2013/11 - Bullk Handling Today by Promech Publishing

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l

T O D A Y

Nov/Dec 2013

Exclusive South African Agent of:

m THE IN’S AND OUT’S OF FLOW PROPERTIES IN MATERIALS HANDLING m BULK HANDLING Nov/Dec m WHO DOES WHAT IN CONVEYING m TODAY

2013

BULK HANDLING TODAY

Nov/Dec 2013

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l

T O D A Y

Nov/Dec 2013

Exclusive South African Agent of:

m THE IN’S AND OUT’S OF FLOW PROPERTIES IN MATERIALS HANDLING m m WHO DOES WHAT IN CONVEYING m

BULK HANDLING TODAY

Nov/Dec 2013

BULK HANDLING TODAY

Nov/Dec 2013

BULK HANDLING TODAY

Nov/Dec 2013

BULK HANDLING TODAY

Nov/Dec 2013

Team Macsteel

BULK HANDLING TODAY

Nov/Dec 2013

Marco Marques, GM at A.J.M. Engineering Services

BULK HANDLING TODAY

Nov/Dec 2013

VSD results in less mechanical wear on the equipment in general

Regardless of the size and level of sophistication of a lifting requirement, quality, and especially safety, is our foremost priority and something we simply wonâ&#x20AC;&#x2122;t compromise on

Weâ&#x20AC;&#x2122;ve designed custom built cranes and lifting devices for several unique applications ranging from large overhead cranes to lift locomotives, through to special solutions for the manipulation of carriages

BULK HANDLING TODAY

Nov/Dec 2013

3-6 FEBRUARY, 2014

Cape Town, South Africa

Cape Town South Africa

Where the World Connects with African Mining. Mention offer code M14BHT and save US$100 through 24 January 2014

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BULK HANDLING TODAY

Nov/Dec 2013

www.m in in gin daba.co m

A massive 80 ton counterweight provides the required tension to keep the belt operating trouble-free and without slippage at either end

BULK HANDLING TODAY

Nov/Dec 2013

Wouter Deijs of BSFSA

There is a direct correlation between the problems and a clear lack of understanding of the behaviour of such materials under various flow conditions

BULK HANDLING TODAY

Nov/Dec 2013

Samples of material for testing

There are just too many variables under different conditions which all have an impact on how the material flows

Material flow testing equipment

All flow problems can be minimised and, in most cases, totally eliminated

BULK HANDLING TODAY

Nov/Dec 2013

ABC Hansen Afripp Projects AMD-Rotolok Africa

Name of company

BMG

Brelko Conveyor Products

Total Number of Employees

1398

160

Employees with tertiary qualifications

Number of years operating in SA

Private

Public

Private

N/A

Yes

Belt, Chain, Bucket, Spiral, Pipe, Pneumatic, Screw

Belt

Chain, Bucket, Screw

Belt, Chain, Bucket, Pocket, Pipe

Belt

Ownership BEE rating ISO Accredited Type of conveyors handled Primary area of expertise: ▪ Overland ▪ Underground ▪ Bulk Handling Machines (stackers, reclaimers, loaders etc)

Contract to supply and install: ancillary items such as crushers, chutes, screens, apron feeders, etc

Yes

R 17.5m

R3.5 m

R2.7 m

R2 m

+-85

Value of largest contract completed in past 5 years

15 m

R2.5 m

R2.8 m

R2 m

Size of largest contract in terms of tons conveyed per hour

450

5000

1500

2 200

▪ Conceptualisation to commissioning

▪ Work to specification

Total value of last two contracts Number of projects completed in 2012

Capabilities:

▪ Sub-contractor for specifics ▪ Turnkey

▪ Manufacture and delivery to site

▪ Assembly on site

▪ Commissioning

▪ On-site supervision

Service support:

▪ Personnel training

ü ü

▪ On-site annual shutdown service Number of export orders: over past 5 years

ü ü

600

Percentage of total business

30%

15%

Total value of export orders: over past 5 years

R30 m

R2.8 m

R70 m

Yes

SAIMechE, CMA, SAIMH, ECSA

CMA

CMA, SAIMH, ISO 9001, Empowerdex OHSAS 18001, International Dry Bulk Terminals Group, SEIFSA

CAD and/or CAM facilities

Professional affiliations

BULK HANDLING TODAY

Nov/Dec 2013

Bulkmatic Solids Machinery

Conveyor & Industrial Supplies

Clyde Bergemann Africa

DemcoTECH Engineering

Dunlop Belting Products

ELB Engineering Services

200

267

167

Private

Public

8 Yes

Yes

Belt, Chain, Bucket, Pipe, Pocket, Spiral, Pneumatic, Screw

Belt, Bucket, Pocket

Pneumatic

Belt, Chain, Bucket, Pocket, Pipe, Sandwich, Pneumatic, Screw

Belt, Bucket, Pocket, Pipe

Belt, Chain, Bucket, Pipe, Sandwich, Pneumatic, Screw

Yes

R154 000

R8m

R30 m

R120 m

R150 m

R2 bn

785 pieces of equipment

R2,07 m

R55 m

R5 bn port expansion

R74 m

R350 m

140

180

10 000

± 3000

4 000

ü ü

ü 52

110

8,2%

50%

35%

R13.5 m

R200 m

R56 m

R1,5 bn

Yes

SEIFSA, ISO 9001

Professional Engineer

CMA, SAIMH, SEIFSA, SABS

CMA, SAIMH, SACOB

BULK HANDLING TODAY

Nov/Dec 2013

Goodyear Engineered Products

Lorbrand

Martin Engineering

Mato Products

Melco Conveyor Equipment

6300(Globally) 189 (S.Africa)

250

175

456

Employees with tertiary qualifications

Number of years operating in SA

Ownership

Private

Subsidiary of overseas principal

Private

Private 26% Black ownership

BEE rating

Yes

Belt, Pipe, Cable

Belt, Chain, Pipe

Belt, Cable

Belt

Belt, Pipe

▪ Overland

▪ Underground

Name of company Total Number of Employees

ISO Accredited Type of conveyors handled Primary area of expertise:

▪ Bulk Handling Machines (stackers, reclaimers, loaders etc)

ü ü

Contract to supply and install: ancillary items such as crushers, chutes, screens, apron feeders, etc

ü ü

Yes

Total value of last two contracts

R200 m

R140 m

R8 m

R18 m

R95 m

Number of projects completed in 2012

138

135

R140 m

R110 m

R65 m

R60 m

22 500

2 000

15 000

Value of largest contract completed in past 5 years Size of largest contract in terms of tons conveyed per hour Capabilities: ▪ Conceptualisation to commissioning

▪ Work to specification

ü ü

▪ Sub-contractor for specifics

ü ü

▪ Turnkey Service support: ▪ Manufacture and delivery to site

▪ Assembly on site

▪ Commissioning

▪ On-site supervision

▪ Personnel training

▪ On-site annual shutdown service

Number of export orders: over past 5 years

800+

Percentage of total business

10%

Total value of export orders: over past 5 years CAD and/or CAM facilities

Professional affiliations

BULK HANDLING TODAY

ü ü

±250

±30

1 120

90%

5-8%

20%

R250 m

600 m

R25 m

± R1.8 - 2 m

R+220m

Yes

CMA

CMA, SABS, IAF - ISO, CEMA, MERSETA, MEIBC, TUV

CMA, SAIMH, ECSA, Merseta, Chamber of Mines

CMA, SAIMH, ISO, SABS, SEIFSA

Nov/Dec 2013

PH Projects Holdings

Protea Conveyors

Rema Tip Top SA

Rula Bulk Materials Handling

Sandvik Mining Systems

Sure Guide

109

120

169

42%

85%

Private

Subsidiary

Private

Yes

Belt, Bucket, Spiral, Screw

Belt, Chain, Bucket, Pocket

Belt, Bucket, Pocket, Pipe

Belt, Chain, Bucket, Pneumatic, Screw. Cable

Belt

Yes

R124 m

R118 m

R11 m

R1 bn

R1500m

R 87 m

R96 m

R2.1 m

R800 m

R750 m

5 500

4 000

10 000

ü ü

60+

+50

15%

30%

26%

R1500 m

Yes

PMI, ECSA, Admitted Advocate, CA

CMA

CMA, German Chamber of Commerce

CMA

CCMA

BULK HANDLING TODAY

Nov/Dec 2013

Delivering Engineering Solutions with World Class Technology Partners Since 1919

Engineered to Deliver

Engineering Long-term Relationships

345 Rivonia Road, Rivonia, Sandton, South Africa PO Box 413149, Craighall, 2024 Tel: +27 (0) 11 772-1400 Facsimile: +27 (0) 11 325-6680 Email: sales@elb.co.za â&#x20AC;˘ Website: www.elb.co.za

BULK HANDLING TODAY

Nov/Dec 2013

Techmatic Engineering

Tenova Takraf Africa

ThyssenKrupp Industrial Solutions (South Africa)

Tubular Holdings

Total Number of Employees

400

2000

Employees with tertiary qualifications

80%

Number of years operating in SA

Ownership

Private

Subsidiary of Overseas Principal

Private

BEE rating

Yes

Belt, Chain, Bucket, Pipe, Pocket, Spiral, Pneumatic, Screw

Belt, Chain, Pipe, Pneumatic

Belt, Pipe

Belt, Chain, Bucket, Cable, Pipe, Sandwich

Name of company

ISO Accredited Type of conveyors handled Primary area of expertise: ▪ Overland ▪ Underground ▪ Bulk Handling Machines (stackers, reclaimers, loaders etc)

Contract to supply and install: ancillary items such as crushers, chutes, screens, apron feeders, etc

Yes

Total value of last two contracts

R14 m

R2 b

Number of projects completed in 2012

103

R32 m

R1.5 b

140

4000

Value of largest contract completed in past 5 years

Size of largest contract in terms of tons conveyed per hour

Capabilities: ▪ Conceptualisation to commissioning

▪ Work to specification

ü ü

▪ Sub-contractor for specifics ▪ Turnkey

ü ü

▪ Manufacture and delivery to site

▪ Assembly on site

▪ Commissioning

▪ On-site supervision

▪ Personnel training

▪ On-site annual shutdown service

Number of export orders: over past 5 years

Percentage of total business

15%

10%

Total value of export orders: over past 5 years

R45 m

R50 m

Yes

CMA, CIDB, NOSA

SAISC

Service support:

CAD and/or CAM facilities Professional affiliations

SAIME, SEIFSA

CMA, SAIMH

BULK HANDLING TODAY

Nov/Dec 2013

One Source

One Source for all your material handling needs FLSmidth delivers a complete line of reliable material handling systems designed for enhancing performance, increasing energy efficiency and safety, while helping to reduce emissions and operating costs. Rely on the brands you’ve come to trust – ROYMEC, RAHCO, KOCH, MVT, Buffalo & ABON. ROM TIPS • CONVEYORS • STOCKYARDS • PORTS • LOADOUT STATIONS • WASTE HANDLING SYSTEMS

For further information please contact us at: Tel: +27 (0)10 210 4000 • www.flsmidth.com BULK HANDLING TODAY

Nov/Dec 2013

BULK HANDLING TODAY

Nov/Dec 2013

Tega offers value added consultancy services and solutions

in Mineral Beneficiation, Bulk Solids handling, Wear and Abrasion customised to suit specific applications. With focus on core engineering applications in the Mining and Mineral Processing Industry, Steel plants, Power, Port and Cement Industries.

Tega Industries (South Africa) Pty Ltd

BULK HANDLING TODAY

P.O Box 17260, Benoni West, 1503, South Africa, Phone: (011) 421 - 9916/ 7, 421 - 6714, 421 - 6761, Fax: (011) 845 1472, Email: info@tegaindustries.co.za, www.tegaindustries.com

Nov/Dec 2013

TOTAL : Solution

BULK HANDLING TODAY

Nov/Dec 2013

Figure 2. Belt speed as a function of time for different additional head drive inertias

BULK HANDLING TODAY

Nov/Dec 2013

Figure 3. Belt tension as a function of time for different additional head drive inertias

BULK HANDLING TODAY

Nov/Dec 2013

Figure 4. Belt speed as a function of time for different additional head drive inertias using a brake

BULK HANDLING TODAY

Nov/Dec 2013

Figure 5. Belt tension as a function of time for different additional head drive inertias using a brake

BULK HANDLING TODAY

Nov/Dec 2013

BULK HANDLING TODAY

Nov/Dec 2013

The XTrack tracking device

Save R12 000 on its fuel bill when the tracking devices revealed repeated daily trips to the nearby township

BULK HANDLING TODAY

Nov/Dec 2013

Choose the type of monitoring they need as well as geo-fence areas that are not to be visited

SKF Power Transmission solutions customised for your system performance

Power transmission products play an important role in overall bearing performance and are the vital link between moving parts in equipment. By creating its own range of power transmission products, SKF can offer products that are well-matched and give engineers a wide design choice according to performance and cost considerations. Bringing power transmission products under a single brand offers significant user benefits apart from the confidence that comes from using a well-known brand.

The Power of Knowledge Engineering SKF South Africa (Pty) Limited Tel: +27 11 821 3500, Fax: +27 11 821 3501 Email: sales.za@skf.com, Web: www.skf.co.za

BULK HANDLING TODAY

Nov/Dec 2013

Managing director of MB Plant SA, Frank Reid

Product Summary

New Holland has a wide range of machines to cover various sectors of the construction, mining and industrial markets. These include: ∆∆ Excavators ranging from 1,5 tons to just under 50 tons.

We are working twice as hard to make sure we regain the trust of existing and new customers by delivering a service that is thoroughly professional

∆∆ Wheel loaders from the popular 18 ton general purpose machines to large 28 ton (5 cubic meter bucket) machines for coal, agricultural, processing yards. ∆∆ Motor graders from 12 ton up to 17,5 tons. ∆∆ Dozers from 15 tons to 40 tons. ∆∆ Telehandlers from 7 - 16 m masts with maximum lift capacities from 3.2 to 4,5 tons. ∆∆ Skidsteers, mini wheel loaders, mini excavators, backhoes skidsteers of various varieties are also available..

BULK HANDLING TODAY

Nov/Dec 2013

BULK HANDLING TODAY

Nov/Dec 2013

Ian Barnard, CEO of Kemach

Brenton Alexander, Kemachâ&#x20AC;&#x2122;s general manager for the central region

BULK HANDLING TODAY

Nov/Dec 2013

Global Leaders in Bulk Materials Handling

• • •

Hundreds of complete systems and equipment supplied globally Offer feasibility studies to turnkey and project-managed materials handling contracts African projects include Mozambique coal sector One of the longest single flight belt conveyors in the southern African region The largest number of Rapid Train Loading Systems and dome covered circular stockpiles in southern Africa

Tenova TAKRAF is a key supplier of equipment and systems for open pit mining & underground solutions, materials handling and mineral processing to the global mining and general industries

Tenova Mining and Minerals (Pty) Ltd, 58 Emerald Parkway Road, Greenstone Hill Ext 21 – Johannesburg, South Africa, 1609 Phone +27 11 201 2300 – Fax +27 11 455 4547 – Enquiries.TMM@tenova.com www.tenova.com a worldwide supplier products and engineering services for the iron and steel and mining industries 34 TENOVA BULKisHANDLING TODAY of advanced Nov/Dectechnologies, 2013

EARTHMOVING EQUIPMENT

New look parts centre

Bust stock yard and workshop

Alta Swanepoel

BULK HANDLING TODAY

Nov/Dec 2013

POWER TRANSMISSION

Better Bearing Life Since developing a range that is inter-changeable with the standard size Plumber blocks, many plant operators today specify that split roller bearings (SRB) be used in certain applications, particularly where the gearbox, or coupling has to be removed when a Plumber block bearing is replaced.

The split bearing concept eliminates the need to remove equipment on the shaft completely in order to change the old Plumber block type bearing By Mick Kerford

E Bearings in Johannesburg developed the “SN” and “SD” range to be equivalent to Plummer blocks in 2002. They then added a clever engineering concept of angled-split housing, introducing the new support system just two years ago. “Bulk Handling Today” talks to MD, Warwick Steinhobel.

Improvements

“Although the split bearing (SRB) concept eliminates the need to remove equipment on the shaft completely in order to change the old Plumber block type bearing, in some situations you still need to lift the shaft a little bit in order to get the bottom half of the split housing out from under the shaft,” Warwick explains. “This is

particularly true of fan installations so we decided to do something about it.” Originally the bearing was split through the middle, dividing the top and bottom support sections of the housing equally. The angled split, however, leaves the bottom part of the support bracket with one ‘leg’ of the bracket being much lower than the other, allowing the lower end to easily slip under a shaft without having to lift the shaft at all.

Features

“Naturally, the new SNQ series retains all the advantages of the original split bearing design,” emphasises Warwick. “The main one being how quickly it can be replaced. We’ve just installed a large 500mm diameter bearing on a bucket wheel stacker/reclaimer machine. In the past, this client set aside four weeks to change the bearing whereas ours took four hours for the fitting of our SRB, once the old one was removed. “Next time a bearing changeover will take no longer than eight hours at the most to remove and replace with a new one,” he adds. “Today time is big money, making the premium on a SRB system insignificant compared with the time saved to get up and going again.”

Alignment

Warwick Steinhobel, managing director of OE Bearings

BULK HANDLING TODAY

Nov/Dec 2013

Another advantage is the amount of swivel-play of the housing assembly within the support. The cradle in which the curved outer surface of the housing assembly sits is also curved, allowing the entire inner housing to swivel off-centre to the outer support. This not only helps to compensate for any slight misalignment, but ensures the seal

POWER TRANSMISSION

Fitting a split bearing on the bucket wheel of a stacker/reclaimer The new seal fitted on a SRB

remains concentric with the shaft at all times which means no ingress of dirt, thus extending the life of the bearing in general. What’s more, the SRB system does not need highly-skilled technicians to fit the bearing as it’s impossible to assemble and fit the bearing and housing incorrectly. Every part of the SRB Plumber block, the support, the housing and the bearing components are not only numbered, but also have offset pins on each half of the component. Technicians simply cannot fit the bearing the wrong way round because the pins won’t allow it. “Our system has been proven over and again to outlast the traditional Plumber block configuration,” Warwick claims. “Not so much because it’s better, but because installation is simple. The biggest mistake made with conventional Plumber block bearing is incorrect installation, and failure in alignment aspects, which we’ve largely eliminated with this system.”

Sealing

Another major improvement made on the SRB system is a unique new additional sealing arrangement on the outer side of the Plumber block housing to prevent the ingress of dirt and water into the housing. “The outer side-face surfaces of our housing are machined, leaving a smooth surface against which a double-lip V-seal now snuggly fits to seal off the gap between the shaft and the body of the housing,” explains Warwick. “This extra seal, criti-

cal for severely wet or dusty conditions, is held in place onto the rotating shaft with a cable-tie and as it is double-lipped, it can simply be flipped to use the other lip once the one side has worn off.

A unique new additional sealing arrangement on the outer side of the Plumber block housing to prevent the ingress of dirt and water into the housing “We’ve tested this arrangement on our test rig with a forced water jet directed directly at it and not even the slightest trace of moisture was found inside the housing after running it for an extended period of time,” Warwick says in conclusion. “All in all, we now have a bearing solution which has not only eliminated the age-old risk in terms of Plumber block installations, but will extend bearing life beyond what any customer has ever experienced to date.” OE Bearings, Warwick Steinhobel, Tel: (011) 493-4463 Email: warwicks@oebearings.co.za

The new angled support system (right) next to the normal support

Testing the new seal under forced water spray

Large angled support system in stock

BULK HANDLING TODAY

Nov/Dec 2013

Peter Small-Shaw, business development manager for Wilecâ&#x20AC;&#x2122;s mechanical division

The chain is branded as a Matco product in South Africa

Chains for conveyor applications

BULK HANDLING TODAY

Nov/Dec 2013

General roller chain for drive applications

BULK HANDLING TODAY

Nov/Dec 2013

MARKET FORUM

Sew Eurodrive GM sales and engineering, Conrad Pilger

ROMECH PUB p - T, O, G 2/20/11 9:54 PM Page 2

omposite

BULK HANDLING TODAY

Nov/Dec 2013

CY CMY

MARKET FORUM

BULK HANDLING TODAY

Nov/Dec 2013

MARKET FORUM

BULK HANDLING TODAY

Nov/Dec 2013

MARKET FORUM

Caterpillarâ&#x20AC;&#x2122;s Positive Pin Retention (PPR2) system is designed to reduce end play by eliminating the movement of the track pin

Spillex is an innovative spill control system developed in response to call from local conveyor companies

BULK HANDLING TODAY

Nov/Dec 2013

MARKET FORUM Osborn marketing director Martin Botha stands on an Osborn 3648 modular jaw crusher plant

An overview of the KOP conveyor installation showing the semi-fines product conveyor head chute

BULK HANDLING TODAY

Nov/Dec 2013

MARKET FORUM

BULK HANDLING TODAY

Nov/Dec 2013

MARKET FORUM

BULK HANDLING TODAY

Nov/Dec 2013

1THREAD_6023_BUL

BOOK YOUR TRAINING TODAY FOR A MORE PRODUCTIVE TOMORROW Take a look at the upcoming Drive Academy courses:

COURSE

Maintenance and repair of geared motors and troubleshooting

MOVIDRIVE速 B Operation, start-up and troubleshooting

MOVIMOT速 D Operation, start-up and troubleshooting

MOVITRAC速 B Operation, start-up and troubleshooting

MOVIGEAR速 B Operation, start-up and troubleshooting

Basics of drive engineering (for students and beginners)

DURATION

2 days

3 days

1 day

DATES

11 - 12 November

5 - 7 November

4 November

13 November

14 November

8 November

25 - 26 November

19 - 21 November

18 November

27 November

28 November

15 November

9 - 10 December

3 - 5 December

2 December

11 December

12 December

22 November

13 - 14 January

7 - 9 January

6 January

15 January

16 January

29 November

27 - 28 January

21 - 23 January

20 January

29 January

30 January

6 December

10 - 11 February

4 - 6 February

3 February

12 February

13 February

13 December

17 February

26 February

27 February

10 January

24 - 25 February

17 January 24 January 31 January 7 February 14 February 21 February 28 February

COST P / P

R5 500.00 excl. VAT R9 020.00 excl. VAT R3 080.00 excl VAT

R3 080.00 excl VAT

R3 300.00 excl VAT

R1 320.00 excl. VAT

Book today with Erika Louw on elouw@sew.co.za or +27 11 248 7294

BULK HANDLING TODAY

Nov/Dec 2013

BULK HANDLING TODAY

Nov/Dec 2013