BULK
HANDLING
T O D A Y
REDUCING FREIGHT CONGESTION LIGHT WORK OF PORT CARGO
BULK
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH
T O D A Y
March 2018
BULK
HANDLING
T O D A Y
REDUCING FREIGHT CONGESTION LIGHT WORK OF PORT CARGO
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 Chief Editor: Lara de Matos Advertising Sales: Linda Patricio DTP: Anne Rotteglia Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas. Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)
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The South African Institute of Materials Handling
Sample
The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions. The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.
Company Affliates as at May 2017 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd
Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd
Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd
Tel: (011) 867-0902 Fax: (011) 867-0036 Email: saimh@global.co.za www.saimh.co.za
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Dave Pitcher
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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
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February 2012
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Piecing together your success.
12415/E
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There are certainly parallels between the South African and Australian scenarios
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The table indicates the availability of citrus fruit See full document from the department of Agriculture, Forestry and Fisheries.
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March 2018
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We drive Industry
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
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BELTCON 19
Craig Wheeler
Figure 1. World’s longest single flight belt conveyors Continuous 10 1
Discontinuous 10
Pneumatic Conveyor Vibrating Conveyor Sliding Belt
10 -1
Belt Conveyor (Idlers, Air)
10 -2
Pipe Line (Liquid, Slurry
1 Aeroplane Truck Train
10 -1 10 -2
Ship
10 -3
10 -3
Figure 2. Loss Factor of Transportation for bulk material handling systems
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Figure 3. Cost analysis for truck, rail and overland belt conveyors
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Figure 4. Rail Conveyor concept
Figure 5. Side-by-side configuration
Figure 6. Carry side beneath return side
Figure 7. Horizontal carriage turnaround configuration
Figure 8. Loading point and carriage turnaround
Figure 9. Discharge point and drive layout
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BELTCON 19
Figure 11. 1:10 Scale model system
Figure 12. Two way transportation
Figure 13. Vertical turnover scale model system (shown in foreground)
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Figure 15. Conveying section of prototype system with carry side above
Figure 16. Carriage of prototype system before belt feeding section
Figure 17. Cable tension measurement on prototype
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BELTCON 19
Figure 18. Cable tension for one track cycle
Figure 19. Laboratory test equipment to measure rolling resistance
Figure 20. Laboratory test equipment to measure track wheel wear and friction
Figure 22. Track wheel friction versus radial load
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BULK HANDLING TODAY
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Figure 21. Rim drag testing apparatus for track wheels
Figure 23. Schematic of forces acting on carriage through horizontal curve
Figure 24. Track wheel axial load measurement
Figure 25. Track wheel friction versus axial load
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BELTCON 19
Design Specifications
Belt Conveyor
Bulk Material
ROM Coal
Rail Conveyor
Bulk Material Density
850 kg/m3
Design Capacity
1000 t/hr
Belt Speed
3.5 m/s
3.5 m/s
Belt Width
1,200 mm
1,200 mm
Horizontal Length
1,000 m
1,000 m
Lift
0m
0m
Table 1. 1 km Long Belt and Rail Conveyor Specifications Design Specifications
Belt Conveyor
Bulk Material
ROM Coal
Bulk Material Density
850 kg/m3
Design Capacity
1000 t/hr
Rail Conveyor
Belt Speed
3.5 m/s
3.5 m/s
Belt Width
1,200 mm
1,200 mm
Horizontal Length
10,000 m
10,000 m
Lift
0m
0m
Table 2. 10 km Long Belt and Rail Conveyor Specifications
(a) Belt Conveyor
(b) Rail Conveyor Assumptions: 1. Costs based on a 30 year service life. 2. Costs based on an 80% utilisation. 3. Costs in US dollars and excludes inflation. 4. Costs based on manufacture in China. 5. Site construction and civil costs excluded. 6. Labour maintenance costs excluded. 7. Carry side idler roll life = 3.2 yrs (22 500 hrs). 8. Return side idler roll life = 5.1 yrs (35 500 hrs). 9. Track wheel life = 6 yrs (42 000 hrs). 10. Rail life = 30 yrs. 11. Belt life = 10 yrs. 12. Energy costs based on 5c/kWh. Figure 26. Cost comparison for a 1 km long belt conveyor and Rail Conveyor system
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BULK HANDLING TODAY
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Figure 27 (a) Belt Conveyor
(b) Rail Conveyor Assumptions: 1. Costs based on a 30 year service life. 2. (2) Costs based on an 80% utilisation. 3. Costs in US dollars and excludes inflation. 4. Costs based on manufacture in China. 5. Site construction and civil costs excluded. 6. Labour maintenance costs excluded. 7. Carry side idler roll life = 3.2 yrs (22 500 hrs). 8. Return side idler roll life = 5.1 yrs (35 500 hrs). 9. Track wheel life = 6 yrs (42 000 hrs). 10. Rail life = 30 yrs. 11. Belt life = 10 yrs. 12. Energy costs based on 5c/kWh. Figure 27. Cost comparison for a 10 km long belt conveyor and Rail Conveyor system
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BELTCON 19
Figure 28. Cost comparison between belt conveyor and rail conveyor
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