Bulk Handling Today Nov/Dec 2016

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

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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

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Conveyor belt widths of up to two metres can be accommodated along with various belt speeds

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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

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16

BULK HANDLING TODAY

November/December 2016

BULK HANDLING TODAY

November/December 2016

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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

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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

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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

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(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

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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

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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)

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BULK HANDLING TODAY

November/December 2016

The company was also tasked with equipping the structure

BULK HANDLING TODAY

November/December 2016

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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

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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

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MARKET FORUM

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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

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MARKET FORUM

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BULK HANDLING TODAY

November/December 2016

MARKET FORUM

BULK HANDLING TODAY

November/December 2016

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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

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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