, and then using drones as a quality-control measure to inspect and verify the final repairs. Skyriders, Mike Zinn Tel: (011) 312-1418 Email: mike@ropeaccess.co.za www.ropeaccess.co.za
New Automation Pack age
For greater safety and efficiency in underground mining, Epiroc has released a number of automation features for the Scooptram underground loader. The Scooptram Automation Regular package allows the loader to be controlled through an operator station from a remote location. "With this new package, the operator can control the loader even while it is out of sight of a safe stationary or mobile control station", explains Vladimir Sysoev, product manager of automation at Epiroc. "The automation package also makes it possible for our customers to quickly and easily transition from manual to automatic mode, which is crucial in mines with a dynamic environment or quick advancements. The automation package is an effective way for our customers to boost their productivity in today's world, where mining operations have to contend
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with a variety of complicated production issues." Production and the efficient utilisation of machinery can continue even during shift changes and when personnel are not safely permitted in the work area,
July 2018
Says Vijay Minocha of Inttra, “Our booking platform links carriers to more than 30 000 shipping companies globally through a single connection, enabling carriers such as Salam Pacific to experience the improved efficiency, lower costs, and enhanced customer service that comes with digitalisation.” SPIL Email: daniel.tandjung@spil.co.id
for example when the mine has not yet been adequately ventilated or when there is a substantial risk of falling debris after blasting. The operator can make swift transitions from manual to automatic mode to quickly adapt to the situation at hand. "The Scooptram Automation Regular package allows our customers to automate a single loader without having to spend lots of time and money making extensive infrastructure alterations," says Vladimir. The automation package includes cameras, sensors and safety modules that are mounted onto the Scooptram as well as a safety system that is easily installed in the mine. If a person or another machine should enter the Scooptram's work vicinity while the safety system is enabled, the loader will automatically shut down to avoid causing potential harm. Epiroc South Africa, www.epiroc.com
MARKET FORUM
At the forefront of standards
In a milestone achievement, Goscor Lift Truck Company (GLTC) has become the first forklift supplier to attain both the ISO 9001: 2015 and OHSAS 18001 accreditations in South Africa.
Quality and health & safety have always been top priorities at Goscor Lift Truck Company, the sole distributor of leading forklift brands, including Crown, Doosan, Bendi and Hubtex. The recent successful upgrade from ISO 9001: 2008 to ISO 9001: 2015 and the OHSAS 18001 accreditation are testimony to their focus on setting the bar high as far as quality is concerned, with no compromise on health & safety. “The route to accreditation wasn’t a walk in the park,” says GLTC Director Anthony Fouché, adding that this called for a lot of hard work and long hours. “The accreditation process started in
Multiple Sizes FLSmidth has launched multiple sizes of its Buffalo Reclaim Feeder, providing a wider range of productivity solutions to meet each customers’ unique requirements. The expanded range offers a
2016 and it was an arduous process, but worth the effort.” One of the major initiatives towards the achievement of the accreditation was having the right people in right positions first. This saw the subsequent appointment of Heather Morgan as National Health and Safety Officer, and Thando Khumalo as Assistant Health and Safety Officer. After another intensive audit by German based TUV, with two days at each national branch, GLTC successfully met the ISO 9001:2015 and OHSAS 18001 standards in February 2018. Unlike the previous ISO 9001: 2008 standard, the revised version, the ISO 9001: 2015, released in September 2015, expects organisations to understand their objectives before establishing a quality management system. This, in turn, requires them to take a completely modular, customisable, economical, and productive solution for mines of any size. The feeders reclaim stockpiles and deliver ROM material to a conveyor belt, sizer, or other processing equipment. The expanded range of these feeders allow customers to select the size best suited for their operational parameters, such as varied discharge heights and loading deck lengths. Additionally, the modular design provides optimised adaptability to customers’ operations,
fresh look at their current quality processes, consider the external and internal issues that affect quality, and define their end goals towards achieving consistent customer satisfaction, something central to GLTC’s operating philosophy. GLTC, www.goscor.co.za
such as replaceable decks and supports, or even containerised transportation to remote locations. FLSmidth’s Manager of Capital Equipment, PC Kruger, explains, "These modular reclaim solutions add value to any operation because they can be customised to meet specific requirements and tailored to improve productivity.” FLSmidth www.flsmidth.com/reclaim-feeder
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PRECISION measurement Siko has solved this task by developing the SG 30 wire-actuated encoder with its extremely compact yet robust design and wide range of applications. Instrotech is offering Siko's innovative wire-actuated encoders for a wide spectrum of applications with measurement lengths ranging from 600 millimetres to 40 metres.
Millimeters can make all the difference when it comes to the stability of cranes and lifting platforms. When safety is jeopardized, cranes can tilt or even topple over. If loads are lifted unevenly, this can result in strain and damage. What is needed is easily integrated measurement solutions with a good price-performance ratio and first-class product quality.
The functional principle of the wire-actuated encoders is fairly simple. A measurement wire is wound onto a drum, when the wire is pulled out, it causes the drum to rotate. A sensor connected to the drum axle records this rotation and generates a measurement signal proportional to the wire movement of the drum, which indicates the position. When extending crane arms, exact position detection of the supports is essential in order to prevent the crane or truck from tilting or toppling over. This is done by measuring the current values of the
Another unique feature of the SG 30 is its wide range of working-temperatures, which enables it to be used from minus 40 to plus 80 degrees Celsius. Four lockable aeration holes are integrated to avoid condensation. The wire outlet has a special protective seal. The wire pullout is flexible, so that 100% alignment with the extension direction of the outlet is not absolutely necessary. Instrotech, Tel: (010) 595-1831 Email: sales@instrotech.co.za
FIRST-EVER ELECTRIC DIGGER
The digger goes on sale at the end of year after being developed in secret at the company’s Staffordshire HQ. Its development has been spearheaded by company Chairman, Lord Bamford, who heralded its arrival as a 'real breakthrough' for the construction sector. Lord Bamford says, “JCB has been at the forefront of developing innovative, low emission diesel powered construction equipment for decades. In fact, thanks to our clean diesel technology, typical JCB machines will be pretty close to zero emissions by next year." The machine, known as the 19C-1 ETec, will not only deliver zero emissions, it will also be the quietest in the range. This means contractors can work after normal hours in urban streets, around hospitals and close to schools without disturbing people. The machine also has a retractable undercarriage to enable it to negotiate tight spaces.
JCB has developed its first ever electric digger which can work indoors, underground and close to people in urban areas. The 1.9 tonne mini excavator can be BULK HANDLING TODAY
Wire-actuated encoders are not only used for cranes operating at great heights. Optimum precision is also needed when extra-long loads have to be lifted. Wireactuated encoders ensure even lifting e,g, of trains, underground trains or trams using a lifting platform.
on the building site, digging with the same speed and power as its diesel counterpart. Super-fast charging will also be available at launch, slashing the charging time in half.
JCB Chairman, Lord Bamford
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extended supports and comparing them directly with the length of the extended crane arm. This means that complete extension of the crane arm is only possible if the supports are also extended to the maximum width.
charged by simply plugging it into a standard 230 volt domestic electricity supply. Once fully charged, it is ready to put in a full normal working day
July 2018
The electric excavator has an electric motor and three advanced lithium-ion battery packs, to deliver a full energy capacity of 15kWh. JCB Sales Ltd, Andrew Boyers Email: andrew.boyers@jcb.com
MARKET FORUM
International Truck of the Year Amid stiff competition, DAF Trucks was awarded the prestigious International Truck of the Year 2018 accolade for its new XF and CF series. Named as making the greatest contribution to road transport efficiency, the DAF XF and CF trucks set new standards of driveline effectiveness and overall performance. Babcock is the sole distributor of DAF Trucks in southern Africa and has successfully grown the brand in the country over the past eight years. The annual International Truck of the
Year award is presented to an individual vehicle or model range introduced into the market in the previous 12 months, with the winner chosen by an independent jury of leading road-transport journalists from 23 European countries. The award is considered the most prestigious honour in the European truck industry and is judged on several criteria including technological innovation, driver comfort, road safety, drivability, fuel economy, environmental ‘footprint’ and total cost of ownership. Innovations in DAF Trucks’ new XF
and CF series such as completely new powertrains with highly efficient transmissions and rear axles, compact aftertreatment systems, and sophisticated software and aerodynamic optimisations result in reduced CO2 emissions and a fuel consumption improvement of an outstanding 7%, impelling the jury to declare the new DAF XF and CF trucks as leading the way in transport efficiency. Babcock Mark Gavin Email: Mark.Gavin@babcock.co.za www.babcock.co.za
Dymot Engineering Company (PTY) LTD Specialist Designers & Manufacturers of Winching Systems WORLD OF WINCHES
Market leaders in conveyor tensioning equipment Take up winches with Overload Protection Gravity Counterweight Handling Braked Capstans Screw Take Ups Hand & Motorised Winches Electrical Control Panels & Systems Sheaves 11 DERRICK ROAD, SPARTAN, KEMPTON PARK SOUTH AFRICA +27 11 970 1920 sales@dymot.co.za www.dymot.co.za
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Agency for Africa Carmaky are excited to announce the signing of a new agreement with Australian based firm, Transmin, as the company’s official agency for the African region. Under the agreement, Carmaky will take on capital equipment sales, servicing and supply of parts for the complete Transmin range.
The agreement includes Transmin original equipment lines, viz: Boomer rock breakers, belt feeders, heavy duty bin isolation gates, ball mill lime slakers, lime processing plants, flocculant plants and most notably, Transmin’s specialist range of Low Profile Feeders (LPF). The original hybrid feeder delivers the advantages of both belt and apron feeders plus additional unique benefits over conventional feeder technology. It has the unique ability to change direction using a bend transition. A change of direction from horizontal to inclined
can be achieved without the requirement of a second machine; therefore creating improved space utilisation, flexibility of plant layout, eliminating transition points between conveyors and reducing capital expenditure. The LPF is available in a range of standard belt widths from 1.2m to 4.0m, and is the only feeder to feature ProEdge: Presupplied hot vulcanised belt edging with 10 times the strength of conventional glue-based edging. The vastly increased bond strength significantly reduces the risk of belt failure, and with it, costly repair and maintenance work. Carmaky, www.transmin.com.au
In TEN Seconds Atlas Copco’s QES mobile generator range is designed and engineered to provide the best air delivery solution combining performance, efficiency, reliability, safety and convenience. Everything about the design of the QES 250kVA 1250kVA range is the delivery of power as soon as possible in as few steps as possible. The machines are defined by simplicity. They are easy to move, easy to operate and easy to service.
of the generator to wherever it is needed on the job site.
The heavy duty base frame is built for regular mobilisation and the structure is able to withstand up to four times the weight of the generator. Integrated forklift slots and a lifting beam facilitate lifting while a purpose built site or road trailer ensures easy and safe transport
Furthermore, the generator’s ultracompact footprint simplifies truck loading and storage. Two generators can also be stacked one on top of each other which, in addition to requiring less storage, makes it possible to move two units simultaneously.
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The machines are ready to operate in just a few seconds. From a cold start, only two clicks are required to power and full stable power is reached in ten seconds. Atlas Copco South Africa www.atlascopco.com www.atlascopco.co.za
Seeing the big picture. The future of mining
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 Tel: +27 11 248 7000 Email: info@sew.co.za Web: www.sew-eurodrive.co.za
Visit us at the BIGGEST Mining, Industrial, Electrical & Power Trade Show in Southern Africa.
10 - 14 September
Hall 6 Stand J20
From pit-to-plant reduce total cost of ownership Recovery of mineral commodities is a complex challenge. Fast start-up, reliable operations and the potential to increase pit-to-plant productivity are essential for sustainable productivity enhancements.
Our innovative thinking and breakthrough technology helps your assets work harder. To help you achieve sustainable productivity, we have developed a platform that integrates pioneering products, extensive process know-how, and endto-end services. We work closely with each of our customers to understand their challenges
South Africa
Tel: +27 (0)10 210 4000
and help them increase output, lower operating costs, and minimise the environmental impact of their operations. Discover how we can help you find simple solutions and achieve sustainable productivity enhancements. flsmidthminerals.com
E-mail: flsm-za@flsmidth.com