BULK
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l
AFRICAN TRADING AFRICAN TRADING GROUP GROUP
T O D A Y
November/December 2015
Leebert Mocambique Leebert Zambia ATS Belting Supplies African Trading Supplies
Conveyor spillage - what are we missing? earthmoving in aFriCan ConDitions
Built solid Metso apron feeders backed by real-world experience Metso apron feeders are designed tough and built solid to handle the most severe impact conditions, because your productivity depends on it. Backed by experience with more than 4,000 feeders worldwide, you can rely on Metso’s equipment and reputation. They’re both rock solid. BEE Ownership Compliant metso.com – email: email: mmsa.info.za@metso.com
BULK
HANDLING
T O D A Y
Promech Publishing wishes all its readers a wonderful December break and a prosperous New Year
BULK HANDLING TODAY
November/December 2015
3
The South African Institute of Materials Handling
Sample
The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions. The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.
Company Affliates as at December 2015 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd
Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd
Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd
4 BULK TODAY 2015 Tel: (011)HANDLING 867-0902 l Fax:November/December (011) 867-0036 l Email: saimh@global.co.za l www.saimh.co.za
Simon Curry
BULK HANDLING TODAY
November/December 2015
5
ENDORSER OF “BULK HANDLING TODAY”
LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA
LEEASA, formed in 2003, is a division of the Chamber of Engineering Technology (COET), a non-profit organisation. The association’s objectives include, but are not limited to: the transfer of knowledge and training within the field of the Lifting Industry, to improve safety, promote the use of standards and to promote Professional and Ethical practices.
I
t is represented on the Engineering Council of South Africa (ECSA) and a number of ECSA committees as well as on various task teams at the South African Bureau of Standards (SABS).
What’s in it for you:
As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year). ECSA registered COET / LEEASA members are awarded one Continuing Professional Development (CPD) credit in category
3 each year. CPD is an ECSA requirement to retain registration. Members obtain a discount on training and seminars validated by the association, especially useful in earning ECSA CPD credits. Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry. LEEASA has some 500 members (Individuals and Companies).
Tel/Fax: (011) 787-1302, Email: engineer@netactive.co.za, www.leeasa.mirrorz.com BULK HANDLING November/December 2015 BULK TODAY HANDLING TODAY February 2012
7 1
8
BULK HANDLING TODAY
November/December 2015
BULK HANDLING TODAY
November/December 2015
9
African Trading Group
Afripp Projects
AMD-Rotolok
BMG
Brelko Conveyor Products
Total Number of Employees
50>
5
23
3000
150
Employees with tertiary qualifications
50%
3
6
-
27
5
15
47
42
28
Private
Private
Private
Public
Private
4
N/A
8
4
4
No
No
No
Yes
Yes
Belt, Bucket, Pipe, Screw
Belt
Chain, Bucket, Screw
Belt, Chain, Bucket, Pocket, Pipe
Belt
▪ Overland
ü
ü
-
ü
ü
▪ Underground
ü
ü
-
ü
ü
▪ Bulk Handling Machines (stackers, reclaimers, loaders etc)
ü
-
ü
ü
ü
Yes
Yes
Yes
Yes
Yes
R8+ m
R3.5 m
R2.7 m
R25 m
R1 m
4
20
+-85
-
30
R4 m
R2.5 m
R2.8 m
R15 m
R3 m
-
5000
1500
7000
2 200
▪ Conceptualisation to commissioning
ü
ü
-
ü
ü
▪ Work to specification
ü
ü
-
ü
ü
▪ Sub-contractor for specifics
ü
ü
ü
ü
▪ Turnkey
ü
ü
-
ü
ü
▪ Manufacture and delivery to site
ü
ü
ü
ü
ü
▪ Assembly on site
ü
ü
-
ü
ü
▪ Commissioning
ü
ü
ü
ü
ü
▪ On-site supervision
ü
ü
ü
ü
ü
▪ Personnel training
ü
ü
ü
ü
ü
▪ On-site annual shutdown service
ü
-
-
ü
ü
Number of export orders: over past 5 years
500>
5
+7
-
750
CAD and/or CAM facilities
No
Yes
Yes
Yes
Yes
CMA
CMA, SAIMH, ISO 9001, ISO 14001, OHSAS 18001, International Dry Bulk Terminals Group, SEIFSA
Name of company
Number of years operating in SA Ownership BEE rating ISO Accredited Type of conveyors handled Primary area of expertise:
Contract to supply and install: ancillary items such as crushers, chutes, screens, apron feeders, etc Total value of last two contracts Number of projects completed in 2014 Value of largest contract completed in past 5 years Size of largest contract in terms of tons conveyed per hour Capabilities:
Service support:
Professional affiliations
10
BULK HANDLING TODAY
-
SAIMechE, CMA, SAIMH, ECSA
November/December 2015
-
Bulkmatic Solids Machinery
Conveyor & Industrial Supplies
Clyde Bergemann Africa
DemcoTECH Engineering
ELB Engineering Services
Lorbrand
Mato Products
53
80
231
17
196
250
15
4
30
100
8
70
36
3
15
33
36
20
94
30
28
Private
Private
Private
Private
Public
Private
Private
8
L2
L3
6
4
-
6
No
No
Yes
No
Yes
Yes
Yes
Chain, Belt, Bucket, Pipe, Pneumatic, Screw, Spiral
Belt
Chain, Bucket, Pipe, Sandwich, Pneumatic, Screw
Belt, Chain, Pipe
Belt
-
ü
-
ü
ü
ü
-
-
ü
-
-
-
ü
ü
-
-
ü
ü
ü
-
-
Yes
-
No
Yes
Yes
No
No
R462 900
-
R19 m
-
R2 bn
R140 m
R18 m
866 pieces of equipment
-
Ongoing
5
12
138
-
R2.01 m
-
$55 m
Design engineers on USD 1.3 billion port
R350 m
R110 m
-
1 000
-
180
15 000
4 000
22 500
-
ü
-
ü
ü
ü
-
-
ü
-
ü
ü
ü
ü
ü
-
-
ü
ü
ü
-
-
-
-
ü
ü
ü
-
-
ü
ü
ü
ü
ü
ü
ü
ü
-
ü
ü
ü
-
-
ü
-
ü
ü
ü
-
-
ü
-
ü
ü
ü
ü
-
ü
-
ü
ü
ü
ü
ü
ü
-
ü
-
ü
-
-
68
-
-
15
19
800+
±30
Yes
Yes
Yes
Yes
Yes
Yes
No
ECSA
CMA, SAIMH, SACOB
CMA, SABS, IAF ISO, CEMA, MERSETA, MEIBC, TUV
-
ISO9001, SEIFA
-
Chain, Pneumatic, Bucket, Belt, Pipe, Screw Screw, Pneumatic
-
BULK HANDLING TODAY
November/December 2015
11
Megaroller Industries
Melco Conveyor Equipment
Nepean Conveyors
PH Projects Holdings
Protea Conveyors
Total Number of Employees
67
342
15
109
10
Employees with tertiary qualifications
6
41
5
13
5
Number of years operating in SA
31
45
20
26
27
Ownership
Private
Private
Subsidiary of overseas principal
Private
Private
BEE rating
4
3
3
5
-
In progress
Yes
No
No
No
Belt
Belt, Pipe
Belt
Belt, Bucket, Spiral, Screw
Belt, Chain, Bucket
▪ Overland
ü
ü
ü
ü
ü
▪ Underground
ü
ü
ü
ü
ü
▪ Bulk Handling Machines (stackers, reclaimers, loaders etc)
-
ü
-
ü
ü
No
No
-
Yes
Yes
Total value of last two contracts
R14 m
R5.7 m
-
R124 m
R22 m
Number of projects completed in 2014
3
27
-
6
7
Value of largest contract completed in past 5 years
R10 m
R60 m
-
R 87 m
R96 m
Size of largest contract in terms of tons conveyed per hour
100 m
15 000
-
5 500
-
▪ Conceptualisation to commissioning
-
ü
ü
ü
ü
▪ Work to specification
-
ü
ü
-
-
▪ Sub-contractor for specifics
-
ü
-
-
-
▪ Turnkey
-
-
-
-
ü
▪ Manufacture and delivery to site
ü
ü
ü
ü
ü
▪ Assembly on site
-
ü
ü
ü
▪ Commissioning
-
ü
ü
ü
ü
▪ On-site supervision
-
ü
-
ü
ü
▪ Personnel training
-
ü
ü
▪ On-site annual shutdown service
-
-
-
-
-
Number of export orders: over past 5 years
25
1741
-
0
70
CAD and/or CAM facilities
Yes
Yes
-
Yes
Yes
CMA, MEIBC, NEASA, ISO 9001
CMA, SAIMH, ISO, SABS, SEIFSA
CMA
PMI, ECSA, Admitted Advocate, CA
CMA
Name of company
ISO Accredited Type of conveyors handled Primary area of expertise:
Contract to supply and install: ancillary items such as crushers, chutes, screens, apron feeders, etc
Capabilities:
Service support:
Professional affiliations
12
BULK HANDLING TODAY
November/December 2015
ü
Rula Bulk Materials Handling
Sandvik Mining Systems
Sure Guide
Techmatic Engineering
Tenova Takraf Africa
Veyance Technologies
-
137
21
55
-
220
-
82
2
6
-
-
45
9
23
29
45
60
Private
Subsidiary
Private
Private
Private
Subsidiary of Overseas Principal
4
5
3
8
3
3
Yes
Yes
No
No
Yes
Yes
Belt, Chain, Bucket, Screw, Pneumatic, Cable
Belt
Belt
Belt, Chain, Bucket, Pneumatic, Screw
Belt, Chain, Pipe, Pneumatic
Belt, Bucket, Pocket, Cable, Pipe, Sandwich
ü
ü
-
-
-
ü
ü
-
-
-
-
ü
ü
ü
-
-
-
-
Yes
Yes
No
Yes
-
No
R50 m
R352 m
-
R15.3 m
-
R250 m
Multiple
2
-
131
-
2
R800 m
R763 m
-
R32 m
-
R170 m
4 000
10 000
-
140
-
-
ü
ü
-
ü
ü
-
ü
ü
-
ü
-
ü
ü
-
-
-
-
ü
ü
ü
-
ü
ü
-
ü
ü
-
ü
ü
ü
ü
ü
-
ü
ü
ü
ü
-
ü
ü
ü
ü
-
ü
ü
ü
ü
ü
-
ü
-
ü
ü
ü
-
ü
-
-
7
15
+50
72
-
-
Yes
Yes
Yes
Yes
-
Yes
CMA
ECSA
CCMA
SAIME, SEIFSA
CMA, SAIMH
-
BULK HANDLING TODAY
ü
November/December 2015
13
EVOLVED
INTELLIGENT CONVEYING
Easy Rolling, Longer Lasting Steel Rollers F^`Zkhee^kÃl g^p% iZm^gm i^g]bg` Lm^^e Khee^kl Zk^ ]^lb`g^] mh ^glnk^ Z\\nkZm^ [^Zkbg` Zeb`gf^gm mh ]^ebo^k ^Zlb^k kheebg`% ^gaZg\^] ^_Ë \b^g\r Zg] e^ll ghbl^ iheenmbhg' Ma^l^ khee^kl h__^k fZgr h_ ma^ [^g^Ë ml h_ ma^ F^`Zkhee^k A=I> Zg] Ar[kb] khee^kl' Innovative Technologies Mechanically Fixed Bearing Housing Gh p^e]bg` h_ ma^ ahnlbg` mh ma^ khee^k [h]r' Mabl ^glnk^l lni^kbhk [^Zkbg` Zeb`gf^gm mh ]^ebo^k Z fhk^ ^_Ë \b^gm% jnb^m^k Zg] ehg`^k eZlmbg` khee^k'
“superior bearing alignment”
Cost Effective and Long Lasting
Megaroller Steel Roller Specs
More accurately aligned bearings means less stress on the bearing operation resulting in longer bearing life. The Megaroller Steel Roller’s easier rolling bearings also produce less friction and less noise.
Roller Options ;b&]bk^\mbhgZe khee^kl :gmb&Kng ;Z\d Khee^kl for incline belts
Main Benefits
Revolutionary design concept for steel rollers ;^mm^k [^Zkbg` Zeb`gf^gm >Zlb^k% lfhhma^k kheebg` Ehg`^k eb_^liZg Jnb^m^k hi^kZmbhg <Zg hi^kZm^ Zm ab`a^k li^^]l
Fhk^ ^g^k`r ^_Ë \b^gm ]n^ mh ^Zlb^k rolling bearings K^]n\mbhg bg mhmZe \hlm h_ hpg^klabi compared to traditional steel rollers Ehp^k fZbgm^gZg\^ \hlml >qm^g]^] [^Zkbg` eb_^liZg ;^mm^k k^mnkg hg bgo^lmf^gm
Available diameters *+0ff *.+ff Available Shaft Options +. L^kb^l hg *+0ff ,) L^kb^l hg *+0ff *.+ff Gauge Length Range *1)ff mh *2*1ff Shaft material Options Fbe] Lm^^e LmZbge^ll Lm^^e
Our leading products
HDPE Rollers
Hybrid Rollers
Impact Rollers
Steering Frames
F^`Zkhee^k A=I> Khee^kl are an innovation in reinforced high-density iher^mare^g^ !A=I>" conveyor rollers.
Megaroller Hybrid Rollers are unique combination steel / high-density iher^mare^g^ !A=I>" conveyor rollers.
Megaroller’s Impact and Rubber Disc Return Rollers absorb the impact of large loads of ore falling onto conveyor belts to prevent damage.
Megaroller’s unique Multisteer conveyor belt steering frames are the key to effective conveyor belt management.
CONTACT US: www.megarollerindustries.com | info@megaroller.co.za | +27(0)12 250 2365
Standard Shaft Variations Hi^g&^g]^] <ehl^]&^g]^] <nlmhf laZ_ml Ë gblabg` hg k^jn^lm' ;^Zkbg`l Zl i^k \nlmhf^k li^\bË \Zmbhgl'
World leader in conveyor idlers
BULK HANDLING TODAY
November/December 2015
15
16
BULK HANDLING TODAY
November/December 2015
BULK HANDLING TODAY
November/December 2015
17
18
BULK HANDLING TODAY
November/December 2015
Protea Automation product manager, Gavin Westley
BULK HANDLING TODAY
November/December 2015
19
Figure 1. Spillage photos
20
BULK HANDLING TODAY
November/December 2015
BULK HANDLING TODAY
November/December 2015
21
22
BULK HANDLING TODAY
November/December 2015
SHIFT HOUR
NUMBER OF SHUTTLES PER HOUR ACTUAL FIGURES FROM A COAL MINE - where average = 8 M
T
W
T
F
M
T
SECTION 1 total shuttles 312 1
1
2 3 4 5 6 7 8
W
T
F
M
SECTION 2 total shuttles 295
3
0
11
4
2
4
0
0
2
1
8
22
0
7
17
0
18
1
15
8
0
1
17
0
15
8
0
5
14
26
0
19
0
5
5
12
19
0
4
6
1
21
21
2
17
0
9
16
2 0
5
7
0
0
9
2
2
T
W
T
F
SECTION 3 total shuttles 348 0
6
0
0
22
7
0
11
14
0
22
14
0
3
17
8
0
11
8
1
0
10
20
0
20
20
5
0
18
6
5
5
0
18
21
21
4
0
17
15
0
18
20
17
0
18
14
21
24
3
0
11
21
19
0
6
6
2
0
4
4
4
Table 1. Spread of the actual production figures
SHIFT HOUR
NUMBER OF SHUTTLES PER HOUR LESS THAN AVERAGE OF 8 - ACTUAL FIGURES FROM A COAL MINE M
T
W
T
F
M
SECTION 1 total shuttles 49 1
1
3
2
2
1
T
W
T
F
M
SECTION 2 total shuttles 39 4
2
5
T
F
4
6
7 3
1
4
W
SECTION 3 total shuttles 55
7
3
T
1
1
5
5
2
4
5
5
6
5
4
4
5
6
4
7
2
8
5
6
1
3 7
2
2
6
6
2
4
Table 2. Spread of the number of shuttles less than average
BULK HANDLING TODAY
November/December 2015
23
Figure 2. Flooded and full belt
SHIFT HOUR
NUMBER OF SHUTTLES PER HOUR MORE THAN AVERAGE AND LESS THAN TWICE THE AVERAGE - ACTUAL FIGURES FROM A COAL MINE M
T
W
T
F
M
SECTION 1 total shuttles 86 1
T
W
T
F
M
SECTION 2 total shuttles 59
T
W
15
3
8
4
15
5
14
8
11
14 14
8
8 11
8
10 12
6
14 9
8
15
11
9
Table 3. Spread of the number of shuttles equal to average and below twice the average value
24
F
11
2
7
T
SECTION 3 total shuttles 80
BULK HANDLING TODAY
November/December 2015
SHIFT HOUR
NUMBER OF SHUTTLES PER HOUR EQUAL TO AND MORE THAN TWICE THE AVERAGE - ACTUAL FIGURES FROM A COAL MINE M
T
W
T
F
M
SECTION 1 total shuttles 177
T
W
T
F
M
SECTION 2 total shuttles 197
T
W
22
2
17 22
18
26
19
17 17
22
4 5
20
6 7
F
SECTION 3 total shuttles 213
1 3
T
21 17
19
20
20
21
17
20
16
18
24
18 18 17
21
18
21 21
21
13
8 Table 4. Spread of the number of shuttles equal to twice the average and above
BULK HANDLING TODAY
November/December 2015
25
Figure 3. Ratio of maximum lump size
Figure 4. Cross-section without lump size consideration
Figure 5. Cross-section with 350mm lump size consideration
26
BULK HANDLING TODAY
November/December 2015
Figure 6. Belt running at 5,5 m/s
Figure 7. Increased belt width
Figure 8. Standard SANS 1313 equal length roller application
BULK HANDLING TODAY
November/December 2015
27
Figure 9. Section at the loading point
Figure 10. Section after material has centralised
Figure 11. Photographic confirmation of the aforesaid
28
BULK HANDLING TODAY
November/December 2015
Figure 12. Five-roll configuration with 35째 trough
Figure 13. Five-roll configuration with 45째 trough
Figure 14. The way forward IDLER CONFIGURATION
Loaded percentage
Actual freeboard distance
3-roll 35 degree trough
70% of full
231 mm
5-roll 35 degree trough
75% of full
199 mm
5-roll 45 degree trough
67% of full
230 mm
5-roll 45 degree trough
63% of full
276 mm
Table 5. This table confirms the improved approach
safrench
BULK HANDLING TODAY
November/December 2015
29
Tough demands have met their match.
With a hydraulic drive system from H채gglunds, you get compact, durable power - without foundations or gearbox. A full range of rugged motor types and complete solutions for monitoring and control give you total assurance, even in the most demanding applications. Let us know your demands. H채gglunds Drives South Africa (Pty) Ltd P.O.Box 2851, 1610 Edenvale, Johannesburg Phone: + 27 (0)11 454 4933, Fax: +27 (0)11 454 5088 E-mail: info@za.hagglunds.com, www.hagglunds.com
Our drive is your performance.
BULK HANDLING TODAY
November/December 2015
31
Willem Gijzelaar
BULK HANDLING TODAY
November/December 2015
33
► EIA Process
► Environmental Risk Assessments
► Geographical Information Systems
► Agricultural Assessment and Advise
► Project Managment
► Wetland and Riparian Services
► Natural Resource Services
► Visual Impact Assessments
► Ecological/Biodiversity Services
► Public Participation Process
► Application Assistance
► Game Ranch Management
► Developement Research, Monitoring and Evaluation
N2 Mnini ECO Duties
Plant rescue
Durban Coal Terminal Site Inspection
Ohlanga Pump station ECO Duties
Freightpak Warehouse Site Audit
Public participation Makhabeleni
Ballito Interchange Botanical survey
Site assessment Sundumbili pipeline
l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l Skills on Site
Septmeber 2012
1
BULK HANDLING TODAY
November/December 2015
35
36
BULK HANDLING TODAY
November/December 2015
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November/December 2015
37
Desmond van Heerden of ELB Equipment
BULK HANDLING TODAY
November/December 2015
39
40
BULK HANDLING TODAY
November/December 2015
BULK HANDLING TODAY
November/December 2015
41
www.promech.co.za
BULK
* Easy navigation through the site * Comprehensive archive * Free to users * No registration * Searchability
BULK
HANDLING IN AFRICA
G U I D E
2015
Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l
BULK
HANDLING Buyers
Guide
Also publishers of “Bulk Handling Today”
2 0 1 5 2 0 1 6
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l
T O D A Y
October 2015
LIFTING gUIDE 2014/15 Also publishers of “Bulk Handling Today”
CRANES: NO PRICE TAG ON SAFETY 086 111 TOCO (8626)
BULK HANDLING INlAFRICA 2015 1 l l Conveying l Crushing l Trucking l Storage Lifting
OPERATIONAL MODELLING DRIVES DOWN COSTS Lifting Guide
2014/15
1
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• Engineers • Technologists • Technicians • and supporting specialist disciplines Job positions described in detail on our website job boards Access us online at: www.engineerplacements.com or email: admin@engineerplacements.com for assistance Personal service and interaction with PROFESSIONAL ENGINEERS As Engineers, we understand your engineering language 42
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1THREAD_7029_BHT
SEW-EURODRIVE – Driving the world
X-Series - your heavy duty solution
SEW-EURODRIVE carries a large local stock holding of this robust product – with its unique modular production concept. Developed as one of the most powerful industrial gear units, this unit is available in finely stepped sizes covering torque ranges of up to 475kNm. A large number of pre-defined accessories offer a high degree of flexibility for adapting to a broad range of applications. Why is this good news for you? Higher accuracy, faster turnaround times and more flexibility on your individual designs are available to you locally! Units are assembled and serviced locally, offering you less downtime and more productivity. This is what we call Drive 360º - Seeing the big picture. SEW-EURODRIVE - Driving the world. Tel: +27 11 248-7000 Web: www.sew.co.za