Bulk Handling Today Nov/Dec 2019

BULK

HANDLING

T O D A Y

Endorsed by: CMA l LEEASA l SAIMechE l SAIMH Nov/Dec 2019

EXTREMELY FAST LIFTING SPEEDS FOR HIGH RISES

MONITORING INDIVIDUAL CYCLONES IN REAL TIME

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BULK

HANDLING

T O D A Y

Endorsed by: CMA l LEEASA l SAIMechE l SAIMH Nov/Dec 2019

EXTREMELY FAST LIFTING SPEEDS FOR HIGH RISES

BULK

HANDLING Nov/Dec 2019

Contents

MONITORING INDIVIDUAL CYCLONES IN REAL TIME

On the cover: Condra Marc Kleiner Tel: (011) 776-6000 Email: sales@condra.co.za www.condra.co.za

T O D A Y

CMA News

Earthmoving

Cover Story

Lubrication

4 5 6

Company Profile From the Desk

28 Excavators Excel in Technology,

Safety and Emissions 30 A Different Kind of Fish Oil

Horses for Courses: Are Bigger Warehouses Worth it?

Mining Maintenance

SAIMH 8

Report Back on Institute Golf day

Beltcon 20

12 Adder Snake: Low-Angle to High-

Angle With no Transfers

Lifting

32 Rubber solves Africa's Largest

Copper Mine's Woes 34 Market Forum

Endorsing Bodies •

CMA (Conveyor Manufacturers Association)

•

LEEASA (Lifting Equipment Engineering Association of South Africa)

25 Driving Down Costs While

Increasing Performance

•

SAIMechE (SA Institution of Mechanical Engineering)

Front-end Loaders

•

SAIMH (SA Institute of Materials Handling)

22 Compact and Easy to Assemble

Minerals Processing

24 Compressed Air to Help Dump

Reclamation Project

Cyclone Circuits

27 Boosting Productivity

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

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BULK HANDLING TODAY

Nov/Dec 2019

3

COMPANY PROFILE

SEW-Eurodrive

D

rive and automation specialist SEW-Eurodrive (Pty) Ltd, is a leading conveying and materials handling solutions provider for a range of industries, supplying Industrial Geared (IG) units for bulk handling applications.

Its range of robust X Series helical and helical-bevel gear units can be optimally adjusted to the task, due to finely-stepped torque ratings. The universal modular system concept sets new standards with respect to availability and options.

The IG units are highly reliable in driving conveyor belts and bucket elevators for horizontal and vertical transportation of materials. They also run the travel and hoist drive on cranes.

The X Series is an invertible gearbox, so it can be used for left- and right-handed applications.

The gearbox can be flipped on its axis by 180°. It features some of the best thermal ratings and characteristics in the market, as the high local ambient temperatures are critical in IG unit applications.

Customers benefit from the fact that they can obtain the complete and fully assembled drive package from a single source, while a large local

stockholding allows for shorter delivery times and increased flexibility.

From project planning to commissioning and operation, SEW-Eurodrive (Pty) Ltd, can ensure the lowest total cost of ownership. As a leading local manufacturer of IG units, it knows its clients’ industries and their associated processes. It ensures that the correct drive technology is supplied for its clients’ conveying systems. Its high-torque IG units impress in every environment, even under difficult conditions.

Generation X.e represents the latest iteration of the highly-successful X Series of IG units, which has gained significant traction globally in industries as diverse as mining, cement and sugar mills, and power generation.

The specific client requirements addressed by the new series are maximum drive utilisation, in the event of continuous operation under specified conditions; peak load, in the case of an irregular travel profile, frequent start-up, or occasional blocking; temperature and environmental factors such as the permissible surface temperature, degree of protection, permissible noise level, accessibility, and serviceability; minimum service life; and extended service intervals.

Such is the quality of the new Generation X.e series that it is particularly suited to harsh operating environments such as mining and general industry. Here an increased thermal saving of 32% has been achieved mainly by reducing the periods between oil changes. Other advances include an improved bevel pinion housing, optimised bearing preload, a non-contact sealing system, a universal cover with a fan system, and optimised gearing topology.

SEW-EURODRIVE–Driving the world

SEW-EURODRIVE (Pty) Ltd offers innovative drive solutions for all applications in the mining industry.

All SEW-EURODRIVE products and systems make the best use of the space available around machines ensuring great flexibility and reliability. Minimum maintenance and simple operation ensure that you will operate machines and equiment efficiently from the very beginning. Thanks to the modular design and countless combination options, all drive engineering components can be replaced quickly, if the need arises.

From gravel mining to the excavation of gold, platinum, coal and diamonds - we put the drive into all facets of the mining industry.

SEW-EURODRIVE – Driving the World Cape Town Branch Tel: +27 21 528 7600

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Nov/Dec 2019

Durban Branch Tel: +27 31 902 3815

Nelspruit Branch Tel: +27 13 752 8007

Port Elizabeth Branch Tel: +27 41 372 2244/6

SEW-EURODRIVE (Pty) Ltd Eurodrive House Cnr. Adcock Ingram & Aerodrome Roads, Aeroton Ext 2 Johannesburg P.O. Box 90004 Bertsham 2013 Tel: +27 11 248 7000 Fax: +27 11 248 7289 www.sew-eurodrive.co.za

CONVEYOR MANUFACTURERS ASSOCIATION

From The Chairman’s Desk

T

his is the last opportunity this year to remind University students that some interesting research projects have been identified for post-graduates looking for career prospects in the conveying industry. These include • Water and dust ingress tests for idlers • Pulley shaft deflection • Energy saving rubber Two research projects have recently been completed and papers on the resultant data were presented at the recent Beltcon 20 conference.

A dedicated test rig was built by CMA members to gather data on uni-directional rollers, images of which can be found on the CMA website www.cmasa.co.za.

A Wits student conducted the research as part of his MSc Mechanical Engineering degree. Data collected will be used by the CMA to draw up recommendations to guide industry on uni-directional rollers as a method of preventing run back in belt conveyors and to set the parameters for the use of non-product specific uni-directional rollers.

The second recently completed research project was to test the forces causing damage to the belt that are present in the idler junction area. Again, a Wits student conducted the research as part of his MSc Mechanical Engineering degree on a second test rig built specially for this purpose.

Anyone interested in participating in research on any of the three new topics of water and dust ingress for idlers, pulley shaft deflection or on energy saving rubber is asked to contact the CMA Secretariat as soon as possible to plan this research for 2020.

Education and training courses planned for early in the year start off with the Bulk Transfer Chute De-

Jay Pillay

sign and Modelling course. In this course, the basic design principles of “Guided Flow” Hood and Spoon chutes, Rock/Dead box chutes and combinations of these two chute concepts are covered in the three days of lectures. The course also covers the use of Discrete Element Modelling as a tool to supplement the traditional calculation methods, with focus on DEM analysis and calibration methods. The three days of theory lectures are followed by the student working on design for construction, fabrication, setup/installation and testing and the associated learnings around the chute fabrication assembly, testing/measurement processes and procedures (operational and safety) to establish the success of the design, and the verification against the model proposed.

Want to know more about any of the training courses?

Visit the website www.cmasa.co.za or contact Beth at the CMA or email her on training@cmasa.co.za.

Jay Pillay, Chairman

Membership at Nov/Dec 2019 All members subscribe to the CMA Code of Ethics Acrow Limited Actom Afripp Projects Altra Industrial Motion South Africa (Pty) Ltd Bauer Bearings International Belt Brokers Belting Supply Services BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CedoTech cc Closeal Manufacturing Collisen Engineering ContiTech South Africa (Pty) Ltd Conveyor & Engineering Equipment Conveyor & Industrial Supplies (Pty) Ltd Conveyor Watch (Pty) Ltd CT Systems David Brown Gear Industries DRA Projects SA (Pty) Ltd Dunlop Belting Products Dymot Engineering Company

ELB Engineering Services Electromote (Pty) Ltd Fenner Conveyor Belting (South Africa) Flexco SA (Pty) Ltd FLSmidth Roymec Giza Technologies (Pty) Ltd – SUSPENDED Habasit South Africa (Pty) Ltd Hägglunds Drives South Africa Hatch Africa (Pty) Ltd HMA South Africa (Pty) Ltd Hosch - Fördertechnik (SA) International Belting & Marketing (Pty) Ltd Iptron Technology cc KevConBelt (Pty) Ltd – SUSPENDED Leoka Engineering Lesa Mining Equipment and Conveyor Belt – SUSPENDED Lorbrand Magnet Service Binder CC Martin Engineering Melco Conveyor Equipment Merlin consulting (Pty) Ltd Moret Mining Nautilus Projects (Pty) Ltd – SUSPENDED

Nepean Conveyors OE Bearings Oriental Rubber Industries SA Osborn Engineered Products Pegasus Industrial Services cc Regal Beloit South Africa – SUSPENDED 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 – SUSPENDED 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

Nov/Dec 2019

5

COVER STORY

Horses for Courses – Are Bigger Warehouses Worth it?

Factories and warehouses are wider than ever, and existing buildings are being extended to make them longer. Both trends beg questions about increases in productivity – are they in proportion to the higher costs of construction?

C

rane manufacturer Condra claims to provide at least part of the answer, supplying the overhead travelling machines that service these larger buildings.

Though the company still delivers many cranes with traditional spans of around 17 metres, there are orders for an increasing number of doublegirder machines greater than 25 metres in span, and managing director Marc Kleiner says that he has in recent years seen buildings

Condra's managing director, Marc Kleiner

Completed double-girder overhead crane leaving Condra’s Johannesburg factory for delivery by road by sister company Transcon Haulers.

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measuring as much as 26 metres by 28 metres served by a single crane.

His opinion is that the economy of building factories of such a size is debatable, because as the span of the overhead crane increases to match factory width, so too does the cost of the factory structure needed to support its weight.

“And the crane itself also becomes more expensive,” Marc adds.

“For example, the 3-ton girder needed for a 17-metre span increases in weight to 12 tons when the span becomes 25 metres (a fourfold weight increase to service a 47 percent increase in factory width) and additional power is also needed to move the heavier crane.”

In the case of factory extensions serviced by a second overhead crane, a similar question hangs over whether the intended increases in productivity are actually achieved, because cranes operating in tandem can lead to production logjams.

Marc comments that single-girder designs are usually fitted with Titan short-headroom (SH) series hoists, underslung to maximise vertical lift by absorbing the dimensions of motor and cable drum into the space of the girder depth.

A conflict

SH-Series hoist profiles are some 20 percent less than that of other underslung hoist models.

“The thinking is that you put up the initial building which is, say, a two-bay layout, and incorporate planning to extend it at a later date and install a second crane to service an additional two bays.

“But what often happens is that goods in Bay One cannot be moved to Bay Three because of the second crane working in Bay Two,” he explains.

Turning to factories with more modest widths, Mark says that single-girder overhead cranes are often a cost-effective alternative to the double-girder ideal.

In Bulgaria, Condra’s subsidiary there has recently delivered single-girder cranes to an engineering company (a 5-ton machine), and to a steel trading company (two machines with capacities of 5 tons and 3,2 tons). Spans of these cranes range between 11 and 13,8 metres. More single-girder machines are under manufacture.

The single-girder design is both durable and robust, and is an effective solution in many standard factory applications Titan hoists lift a maximum load of 16 tons, and incorporate refinements such as automatic rope tensioning, smooth travel, built-in load limiter, standardised direct drive and universal carriage.

Two alternatives

Design of all Condra cranes, both single-girder and double-girder, takes place at Condra’s Gosforth Park factory outside Johnnesburg, where design teams examine the application and compare the suitability of the two alternatives.

Manufacture to specification is carried out using selected components from some 250 sub assemblies, the main ones being hoists, drives, end-carriages,

Marc emphasises the functional design of this type of crane. “The single-girder design is both durable and robust, and is an effective solution in standard factory applications.

brakes, gearboxes and motors.

“Of course, the double-girder design provides the advantages of greater stability, lift precision and lifetime durability, but these benefits come at a higher initial price that is later justified many times over by a much extended useful life.

All manufacture is carried out in accordance with the quality management standards of ISO 9001:2015.

“A tight budget may therefore dictate consideration of the single girder design, which in many cases will be adequate.”

Hoists are assembled from standard Condra parts, and fitted with either hooks, grabs, magnets, ladles, buckets or spreaders according to requirement.

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

BULK HANDLING TODAY

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7

SAIMH

Report Back on Institute Golf Day I would have loved to say that the golf day went off fantastically well. It was a lovely day and the participants all enjoyed the game and the company. Unfortunately we were a little short on the quantity of four balls. Possibly a sign of the times but also a reflection on the ability of the committee to market the day and the Institute. We did have some serious set-backs the passing of Ronnie Bawden (RIP) who had taken on the challenge of coordinating the event. However we came through nicely again thanks mainly to the assistance provided (at very short notice) by our secretary Jean-Ann McGredy. Yet again we were able to make a small but no doubt very welcome contribution to Avril Elizabeth Home, and our thanks go to Brelko for their generous contribution to this worthy cause.

his year was a Rugby World Cup Year and our raffle consisted of a RWC survival package comprising a large cooler box filled, or rather over-filled, with lots of booze, mixers, biltong and nuts. The winner, again confirming that if you don’t buy you don’t win, was Jay Pillay of Brelko who decided that his kidneys were rather tender and sold off the prize, with proceeds being added to the raffle takings.

T

forward to our next event. Although this is not a money making event we will in future endeavour to obtain sponsored prizes from our member companies in order to reduce the financial impact on the Institute.

We thank our hole sponsors Rio-Carb, Zest, Actom, Bosworth and Dunlop. Their presence with accompanying refreshments and encouragement to the players was most welcome.

We thank the management and staff of ERPM Golf Club for their efforts in ensuring that all went to plan.

In keeping with our ensuring that each team took away a prize the Institute sponsored a large number of prizes. We do however thank "Bulk Handling Today", Afripp, and Brelko for their prize donations. Martin Engineering did provide prizes and we thank them for this, however these will be carried

First prize went to Dunlop Industrial with Rio Carb in second place and Brelko third. Murray Calder from the Zest team won both the longest drive and closest to the pin prizes, with the Martin Engineering Team taking the longest day award.

Last but certainly not least we thank each and every one of those who participated and we certainly look forward to welcoming you back next year.

Adriano (Adi) Frittella

1st Place: Dunlop Industrial Africa (Pty) Ltd

2nd Place: Rio Carb

3rd Place: Brelko, Jay Pillay and Craig Abbey

4th Place: Martin Engineering

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Dinner and prize-giving at the annual SAIMH fundraising Golf Day

Murray Calder winner of Nearest to Pin and Longest Drive

OBITUARY of Ronnie Bawden 18 July 1954 – 31 August 2019 It is with sadness that we report the passing of Ronnie Bawden after a short illness. Ronnie will long be remembered for his work on underground hard rock systems including crushing and screening and belt conveying plants, many of which were completed as a long time employee of RSV. Ronnie was an active member of our materials handling community, actively serving on committees of both the SAIMH and the CMA. We remember him as a humble gentleman always willing to assist. The materials handling industry mourns his passing and shares in the family’s sorrow.

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“THE LINK FOR AFRICAN TRADING”

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TRANSNET FREIGHT RAIL

www.transnetfreightrail-tfr.net

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BELTCON 20

Adder Snake: Low-Angle to HighAngle With no Transfers

I

n his landmark Society for Mining, Metallurgy and Exploration (SME) 2000 writing, “Theory and Design of Sandwich Belt High Angle Conveyors According to The Expanded Conveyor Technology” J. A. Dos Santos generalised the belt conveyor technology to include all possible variations and augmentations including, particularly, multiple belts along a common carrying and/or return path as is the case most notably in the sandwich belt high angle conveyor technology and belt-on-belt type intermediate (booster) drives. Figure 1, excerpted from his paper, represented the proposition of the generalised “Expanded Conveyor Technology”, abbreviated ExConTec. This formed the basis for the generalization which was completed in theory and in math before 2000 and presented by J. A. Dos Santos at the Y2K SME Annual Meeting and in the writing which can be found in the SME library2. While Figure 1, with the supporting mathematical development solved the generalisation, it failed to identify the variation that would prove to have the greatest significance. As with most significant developments, necessity is the mother of invention. This is the case with the Adder Snake belt technology, Marcus J. dos Santos the subject of this writing.

The concept of elevating bulk materials at a high angle using the sandwich belt concept was first introduced in 1951. That introduction did not produce any lasting success. Commercial success in sandwich conveying was achieved in the 1970s with the Loop Belt, a sandwich belt elevator of C-shaped profile developed by Stephens Adamson of Canada. The Loop Belt was and is the vital element of a conveyor based self-unloading ship system. Such self-unloading ships have had great success achieving unloading rates above 10 000 t/h with Loop Belts of width to 3 048mm (120”).

Being strictly of C-profile, Loop Belts could not be adapted to the general high angle conveying path which is predominantly along a straight incline. It was the success of the Loop Belts that inspired the Dos Santos Sandwich Belts of the 1980s.

These expanded the Loop Belt capabilities by producing endless elevating profiles that could take the most direct and/or conforming path between the loading and discharge points.

Sandwich Belt high angle conveyor systems have seen great success through the years, with more than two hundred installations throughout the world.

Sandwich conveyor

The sandwich belt conveyor technology has been implemented in a variety of roles, including plants, mines, and marine applications. As these have typically been custom applications, the layout of the system was usually tailored to work with incoming and outgoing equipment, leaving the sandwich conveyor itself as an isolated solution to the requirement of a high-lift, short-footprint system, often fed by, or discharging

Figure 1: Y2K basis model for the Expanded Conveyor Technology (ExConTec)

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onto, low angle conventional equipment. The primary advantage of the sandwich conveyor in these cases is therefore the ability to eliminate long, low-angle elevating conveyors with their heavy, expensive elevated structure.

In another writing1, the value of the sandwich conveyor is compared to conventional conveying methods. A sandwich conveyor must use wider belts than a conventional conveyor carrying the same capacity at the same speed to maintain a proper belt edge seal. Accordingly, a conventional conveyor will be cheaper than a sandwich conveyor of the same carrying length.

However, as the lift requirement increases, the high angle capability of the sandwich conveyor allows it to take a shorter path, which the conventional conveyor must use increasingly heavy elevated structure to reach the same end point. With this in mind, it is expected that at low lifts, the conventional conveyor would have the economic advantage and that the sandwich conveyor gains an advantage as the lift increases (see Figure 2).

Crossover

The Cost/Value article calculates the crossover point at which a 15° conventional conveyor becomes more expensive than the small-footprint sandwich belt conveyor for the same capacity. A premise of this comparison is that the loading point of the sandwich conveyor can be much closer to the discharge point (horizontally) than that of the conventional conveyor, allowing for considerably less structure on a high lift sandwich conveyor.

When the start point and end point are fixed, however, the economics change. There is still a crossover where it is advantageous to use the sandwich conveyor in conjunction with a conventional conveyor running along grade, rather than slowly elevating over the entire length. Historically, this combination of equipment would be the most economical solution for a high lift requirement which could run at grade until close to the end point.

Various applications through the years have required arrangements such as described here, and the determination had to be made regarding the most economical of three choices: 1) A shallow-angle elevating conventional conveyor; 2) A sandwich conveyor combined with a conventional conveyor along grade; or 3) A sandwich conveyor with its wider bottom belt extended back to the start point.

A very high lift would eliminate the first choice, as the elevated structure would quickly become exceedingly expensive. The choice then became whether to extend the wider sandwich belt or to employ a transfer between a conventional conveyor along grade and a high angle elevating conveyor.

Unique requirement

These options offered sufficient flexibility for a number of applications through the years. However, in August 2014, a unique requirement demanded development of a better solution. In a raw sugar and grain application, the abrupt upturn of underground collecting conveyors that reclaimed from multiple inline feeding points from the above dome storage silos was considered (See Figure 3 and Figure 4 ).

Figure 2: Investment summary from Cost/Value article

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Eight such conveyors came together to feed onto three outgoing conveyors, five from one side and three from the other.

These outgoing conveyors took the collected material to ship loading. Because of the tight space between the domes and the outgoing conveyors, without an abrupt upturn the outgoing conveyors had to be underground, in a concrete vault. This was at significant expense and vulnerability to water as the water table was near the surface. Further, the material flow had to be routed to any one of the three outgoing conveyors, requiring a shuttling head in the initial subsurface arrangement developed by a third-party consulting firm.

The historical solutions for this problem were the first instinct, but these came at a cost. The sandwich belt high angle conveyor technology with its tight convex curves could be used to accomplish the needed abrupt upturn, bringing the discharge points to above the three surface conveyors. However, this would require extending the (wide) bottom belt tail to act as the collecting conveyor. Subject to the reduced cross-sectional filling of the sandwich belt, the extended collecting bottom belt would have to be wider along its entire length (around 320m), driving up the cost of the conveyor and the tunnels beneath the domes.

Alternately, the narrow conventional collecting belt could discharge onto the sandwich conveyor shortly before the upturn. However, there was very limited space available to accommodate a transfer between the two conveyors, and the

end user did not like the idea of this underground transfer with its maintenance implications.

Combination

During a brainstorming session, the idea occurred to the writer to combine the economics of the narrower conventional conveyor and the advantage of the abrupt upturns of the sandwich belt, while eliminating the transfer. Limiting the high angle conveying to a short upturn and discharge, each conventional collecting conveyor could continue directly into the sandwich, be carried through the upturn, and the material could then be discharged well above ground.

The resulting arrangement not only allowed the subsurface conveyors to be elevated to grade, but also provided ample space for a trifurcated chute to distribute the collected material to the appropriate surface conveyor, eliminating the complication and added expense of a shuttling head end.

(See Figure 5) As a result of this development, the Expanded Conveyor Technology basis is now updated to include the Adder Snake technology as shown in Figure 6. Though the difference in the image is subtle, the implications are quite extensive. By simply adding the possibility of varying belt widths running along the same path, the Adder Snake technology and all its advantages can be further explored.

Once conceived, the broad implications came to light in rapid

Figure 3: Plan view of dome unloading conveyors

Figure 4: Subsurface solution for outgoing conveyors loaded by dome storage reclaimer

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succession. The remainder of this writing will present some of the possible variations and the positive possible implications. As in the Y2K Figure 1, the 2017 Figure 6 does not present all possibilities as such are infinite.

A patent for the Adder Snake design was applied for in December of 2015 and awarded 14 November 2017.

Development, applications

The conception of the Adder Snake system was spurred by a specific application. The tunnel gathering arrangement which was subsequently developed is certainly a very good application of the Adder design. However, the use of this technology extends to a variety of other applications, many of which are yet unrealised.

The primary advantage of the Adder Snake in the tunnel gathering project was that it eliminated a potentially messy transfer, while not penalizing the overall conveying path with a wider belt than necessary.

In further developing the concept for use and for patent protection, a wide variety of applications were considered.

Two of these are discussed further here.

Overland systems

The 2017 Expanded Conveyor Technology model (Figure 6) hints at the application of the Adder Snake concept in complex overland systems. Indeed, there are many applications in which a long conventional conveyor encounters significant steep terrain in its path, both elevating and lowering, in order to negotiate a relatively modest net lift. In other cases, a conveyor or its path is modified to avoid an abrupt elevation change. This may be accomplished by cut-and-fill, additional superstructure, adding transfers and conveyor flights, or by introducing complexities to the conveyor that would not otherwise be needed.

A sandwich conveyor can be arranged to receive material from one flight of overland conveyor and deliver it to a receiving flight at a higher or lower elevation, but this will require two additional transfers, along with all the terminal equipment that accompanies a complete conveyor system. The Adder Snake technology can better handle such a scenario by swallowing the conventional overland belt into a sandwich

Figure 5: Surface solution for outgoing conveyors employing Adder Snake technology

Figure 6: 2017 Basis Model for the Expanded Conveyor Technology

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conveyor that exists only at the steep grade. The overland conveyor can therefore negotiate a previously unachievable path, with no disruption.

As an added benefit, the sandwich conveyor that envelops the conventional belt can double in function as a belt-on-belt type booster drive for the overland conveyor. The sandwich conveyor drives can be sized and controlled to handle the local elevating requirements and further drive the belt as desired to control the tension of the overland belt, allowing for a reduction in the belt strength, and therefore, in the cost of the overall system.

Marine terminals, docks and shiploading

Dock length (structure) is very expensive in any marine terminal. As larger ships become more commonplace, shiploaders must increase their height. In turn, this requires the conveyors that feed these shiploaders to elevate material higher. A simple geometric calculation, based on the low incline angle alone, indicates that for every metre of additional lift, the

standard tripper design used at many docks will require more than three and a half metres of length. This does not include the substantial additional length of the conventional empty belt uplift curve from tangency at the dock belt structure to tangency at the tripper incline.

Sandwich belt systems have already been employed at shiploading applications to mitigate this problem, though these were executed before the Adder Snake design was conceived.

A historical method was therefore used, discharging from a dock conveyor at grade onto the sandwich conveyor tail via a short tripper and transfer station. While successful, such installations could have benefitted from the Adder Snake arrangement.

Dos Santos International has been offering the Adder Snake for a variety of ship-loading applications. Figure 9 and Figure 10 show views of one such offering, in which a 20 metre lift is required to reach the outgoing shiploader.

In the overall view (Figure 9), a phantom profile is included for the conventional arrangement that would be required to accomplish the same lift as the Adder Snake. The Adder design in this function consumes just under 40m of horizontal space from the uplift of the belt to the head end. By contrast, the conventional solution extends nearly 135m back from the head end.

It is worth noting that, because the elevated material is wood chips in a tropical environment this conventional arrangement is given the benefit of conveying at an incline up to 20°. Many designers will not allow conveying angles beyond 15-18°, which would further amplify the benefit of the Adder Snake.

Belt modulus, tension considerations Figure 7: Adder Snake generalized sandwich entrance – conventional belt in red; Sandwich belts semi-transparent

A key feature of the Adder Snake design lies in the elastic modulus constraints that are so important in sandwich conveying. To maintain

Figure 8: Adder Snake generalized layout – conventional belt in green; Sandwich belts in red

Figure 9: Comparative view of Adder Snake and conventional dock conveyor design

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the tight curves that keep the sandwich conveyor compact, a low elastic modulus nylon-nylon carcass belt is typically used. While this belt was once a standard offering, it has become more difficult to obtain as polyester-nylon belts have become dominant in the industry. Accordingly, the price can sometimes be higher than the corresponding conventional belt.

The beauty of the Adder arrangement in this case is that the narrower conventional belt, typically of polyester-nylon construction, will take an advantageous shape through the tight sandwich curves. Whereas the wider sandwich belt will take the typical troughing profile with the belt centre at approximately one third of the belt width, the conventional belt will effectively have a long centre roll arrangement, bringing down its neutral axis considerably. This allows the higher modulus conventional belt to travel comfortably through the tight sandwich curves.

As the required angle of the sandwich conveyor increases, the advantage of the Adder Snake is amplified. This is a result of the de-rating of the allowed sandwich cross-sectional filling with increased incline angle.

A detailed analysis of belt width combinations was executed to determine the optimal choice considering a few variables.

The analysis was executed as follows: 1. Material density was set at 1t/cu-m, troughing angle in the sandwich was set to 20 degrees and troughing angle on the conventional (Adder) belt was set to 35 degrees.

2. Conveying rate was incremented from 200t/h to 4000t/h

in 200t/h increments.

3. Conveying angle was incremented from 60 degrees to 90 degrees in 10 degree increments.

4. The conventional (Adder) belt width was set at each capacity scenario to be loaded at approximately 80 percent to 85 percent of the CEMA load when running at a conservative belt speed (1-3m/s for smaller capacities, 3-5m/s for larger capacities) 5. The sandwich belt width was then chosen to achieve 90 percent to 95 percent of the DSI sandwich conveyor loading criteria. For reference, 100 per cent DSI sandwich loading at 50 degrees is equivalent to around 70 percent of CEMA load on the same conventional belt width. At 90 degrees, it is about 42 percent of CEMA. 6. The conventional belt in each case was assumed to be of polyester-nylon construction, while the sandwich belts were of nylon-nylon construction.

7. The initial curve radius of the sandwich conveyor was set to a value that would ensure the edge of neither belt was overstressed, and the tension was set to keep the centre of either belt from buckling.

Fig 12 offers a visual summary of the corresponding belt widths that were determined as a result of this analysis.

The first area, nearest to the conveying rate axis, shows the belt width of the conventional belt for a given conveying rate. Each of the following areas, labeled 60, 70, 80 and

Figure 10: Sample Adder Snake application with cross-sections

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BELTCON 20

90 indicate the belt width of the corresponding sandwich belts at that conveying rate that will envelop the conventional Adder belt. As is required by the DSI criteria, the steeper conveying angle requires a wider sandwich belt to match the conventional conveyor belt.

when considering the shape that the conventional belt takes in the sandwich in the various cases. At the lower angles, the difference between the conventional belt width and the sandwich belt width is smaller. As a result, the neutral axis of the conventional belt is not greatly reduced.

The difference between the conventional and sandwich belt widths for proper compatibility range from 450mm at the lower capacities and angles up to 1200mm at the high end.

However, at steeper angles, the sandwich belts are quite a bit wider than the conventional belt, which results in an effective long center roll for the conventional belt, bring its neutral axis down considerably. At around 70 degrees, the sandwich belts begin to dictate the curve entrance radius.

A more interesting point that is not shown in this chart is that at the lower conveying rates, the size of the entrance curve to the sandwich conveyor is dictated by the conventional belt, rather than the sandwich belt. This makes sense

Fig 13 offers a more visual explanation of this phenomenon.

The images in each column progress through the conveying angle increments from 60 degrees to 90 degrees. The first column shows the 1200t/h conveying rate, and the second column shows the 2400t/h conveying rate. The orange belt line is the Adder, or conventional belt. From the images, it is clear that at the lower conveying angle, the conventional belt has a narrower effective center roll length. As a result, its neutral axis is higher, and its ability to wrap around a curve is reduced.

At the higher angles though, the conventional belt is quite narrow compared to the sandwich belt, so even with its high modulus of elasticity, it is no longer the determining factor in wrapping around a tight sandwich curve.

Other applications

Figure 11: Adder Snake belt cross-sections: from top to bottom – Conventional belt only in loading and approach area; conventional belt (with effective long centre roll) after combining with sandwich bottom belt; Sandwich profile with conventional belt between top and bottom belts

Figure 12: Chart showing belt widths of conventional (Adder) and corresponding sandwich belts at varying conveying rate and angle.

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Very good applications of the Adder Snake will be at ports and terminals in ship-loading applications, particularly as shiploaders must increase their reach as they are elevated to accommodate larger vessels. Historically, sandwich conveyors in this capacity have been arranged as a separate piece of equipment, each receiving material from a dock conveyor mounted along the surface with a traveling tripper.

By employing the Adder Snake design, the low cost conven-

BELTCON 20

tional conveyor can remain in place. The sandwich conveyor portion will be integrated into the traveling tripper. The only modification necessary is to splice in additional belt to achieve the new, increased lift.

In mining, the primary application of the Adder design will be in overland systems. Any scenario in which the conveyor path must take a large and abrupt upturn or downturn will benefit from employing an Adder Snake rather than the alternatives of rerouting the conveyor, disturbing the environment to excavate a low angle path, or using extensive elevated structure.

The reduction of the conventional belt tension in this case is available as a byproduct of the primary Adder Snake function. Depending on the requirement, boosting (or braking) of the belt may prove advantageous. This benefit is available to use either way.

Adder snake case study

Dos Santos International is currently executing an Adder Snake design for a shiploading application in Holland. The benefit of the design in this application is different from those advantages noted thus far.

design was employed, using a light, thin main belt that can be wrapped around a somewhat smaller tail pulley. This belt, which is also 400 mm narrower, will carry the material through the loading point and will travel just under 7 meters before being enveloped into the 1600 mm wide sandwich belts.

Closing

Though the Adder Snake concept, using belts of varying width, was conceived only a few years ago, it has a very solid basis in the sandwich belt technology that is approaching 70 years of existence, and the expanded conveyor technology that is nearly 40 years old. This paper likely does not cover all important points and capabilities of the technology. Such will continue to be discovered as the system is applied to the various projects that may benefit from it.

This paper was first presented at the Beltcon Conference in 2019.

Copyright is vested with IMHC. www.beltcon.org.za Marc dos Santos Tel: +1 404 518 0620 Email: marc@dossantosintl.com.

In this application, as is typical, the new shiploader is perpendicular to the existing dock conveyor, and its elevation is such that a high angle path is necessary to reach the height required within the horizontal space available. The sandwich conveyor was therefore integrated into the design.

The initial design concept used a conventional conveyor stinger boom from the tripper to the tail of the high angle conveyor.

This had the disadvantage of the transfer and extra equipment so the client readily embraced the idea of running the tail of the high angle conveyor back to receive the material directly from the dock conveyor tripper. Attempted implementation of this new arrangement immediately revealed that sufficient tripper height did not exist to allow the tail of the sandwich belt high angle conveyor.

The space around the existing dock conveyor is very restricted in height, and the tripper onto the high angle conveyor tail accordingly does not allow enough space for the transfer (See Figure 14). The limitation is so severe that the minimum pulley diameter required for the standard sandwich conveyor belt consumes too much of the space. Therefore, the Adder

Figure 14: Limited space in case study tail section

Figure 13: Adder Snake cross-sections at increasing angles. Left column of images is 1200 t/h capacity, right column is 2400 t/h capacity. Rows start at top at 60 degrees and progress to bottom at 90 degrees. Orange (Adder) belt’s center length increases, which in turn decreases neutral axis depth.

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nternational, Inc. obally recognized bribery business organization and provider of third isk management solutions.

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LIFTING

Compact and Easy to Assemble The Potain MR 418 luffing jib cranes, which are equipped with full frequency-controlled mechanisms for precision control, offer fast lifting speeds with a maximum capacity of 24 tons and a maximum jib length of 60 metres.

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vailable from Crane & Hoist Equipment SA, the crane is extremely compact, is quick to assemble, quick to commission and capable of extremely fast lifting speeds on high rise job sites.

The crane delivers its best performance when fitted with the optional 270 LVF 120 hoist which offers a great lifting capability and is perfect for high rise buildings, including super tall structures.

The flexibility of choice with the design means customers can select the optimal configuration for them, ensuring they earn the best possible financial returns for their requirements

The Potain MR 418 offers faster lifting speeds.

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Impressive statistics

The 200 kW hoist provides 826 metres of rope capacity, which means that in a singlefall configuration a hook path of 413 metre is possible, while in a two-fall configuration 206m of vertical reach is possible.

In addition, the winch can reach speeds of up to 254 m/min for better productivity, while the power control function means it can operate off varying power inputs, allowing it to cope with lower power supplies on site.

Spoiled for choice

Customers not requiring the full power of the 270 LVF 120 hoist winch can choose the 150 LVF 120 hoist. This hoist has a drum capacity of 552 metres and can produce line speeds of up to 210 m/min. The flexibility of choice with the design means client can select the optimal configuration for them, ensuring they earn the best possible financial returns for their requirements.

But it is not only new mechanisms and better lift capabilities that are likely to appeal to customers, the crane’s user-friendly design has the luffing mechanism and hoist mounted inside the counter jib while there is also a large, easily accessible service platform behind the cab, giving technicians a single location from which to access all major service points.

The crane is extremely compact, is quick to assemble, quick to commission and capable of extremely fast lifting speeds on high rise job sites Quickly getting the crane into service comes courtesy of a new on-board control system that allows the technician to commission the crane into operation just minutes after assembly is completed. Simple input of the jib length, working height and test load into the crane’s control board allows for a fast and accurate calibration.

In terms of working height, Potain’s intelligent mast system gives the crane enhanced flexibility to cope with the challenges of modern high-rise buildings. The crane can be installed on fixing angles or on various sized chassis of 6 metres x 6 metres, 8 metres x 8 metres and 10 metres x 10 metres.

Crane & Hoist Equipment SA Brenden Crous Tel: (083) 424 2658 Email: info@che-sa.co.za www.che-sa.co.za

Among the advantages of the luffing jib crane is that it is extremely compact, quick to assemble, quick to commission and capable of extremely fast lifting speeds on high rise job sites

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MINERALS PROCESSING

Compressed Air to Help Dump Reclamation Project Rand-Air’s latest project involves the reclamation of four historical mine dumps at the site of the former Zincor zinc refinery just to the south of Springs. The refinery was constructed from a former uranium plant belonging to the defunct Vogelstruisbult gold mine.

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he dumps include a high-hazard certified waste tailings dam, two gold tailings dams and an iron/lead/zinc residue dump.

The initial phase of the project entails hydromining the neutral leach dump, which comprises 2.5 million tons of zinc material that will be processed over an eight to nine year period. The neutral leach dump was formed between 2000 and 2010 as a result of zinc/copper ore treatment from the effluent plant. The zinc tailings will be treated with acid

leach filtration followed by hydroxide precipitation and filtration.

Valuable minerals

This metals reclamation project is being carried out by mineral and metals processing company, EBM Projects. The project has a net present value in excess of R1 billion and the estimated value of the property’s remaining in-situ lead, silver, gold and iron-ore resources is estimated at about R22 billion.

The project has a net present value in excess of R1-billion and the estimated value of the property’s remaining in-situ lead, silver, gold and iron-ore resources is estimated at about R22 billion By removing potentially hazardous metals from these defunct dumps, EBM Projects is eliminating a potential environmental risk, while creating direct and indirect work opportunities for some 700 individuals.

This initiative is welcome in a region where job opportunities are relatively scarce.

Air to remove water

“We are hiring out three of our top-ofthe-range compressors, two GA315FF and a GA160VSDFF. The compressed air is being used to operate the filter presses which remove water from the mineral products,” explains Rand-Air’s business development manager, Henry Fourie. The rental contract commenced in February this year and will continue for a five-year period.

In line with their long-term rental solutions ethos, all support and necessary maintenance is undertaken by Rand-Air. “We have made commitments to rapid response in the unlikely event of a technical issue and, if we are not able to provide an immediate solution, we’ll provide EBM Projects with an exchange unit.”

By doing this, Rand-Air relieves EBM Projects of the burden of sourcing compressed air, allowing the minerals company to concentrate on its core business.

Rand-Air Henry Fourie Tel: (011) 345-0700 Email: benita.oosthuizen@randair.com www.randair.co.za

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CYCLONE CIRCUITS

Driving Down Costs While Increasing Performance Process plant optimisation techniques have become a necessity for mines looking to maximise their operating performance by keeping costs low, throughput high and downtime to a minimum.

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LSmidth’s automated SmartCyclone system is a solution that delivers in all three areas for cyclone circuits, a vital processing element in any plant.

It is a monitoring and control solution for reducing cyclone-related process deviations. It also improves overflow particle size distribution, predicts and controls cyclone maintenance schedules, and optimises closed-circuit grinding processes.

Reducing or eliminating manual operation, which decreases the potential for human error, is in fact one of the overarching benefits of the system This equates to monitoring the performance of individual cyclones within a circuit in real time, preventing unplanned breakdowns from occurring and monitoring wear rates while ensuring the cyclones are operating optimally at all times. This

translates into higher efficiencies in the plant and ultimately, higher profitability.

Technology to sense malfunctions

The SmartCyclone closed circuit grinding optimisation system combines a variety of FLSmidth patented technologies which includes the Krebs SmartCyclone wear detection sensor technology as well as the Krebs’ patented roping sensor technology with a wireless controller system. This immediately identifies if a cyclone is malfunctioning.

The closed circuit grinding optimisation system also incorporates FLSmidth’s ECS/ProcessExpert process control software with a SmartWear cyclone maintenance algorithm. One of the largest benefits associated with this software is the ability to develop a uniform operation strategy that outlines the best way to run the plant. Once this strategy has been established, the necessity to train new operators is reduced.

Reducing or eliminating manual operation, which decreases the potential for human error, is in fact one of the overarching benefits of SmartCyclone.

FLSmidth www.flsmidth.com

SmartCyclone manifold system installed with roping sensors monitor and react to cyclones when roping occurs

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WORLD-CLASS performance requires speed, agility and endurance

STRATEGY

INFRASTRUCTURE

OPERATIONS

Planning strategic direction benchmarked to world-class standards

Development of world-class infrastructure from concept to realisation

Development of operations to best practice and world-class standards

Supply Chain Strategy

Facility Design & Development

Process & Operations Design

• Supply Chain network analysis & design • National & Regional DC strategy development • Facility Sizing and OPEX estimates • On-line fullllment • Slow vs. Fast movers network set-up • A Supply Chain that supports business strategy • Site development strategies • Technology, IOT and digitilisation strategy

• Greennelds site development

• Operations assessment and benchmarking • WMS / WCS review • WMS / WCS functional requirements • Process and operations optimisation • Long term operational development strategies • Process audit • Labour standards and incentive programs

planning • Brownnelds site development planning • Functional building requirements speciication • Technical liaison to professional / development team • Facility sizing requirements (short to long term) • Design to execution • Procurement, program and vendor management

In today’s competitive business world you need to focus on every opportunity to advance your company mission

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ils-ct@ils.co.za ils-jhb@ils.co.za www.ils.co.za

FRONT-END LOADERS

Boosting Productivity Special Sany coal-handling buckets boost productivity at Kusile Mining

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he addition of special coal-handling buckets to the three Sany SYL956 front-end loaders acquired by Kusile Mining from Goscor Earth Moving has improved productivity at the company’s two opencast mines. Kusile Mining is part of African Coal Trading (ACT).

Kusile Mining operates Uitspan Colliery just outside Emalahleni, and Noodhulp Colliery close to Eskom’s Hendrina power station. Uitspan Colliery supplies its run-of-mine material to Puleng, while Noodhulp Colliery supplies Woestleen. The two processing plants have a combined throughput of about 220 000tph.

The front-end loaders have an operating weight of 17 100 kg, with the larger buckets, to allow for quick and precise loading, resulting in faster cycle times

that the bigger bucket loads a typical 15m3 tipper in three loads, compared with six or more with a standard bucket.

The relative density (RD) of coal is light at 1.2 compared with other materials like sand at 2.7.

“We took into account the lifting capacity of the wheel loader, the weight and dimensions of the bucket, and the specific weight of the material being handled,” adds ACT Group Engineer, Hendrik Pieterse.

This made it possible to equip the 5 ton SYL956H front-end loaders, with an operating weight of 17 100 kg, with the larger buckets, to allow for quick and precise loading, resulting in faster cycle times.

It not only increases productivity, but reduces fuel consumption significantly.

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

Finance offered

Two of the three SYL956H loaders have been deployed at Puleng, while the third works at Woestleen.

Brad Freeman, sales consultant for both brands under GEM explains that, having previously used rented front-end loaders, Kusile Mining recently decided to purchase its own equipment outright due to assistance from Goscor Finance.

Less work with bigger buckets The front-end loaders had to be supplied with special 4.6 m3 coal buckets, as opposed to the standard 3.2m 3 buckets.

Mine Manager Dries van der Vlies, explains

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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EARTHMOVING

Excavators Excel in Technology, Safety and Emissions The first Hitachi 120t EX1200-7 excavator, a new addition to the EX-7 Series, recently arrived in South Africa.

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he smallest machine in the EX-7 series, the EX1200-7, comes in two configurations, backhoe or shovel, and packs a punch with a 4.5% increase in bucket capacity, optimised swing control and an upgraded hydraulic system, including a flow-regeneration valve, which means lower power requirements, lower fuel consumption, and increased pump life.

“Fuel efficiency was a major factor in the design of this series because we recognised the importance of caring for the environment while remaining profitable. These machines make this easier than ever before,” says Hitachi Construction Machinery (HCM) Africa’s marketing & business development manager, Marius Weber.

Clients can access excavator information from a personal computer on a daily basis thanks to built in technology The electric-controlled main pump and a hydraulic regeneration circuit added to this latest line of machinery, reduces fuel consumption by up to 10% in some models, and also includes a linear controlled oil cooler and radiator fan clutch throughout the EX-7 series.

Emissions under control

In addition, different engine options are available, in particular the FCO (Fuel Consumption Optimisation) configuration chosen for the African market, thanks to the emissions reduction technology employed in their design.

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Improvements have been made in terms of fuel economy, with functions such as shutdown control which, when activated, prompts the machine to switch to “soft key off” status” to prevent unnecessary fuel burn.

“Customers now have the option to choose between various power supplies, allowing for regional regulatory compliance and/or preferential satisfaction,” Marius adds.

HCM provides a choice between an MTU internal combustion engine or a Cummins gas engine for all models from the EX2600 upwards.

Meanwhile, the EX1200-7 offers some structural improvements on its predecessor, the EX1200-6, with the track frame’s swing circle having been upgraded from a cast structure to a forged structure, and the top plate thickness increased from 50mm to 55mm for greater durability. The EX1200-7 also has an improved grease system that enables automatic lubrication to grease all points in the superstructure, including the bucket pins.

Technology to help with maintenance

Further to the reduction in operating costs and increasing of production capacity, the excavators include a number of Hitachi’s technologies for digital integration.

Global E-service and ConSite are remote machine management systems that monitor and report on machine health, allowing clients to ensure that the EX-7 machines consistently deliver at maximum efficiency. ConSite also allows clients to access status

Functions such as shutdown control prompt the machine to switch to “soft key off ” status” to prevent unnecessary fuel burn

information on their machines from a personal computer on a daily basis.

Contamination sensors on all main hydraulic pumps, centre joints and swing motors of the new EX-7 Series can detect contaminants that may cause damage to any of these components and alert the operator of potential contaminants and record the fault in the DLU (Data Logging Unit), even remotely advising maintenance control.

Addressing safety issues

Among several new features added to the series is the Aerial Angle, which is a 360º peripheral vision

display system that feeds live footage from cameras mounted on the excavator, improving overall safety for both operator and mine.

In terms of safety, the EX-7 now also has an MDG 15 regulation standard dual isolator switch for both the engine starter and the battery, which aids in safely troubleshooting and downloading machine information.

Hitachi Construction Machinery Marius Weber www.hitachicm.co.za

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LUBRICATION

A Different Kind of Fish Oil The harsh environments experienced by supply ships and their limited down-time between jobs means that maintenance of standard components, such as wire rope is both essential and challenging.

The SKF automatic lubrication solution for wire rope is proving popular with Thor an operator of support vessels for the oil, gas and pipelaying sectors, where it is being used across their global fleet, as it promotes safety as well as profitability.

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he loads that supply ships carry are frequently heavy, making thorough care of winches crucial. At regular intervals, the crew must lubricate the steel cable to reduce friction and minimise wear. Frequent lubrication is important, as the fleet often has a full schedule and cannot afford downtime.

Reducing downtime

The wire rope lubricator (WRL), launched by SKF in 2016, has been reducing downtime and prolonging service on many fleets. It eliminates manual lubrication and is available in a range of models for use with any wire rope up to 52mm in size. It is designed to deliver highly effective lubrication in virtually any application using wire rope, including oil and gas rigs, wharf and ship cranes, deck winches, ship hoists, remotely operated vehicles

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and winding machines in mines. The WRL can also significantly increase of the steel wire rope lifetime compared with wire rope lubricated conventionally.

ensuring every strand is evenly coated.

This reduces friction and heat generation, while protecting against corrosion.

In the case of Thor the company has already installed automatic lubrication on five of its eleven ships that are often working for weeks at a time servicing locations ranging from Angola to Greenland. Lubrication was previously applied by hand, sometimes to ropes that are several hundred meters in length.

The automatic system can easily be operated by every crew member from a knuckleboom crane or winch, which significantly reduces potential risks to crew members, while increasing the lifespan of each wire rope.

In addition, a groove cleaner also removes old lubricant before applying the new protective coating.

Exact amounts applied

Supporting all lubricants typically used with wire rope, the WRL ensures optimum lubrication by applying the exact amount of grease required.

The system distributes grease across the surface of each rope and forces it deep into the rope’s core

It is designed to deliver highly effective lubrication in virtually any application using wire rope, including oil and gas rigs, wharf and ship cranes, deck winches, ship hoists, remotely operated vehicles and winding machines in mines

SKF Samantha Joubert Tel: (011) 821-3602 samantha.joubert@skf.com www.skf.com

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MINING MAINTENANCE

Rubber Solves Africa’s Largest Copper Mine’s Woes Kansanshi mine has significantly reduced costs and improved productivity by applying Weir Minerals’ Linatex rubber lining solutions.

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ansanshi, Africa’s largest copper mine, is located near Solwezi in Zambia. The mine site is very remote, so getting parts and replacement material to site is time consuming and costly.

The CCD overflow tank during the Linagard lining installation process at Kansanshi

Of particular concern for the operation was excessive

The lining was completed well within the allotted time, saving Kansanshi unnecessary and costly plant downtim

Weir Minerals Africa also does rubber lining at the factory based in Alrode

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A tailings pipe lined with Linatex premium rubber.

wear in the tailings lines, as well as the overflow tank in the continuous counter-current decantation (CCD) circuit.

There is approximately 8km of tailings pipes running from the plant to the tailings dam. The mine had previously lined their pipes with a combination of HDPE liners and ceramic tiles. These, however, only achieved a wear life of approximately nine months.

An alternative solution

The CCD overflow tank during the Linagard lining installation process at Kansanshi

Kansanshi approached Weir Minerals Africa for an alternative solution and the company, which has a long-standing relationship with the mine, specified Linatex premium rubber to line the tailings

After 36 months in operation the lining showed minimal signs of wear, and the installation has reduced the mine’s total ownership cost by over R1,6 million per annum pipeline. Known for its wet abrasion properties, Linatex rubber also requires a considerably shorter time for lining installation when compared to tiles.

The lining was completed well within the allotted time, saving Kansanshi unnecessary and costly plant downtime.

After 36 months in operation, the lining showed minimal signs of wear, and the installation has reduced the mine’s total ownership cost by over R1,6 million per annum.

Overflow tank also talking strain

Kansanshi also needed a more cost effective wear solution for the overflow tank in the CCD circuit.

This had previously been lined with ceramic tiles, which only lasted between 60 and 90 days. The tiles were wearing away quickly due to the high impact and abrasion of the stones and sand flowing through the tank. Wash out between the tiles was preventing the tiles from sticking to the metal substrate and the subsequent damage to the tank required repair work.

In response, the Weir Minerals team specified Linagard nitrile-based rubber (NBR). The expected cost savings from the increased production and reduced maintenance offset the installation costs.

Since installation, the Linagard NBR 30 has lasted 36 months without any visible signs of wear. This represents 18 times longer wear life than the previously installed products.

Weir Minerals Africa Email: contact-us@mail.weir www.minerals.weir

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MARKET FORUM

Enhancing safety with curtains According to statistics, a significant number of forklift fatalities occur within manufacturing facilities. While driver education on the correct operation of forklift trucks is a primary goal in reducing this risk, other elements also come into play.

Wim Dessing, sales executive of Apex Strip Curtains & Doors, says that accidents can occur at entry and exit points and that by ensuring maximum visibility, the risks associated with the movement of vehicular traffic can be substantially reduced.

Apex general purpose strip curtains are produced using specially formulated PVC material which is transparent for increased visibility and will not discolour, crack or tear over time. The individual strips incorporate the company’s patented Balledge feature which, while ensuring an effective thermal seal at all times, allows the strips to part easily allowing unimpeded movement of personnel or vehicular traffic.

Apex Strip Curtains & Doors Wim Dessing Tel: (011) 452-8723 Email: apexstri@global.co.za www.apexstrip.co.za

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BMG-PT18102019 - BHT

Nov/Dec 2019

MARKET FORUM

Phase two of Tema port expansion under way

Aecom has been awarded phase two of the Tema Port expansion project (TPEP) in Ghana, on behalf of Meridian Port Services (MPS), operator of the container terminal.

Phase one of terminal three was formally opened for shipping business on 28 June, following successful tests and simulation exercises of the project by MPS. “Phase two includes project management services for the fourth berth marine and landside works, due for completion

by December 2020,” says Darrin Green, managing director for civil infrastructure at Aecom.

The team is currently overseeing project management and construction supervision services as part of the first phase, including marine, land, and building works packages, as well as project controls, contract administration, construction

management, health, safety and security management, and environmental and social performance management.

Once complete, the TPEP will have a new, state-of-the-art container terminal. This will include a new 1.4km long quay housing four container berths, container stacking yards, a 4km rubble-mound breakwater, a 19 metre deep port access channel, and various supporting port infrastructure and services.

The development will enable the port to accommodate some of the world’s biggest container ships, and improve cargohandling services and capacity.

Aecom Lara Lombard Tel: (012) 421-3832 Email: lara.lombard@aecom.com, www.aecom.com

Loader crane market on the increase The versatility and flexibility of a loader crane makes it a preferred choice for many industries such as construction, forestry, agriculture, oil and gas, manufacturing industry, transport and logistics, and waste management due to its efficient loading and unloading abilities.

A study projects that increasing demand from construction, logistics and, building activities will continue to create an overall positive growth scenario for the loader crane market in the near future.

verability, the high lifting capacity offered by loader cranes, will also drive the adoption in coming years.

Persistence Market Research Tel: +1 0800 961 0353 Email: sales@persistencemarketresearch.com www.persistencemarketresearch.com

Since lifting limitations associated with conventional cranes include lifting capacity, poor driving comfort, and difficulty in steering maneu-

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MARKET FORUM

Compressed air on the back of truck Featuring a compact, rugged design and extended service intervals, the 8 Series Utility portable compressor range has been specially engineered and developed by Atlas Copco for secure integration into utility trucks and other OEM applications in the mining and construction sectors.

Ian van der Walt, sales manager at Atlas Copco Power Technique dealer, Airlif Compressors, explains that the mining sector uses mobile service trucks on their plants to attend to breakdowns on mobile equipment. “Portable air compressors mounted onto these trucks supply the compressed air to pneumatic tools required to complete repairs.

“With a 10% smaller footprint on average compared with other compressors, the unit’s compact, generator-like box shape design fits easily on the back of the utility truck. In addition, the lightweight compressors can be lifted and mounted onto these vehicles,” says Ian Easy-to-open panels, easy-to-access components and no special tools required, enables excellent serviceability of the Utility range. Added to this, with service intervals of up to 1 500 hours compared with the standard 250 hours for comparable units, customers can enjoy up to six times more uptime and productivity.

Atlas Copco products are engineered and not assembled which is one of the reasons why the Utility range is the best-

Airlif compressors standardises on Atlas Copco U110 and U110PACE compressors

fit portable, flexible compressed air solution,” Ian concludes.

Atlas Copco Sara Liljedal Tel: +46 8-743-8060 Email: media@se.atlascopco.com www.atlascopcogroup.com

Low cost, high performance bearings roll into SA A European supplier of high-quality, low-cost bearings for a range of industrial, agricultural, and automotive aftermarket applications is the latest international brand to be added to the product stable of Bearings International (BI).

“The supplier, Craft Bearings, gives end users the assurance of quality, tested bearings that are also more affordable,” BI business unit head, Ross Trevelyan comments.

BI offer marketing manager, Victor Strobel, reveals that the new range will be introduced in a phased approach. Ball bearing units, the largest-volume sellers, will be introduced

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initially, and tapered roller bearings, cylinder roller bearings, and deep groove roller bearings later on.

Craft Bearings is the only manufacturer at the lower end of the price market that boasts a laboratory where product batches are tested in accordance with an acceptable quality limit. “Our rigorous testing protocol encompasses visual and dimensional testing, as well as measuring longevity for particularly arduous applications,” Craft sales director, Virgilijus Lapènas concludes.

Bearings International, Victor Strobel, Tel: (011) 899-0000 Email: info@bearings.co.za, www.bearings.co.za

MARKET FORUM

Equipment to clean-up KZN delivered

Equipment to be used for the clean-up of the province’s municipal areas

ELB Equipment has secured a large order for Government’s Green Good Deeds campaign which is aimed at cleaning-up rubble within the municipalities of KwaZulu Natal.

The campaign aims to bring financial relief to municipalities which have been hiring equipment such as backhoe loaders (BHL), graders, rollers and trucks at great cost to clean up their areas. In addition to clean-ups, the equipment will be used to build, maintain and renew infrastructure such as drains, pipelines, outfalls and clearing operations.

ELB Equipment divisional director, Desmond van Heerden, says the company was able to supply the majority of yellow equipment (27 machines) for the R104 million contract, with trucks, water tankers, honey-suckers and a fire engine secured by vehicle suppliers.

ELB Equipment Desmond van Heerden Tel: (011) 306-0722 Email: desmondv@elbquip.co.za, www.elbequipment.com

Predictive maintenance thanks to AI SKF has acquire Presenso, a company that develops and deploys artificial intelligence (AI) based predictive maintenance software. Presenso’s AI capability enables production plants to find and act on anomalies that were previously difficult to detect, automatically and without the need to employ data scientists. Presenso’s competence will be used to strengthen SKF’s rotating equipment performance offer.

Victoria Van Camp, CTO and president, innovation and business development, says, “SKF is all about solving real world challenges and we are welcoming a team of world-class AI developers, with a productionready analytics solution into SKF.” SKF Samantha Joubert Tel: (011) 821 3500 Email: samantha.joubert@skf.com www.skf.com

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MARKET FORUM

Cold crushing Metso is delivering three Lokotrack crushing and screening plants retrofitted for extreme cold for the reconstruction of the U.S. National Science Foundation’s (NSF) McMurdo research station in Antarctica. The equipment enables crushing in temperatures as low as -40 °C. McMurdo Station, located on an island in the Ross Sea, is the U.S. Antarctic program’s logistics hub and the largest of the three stations that the U.S. operates in Antarctica. McMurdo is being rebuilt under the Antarctic Infrastructure and Modernization for Science (AIMS) project, a long-range initiative to upgrade the station to make it logistically and energy efficient.

years in crushing the ground materials for the new buildings. All in all, this will amount to more than 126 000 cubic metres of aggregates.

In the extreme conditions of Antarctica, the equipment can only be used during the Southern Hemisphere summer, which lasts from October to April. The hard basalt to be crushed will come from an area near the station.

The equipment to be delivered to Antarctica, the Lokotrack LT106 jaw crusher plant, the LT200HP cone crusher and the ST3.8 mobile screen are all retrofitted

for extreme cold. “Every part sensitive to cold has been fitted with immersion heaters and extra insulation. The selected oils and other fluids are suitable for the Antarctic climate and the specially manufactured conveyor belts run even in extremely cold weather,” says Marko Salonen, Project Manager at Metso’s aggregates equipment business area.

Metso Marko Salonen Tel. +358 40-515-9853 Email: marko.salonen@metso.com www.metso.com

Metso’ equipment will be used for three

A one stop shop With a wide range of products and services under one roof, Smith Power Equipment has over the years redefined the one-stop shop model when it comes to the provision of application-specific equipment solutions specially adapted to suit an array of applications in an array of industries. One industry that has benefitted from this approach is the materials handling sector.

In recent years Smith Power Equipment positioned itself as a solution for the materials handling sector following distributorship agreements with AUSA, a Spanish OEM renowned for its extensive range of rough terrain forklifts and allterrain telescopic handlers, and Baoli, a leading global manufacturer of materials handling equipment. The brands, complementary in their very nature, offer a wide range of capabilities for materials handling customers.

Tom Bloom, Director at Smith Power Equipment says, “The model gives us the ability to support a customer in more

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ways than one. It’s our strategy when it comes to being able to help a customer will all their equipment needs from a single provider.”

Nov/Dec 2019

Smith Power Equipment Robert Keir, Tel: (011) 284-2000 Email: robertk@smithpower.co.za Web: www.smithpower.co.za

High security welded mesh

Pallisade

Gates

Gate Automation

Razor wire and more ....

What is High Security Weld Mesh HIGH Security Weld Mesh is wire fused and welded at a Horizontal distance of 76.2mm and a vertical distance of 12.7mm also known as 35B/3510 where 3 denotes 3”(distance between vertical wires), 5 denotes 0.5” (distance between horizontal wires), and B or 10 denotes gauge of wire

Salient Features • Difficult to Climb: The spaces between the Horizontal wires are too narrow for fingers to have grip • Impregnable: Extremely difficult to cut with a hand cutter as the beak of a wire cutter will not be able to penetrate the horizontal wires • Excellent Replacement option to Solid Wall as: 1. More economical than a solid wall 2. Faster to install than a solid wall 3. CCTV Camera has a clear view • Further upgrade possible with electric security system • Anti-corrosive & low maintenance

Standards

• Manufactured according to BS EN 10016-2 • Wire Sizes in accordance with BS EN 10218-2 • Tolerance on Mesh Size in accordance wiht EN 10223-7 • Tolerance on Panel Size in accordance with EN 10223-4 • Welding Strength in accordance with BS EN 1461 • Zinc Coating in accordance with EN 10245-1 • Anti Corrosion in accordance with BS En 3900 E4/F4

Tensile Strength • Wire has a tensile strenght of min 550 MPA

MARK: 083 454 6488

Email: mark@palifence.co.za

www.palifence.co.za BULK HANDLING TODAY

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