BULK
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH
T O D A Y
Nov/Dec 2016
PREMIER SUPPLIER OF CONVEYOR IDLERS, FRAMES, STRUCTURE & MOTORIZED PULLEYS FIRE SAFE BELT SYSTEMS SILO 20 REINSTATEMENT PROJECT
BULK
HANDLING
BULK HANDLING TODAY
T O D A Y
November/December 2016
3
ENDORSER OF “BULK HANDLING TODAY”
LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA
• A recognised ECSA Voluntary Association (VA) •
LEEASA is a fully-fledged association devoted to the lifting industry across Southern Africa. Members hale from the crane, forklift, mobile elevated work platform, aerial and suspended access platform, chain hoists, rigging and lifting tackle arenas, etc. Primarily devoted to the LMI’s (Lifting Machinery Inspectors), and LME’s (Lifting Machinery Entities), the association considers safety paramount. As such it serves in an advisory capacity to the SABS, the Department of Labour, various training bodies and the industry at large. LEEASA is recognised by ECSA as a voluntary association. What’s in it for you:
As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year).
and other training courses accredited by the association attract ECSA CPD points.
ECSA registered LEEASA members are awarded one Continuing Professional Development (CPD) credit each year. CPD is an ECSA requirement to retain registration.
Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry.
Members obtain a discount on LEEASA seminars. Both these
LEEASA has some 500 members (Individuals and Companies).
• • •
LEEASA Occupational Health & Safety Act and Regulations LEEASA Mine Health & Safety Act and Regulations LEEASA Lifting Equipment Inspection & Legal Compliance Register
Available for purchase online at www.leeasa.co.za
1
LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SOUTH AFRICA Head Office: 8 Boris Road, Bordeaux, Randburg, Johannesburg P.O.Box 2348, Pinegowrie. 2123, Republic of South Africa Tel: 074 900 8378 • www.leeasa.co.za Secretary: Arni Sommer • email: arni@leeasa.co.za
BULK HANDLING TODAY
February 2012
Jay Pillay
BULK HANDLING TODAY
November/December 2016
5
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 November 2016 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
www.saimh.co.za
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
BULK HANDLING TODAY
November/December 2016
7
Conveyor belt widths of up to two metres can be accommodated along with various belt speeds
8
BULK HANDLING TODAY
November/December 2016
We are confident those who are already operating our conventional motorised pulleys will appreciate the same benefits from the new flame proof units
BULK HANDLING TODAY
November/December 2016
9
African Trading Group
Afripp Projects
AMD-Rotolok
BMG
Brelko Conveyor Products
Total Number of Employees
50>
-
23
3000
150
Employees with tertiary qualifications
50%
-
6
-
27
5
16
47
42
29
Private
-
Private
Public
Private
4
4
8
4
4
No
-
No
Yes
Yes
Belt, Bucket, Pipe, Screw
Belt, Pipe
Chain, Bucket, Screw
Belt, Chain, Bucket, Pocket, Pipe
Belt
▪ Overland
-
-
-
ü
ü
▪ Underground
-
-
-
ü
ü
▪ Bulk Handling Machines (stackers, reclaimers, loaders etc)
-
-
ü
ü
ü
Yes
-
Yes
Yes
Yes
R8+ m
R2 m
R2.7 m
R25 m
R300 000
4
-
+-85
-
20
R4 m
-
R2.8 m
R15 m
R3 m
-
15 000
1500
7000
2 200
▪ Conceptualisation to commissioning
ü
-
-
ü
ü
▪ Work to specification
ü
-
-
ü
ü
▪ Sub-contractor for specifics
ü
-
ü
ü
▪ Turnkey
ü
-
-
ü
ü
▪ Manufacture and delivery to site
ü
-
ü
ü
ü
▪ Assembly on site
ü
-
-
ü
ü
▪ Commissioning
ü
-
ü
ü
ü
▪ On-site supervision
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 2015 Value of largest contract completed in past 5 years Size of largest contract in terms of tons conveyed per hour Capabilities:
Service support:
ü
-
ü
ü
ü
▪ Personnel training
ü
-
ü
ü
ü
▪ On-site annual shutdown service
ü
-
-
ü
ü
Number of export orders: over past 5 years
500>
10
+7
-
900
CAD and/or CAM facilities
No
-
Yes
Yes
Yes
CMA
CMA, SAIMH, ISO 9001, ISO 14001, OHSAS 18001, International Dry Bulk Terminals Group, SEIFSA
Professional affiliations
10
BULK HANDLING TODAY
-
November/December 2016
-
-
ContiTech SA
Conveyor & Industrial Supplies
Clyde Bergemann Africa
DemcoTECH Engineering
ELB Engineering Services
Lorbrand
220
80
258
25
176
250
-
30
127
13
90
36
60
33
37
20
95
30
Subsidiary of Overseas Principal
Private
Private
Private
Public
Private
3
L2
4
6
4
-
Yes
No
Yes
No
Yes
Yes
Belt, Bucket, Pocket, Cable, Pipe, Sandwich
Belt
Chain, Pneumatic, Screw
Belt, Chain, Bucket, Pocket, Pipe, Sandwich, Pneumatic
Belt, Chain, Bucket, Pipe, Sandwich, Pneumatic, Screw
Belt, Chain, Pipe
ü
ü
ü
ü
ü
ü
ü
ü
-
-
-
ü
-
-
-
ü
ü
-
No
-
Yes
Yes
Yes
No
R250 m
-
R29.8 m
-
R2.7 bn
R140 m
2
-
4
6
25
138
R170 m
-
R100 m
Design engineers on USD 1.3 billion iron ore port
R500 m
R110 m
-
-
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
-
-
-
2
14
33
800+
Yes
Yes
Yes
Yes
Yes
Yes
ECSA
CMA, SAIMH, SACOB
CMA, SABS, IAF ISO, CEMA, MERSETA, MEIBC, TUV
-
-
-
BULK HANDLING TODAY
November/December 2016
11
Mato Products
Megaroller Industries
Melco Conveyor Equipment
Nepean Conveyors
PH Projects Holdings
Total Number of Employees
16
50 - 100
345
16
116
Employees with tertiary qualifications
3
-
41
5
11
Number of years operating in SA
29
-
46
21
27
Ownership
Private
Private
Private
Private
Private
BEE rating
5
-
3
5
6
ISO Accredited
Yes
Yes
Yes
Yes
No
Type of conveyors handled
Belt
Belt
Belt, Pipe
Belt
Belt, Chain, Bucket, Spiral, Pipe, Screw
▪ Overland
-
ü
ü
ü
ü
▪ Underground
ü
ü
ü
ü
ü
▪ Bulk Handling Machines (stackers, reclaimers, loaders etc)
-
ü
ü
-
ü
No
Yes
No
Yes
Yes
Total value of last two contracts
-
-
R5.7 m
TBA
R120 m
Number of projects completed in 2015
-
-
78
4
31
Value of largest contract completed in past 5 years
-
-
R72 m
R40 m
R93 m
Size of largest contract in terms of tons conveyed per hour
-
-
15 000
8 000
8 000
▪ Conceptualisation to commissioning
-
ü
ü
ü
ü
▪ Work to specification
ü
-
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
▪ On-site supervision
ü
Name of company
Primary area of expertise:
Contract to supply and install: ancillary items such as crushers, chutes, screens, apron feeders, etc
Capabilities:
Service support:
ü
-
ü
ü
▪ Personnel training
ü
-
ü
-
▪ On-site annual shutdown service
-
-
-
-
ü
Number of export orders: over past 5 years
20
-
1 741
4
-
CAD and/or CAM facilities
Yes
Yes
Yes
Yes
Yes
-
CMA, ISO 9001
CMA, SAIMH, ISO, SABS, SEIFSA
CMA
PMI, ECSA, Admitted Advocate, CA
Professional affiliations
12
BULK HANDLING TODAY
November/December 2016
Protea Conveyors
Rula Bulk Materials Handling
Sure Guide
Tenova Takraf Africa
Thyssenkrupp Industrial Solutions
10
118
23
130
344
5
60
3
80
55%
27
46
24
90+
30+
Private
Private
Private
Subsidiary of Overseas Principal
Subsidiary of Overseas Principal
-
3
2
8
4
No
Yes
No
Yes
Yes
Belt, Chain, Bucket
Belt, Chain, Bucket, Screw, Pneumatic, Cable
Belt
Belt, Bucket, Chain, Pipe, Pocket, Pneumatic
Belt, Cable, Pipe
ü
ü
ü
ü
ü
ü
ü
ü
-
-
ü
ü
ü
ü
ü
Yes
Yes
No
Yes
Yes
R22 m
R700 m
-
R450 m
R60 m
7
Multiple
-
6
20
R96 m
R800 m
-
R3.2 b
R1.2 b
-
4 000
-
-
10 000
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
70
7
120+
12
-
Yes
-
Yes
Yes
Yes
CMA
CMA
-
CMA, SAISC, SAIMechE
CMA
BULK HANDLING TODAY
November/December 2016
13
14
BULK HANDLING TODAY
November/December 2016
BULK HANDLING TODAY
November/December 2016
15
16
BULK HANDLING TODAY
November/December 2016
BULK HANDLING TODAY
November/December 2016
17
Paul Runge
Successful formula for introducing South Africabased businesses to opportunities across the continent
18
BULK HANDLING TODAY
November/December 2016
BULK HANDLING TODAY
November/December 2016
19
Figure 1. Steady state belt tension distribution for a horizontal belt conveyor
20
BULK HANDLING TODAY
November/December 2016
Figure 2. Idler roller rotating resistance and bearing temperature versus time for a Ă˜152 mm at 6m/s
Figure 3. Typical labyrinth seal configuration and resistance analysis
BULK HANDLING TODAY
November/December 2016
21
No-load bearing
Average Rim Drag (N)
Rotational Resistance (N)
Labyrinth seal
Manufacturer A Manufacturer B Manufacturer C
Lip seal
Load dependent bearing
Ambient Temperature (°C)
Temperature (°C) (a) Idler roller rotating resistance vs temperature Figure 4. Idler roller rotating resistance versus temperature
22
BULK HANDLING TODAY
November/December 2016
(b) Measured data
Rotational Resistance (N)
Rotational Resistance (N)
Labyrinth seal friction
No-load bearing friction
Lip seal friction
Load dependent bearing friction
Labyrinth seal friction
No-load bearing friction
Lip seal friction
Load dependent bearing friction
Speed (rev/s)
Load (N)
(a) Idler roller rotating resistance vs speed
(b) Idler roller rotating resistance vs radial load
Figure 5. Idler roller rotating resistance versus speed and load
(b) Asymmetric pressure distribution
(a) Cyclic compression and recovery Figure 6. Indentation rolling resistance
x 10 7
1.8
Relaxation Modulus (Pa)
1.6 1.4 1.2 0.05%
1 0.8
1.0% 0.6 2.0% 3.0% 4.0% 5.0%
0.4 0.2
0
0.02
0.04
0.6
0.08
0.1 0.12 Time (s)
0.14
0.16
0.18
0.2
Figure 7. Relaxation modulus data for a pulley cover compound under varying strain
BULK HANDLING TODAY
November/December 2016
23
(a) Winker foundation model
(b) Finite element model
Munzenberger et al
Figure 8. Indentation rolling resistance models
24
BULK HANDLING TODAY
November/December 2016
(a) DIN22123 large sample test method
(b) Alternate large sample test method
Figure 9. CEMA’s indentation rolling resistance large sample methods
BULK HANDLING TODAY
November/December 2016
25
Figure 10. Indentation rolling resistance and belt flexure resistance versus normal load for a range of belt sag ratios (idler roller dia. = 150 mm, temperature = 40°C and beltspeed = 4 m/s)
Belt Width, B w = L c + 2L b,s
Figure 11. Normal forces acting on side and centre rollers due to the belt and bulk material
26
BULK HANDLING TODAY
November/December 2016
(a) Cross section showing normal force between idler rollers and belt
(b) Bottom view showing indentation rolling resistance distribution Figure 12. Normal force distribution and resulting indentation rolling resistance for a three- roller troughing idler set
BULK HANDLING TODAY
November/December 2016
27
Coefficient of Bulk Material Flexure Resistance, fm,flex
Coefficient of Bulk Material Flexure Resistance, fm,flex
Sag Ratio (%)
(a) Sag ratio = 1%
Internal Angle of Friction φi (Degrees)
(b) Internal angle of friction = 35°
Figure 13. Coefficient of bulk material flexure resistance versus internal angle of friction and sag ratio (belt width = 1.2 m, bulk density = 1 000 kg/m 3)
28
BULK HANDLING TODAY
November/December 2016
The company was also tasked with equipping the structure
BULK HANDLING TODAY
November/December 2016
29
The upper section of Silo 20 collapsed in November 2014, following a catastrophic wall fracture
Rodney Goosen
30
BULK HANDLING TODAY
November/December 2016
BULK HANDLING TODAY
November/December 2016
31
No coal supply to any of the silos was possible
Altra
®
Industrial Motion
South Africa (Pty) Ltd
THE POWER OF EXPERIENCE A complete range of industrial and high performance couplings together with a comprehensive selection of torque limiting products available from a single source. Turboflex Couplings
Gear Couplings Marland Backstops Grid Couplings Westcar Rotofluid Couplings
Unit 11. Middle Park, Cnr.Craig & Dormehl roads, Anderbolt, Boksburg. PO Box 16524, Atlasville, 1465 Tel: +27 11 918 4270 • Fax +27 11 918 4240 • Email: salesza@altramotion.com
32
BULK HANDLING TODAY
November/December 2016
Svendborg Brakes
MARKET FORUM
BULK HANDLING TODAY
November/December 2016
33
MARKET FORUM
34
BULK HANDLING TODAY
November/December 2016
MARKET FORUM
Verlinde Eurobloc VT3 electric wire rope hoists are located either side of the crab unit on the turntable crane at Special Metals
BULK HANDLING TODAY
November/December 2016
35
MARKET FORUM
36
BULK HANDLING TODAY
November/December 2016
MARKET FORUM
BULK HANDLING TODAY
November/December 2016
37
MARKET FORUM
Promech Publishing wishes all its readers a wonderful December break and a prosperous New Year
find out if you qualify to #joinourtable at pps.co.za PPS is an authorized Financial Services Provider.
38
BULK HANDLING TODAY
November/December 2016
REMAPRESS-IVE REMA TIP TOP has developed a reputation over the years as being one of the world's foremost splicing companies. We use state of the art equipment, tools, materials and splicing methodologies. �ese have been developed according to the REMA TIP TOP global standard, aligned to SABS 484/485/486 and incorporate relevant customer and industry trends and requirements. �e new “REMAPRESS IVE” with pressure bags, heating plates, and silicone heating mats, developed and marketed by REMA TIP TOP, has been designed to impress with the highest quality features, application-oriented design, and German TÜV certification. Press Features ä ä ä ä ä ä ä ä ä
ä ä ä ä ä ä ä ä
Equal surface pressure over the complete splice due to the REMA TIP TOP pressure bag certification by German TÜV Pressure bag with aramid inlays meets highest safety standards 20% less deflection of crossbeams 20% less liquid requirement, therefore faster build-up of pressure than comparable presses from market competitors Despite being made of high-strength steel, the tension bolts weigh 2kg less a piece than conventional steel tension bolts Tension bolts sealed up and in that way protected against soiling Lightweight, high-strength pressure distribution sheet made of aluminum Water pressure system for pressures up to 140 N/cm² (200 Psi) CE-, CSA- and UL-certified electronics
Heating plate connection, protection class IP 64 > certified by German TÜV Optimized monitoring of temperature difference Available for voltages from 230 to 600 Volt Control cabinet, protection class IP 64 Optional data recording within control cabinet, data export via USB interface Useable in admissible ambient temperature from -20°C to +55°C Silicone heating mat with vulcanized-on intermediate plate Transport-proof, plugable connection cable
Tel: +2711 741 2500 Email: info@rematiptop.co.za Website: www.rema-tiptop.co.za
Physical Address: 22-24 Lincoln Road, Industrial Site, Benoni