2015/11 - Bullk Handling Today

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

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Hybrid Rollers

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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

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36

BULK HANDLING TODAY

November/December 2015

BULK HANDLING TODAY

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

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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