BULK
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH
T O D A Y October 2018
ON-SITE CERTIFICATES AHEAD OF THE CHARTER
C16092
THE GLOBAL STANDARD IN CRANES AND HOISTS DESIGN • MANUFACTURE • SERVICE • SALES As a global manufacturer and provider of cranes in varying industries, Condra provides high quality engineering, flexible inhouse design and an impressive range of products to mining, shipping, steel, fabrication, robotics, railways and ports. Since 1966, Condra has mastered the engineering, manufacturing and installation of cranes all over the world to large, medium and small industries. We are constantly innovating to provide manual, electric and combo cranes that provide solution to lifting, hooks, grabbing, magnets, ladles, buckets or stacking duties.
Overhead travelling cranes Wire rope hoists Portal or semi-portal cranes and bridge cranes Cantilever cranes (pillar, jib and wall)
Tel: +27 11 776 6000 | 0861 CONDRA (266372) | 24hr Mobile: +27 82 491 7525 | Email: sales@condra.co.za
www.condra.co.za South Africa | Africa | Middle East | Europe | Russia | Australia | South America | North America
BULK
HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH
T O D A Y October 2018
BULK
HANDLING October 2018
T O D A Y
ON-SITE LOAD TESTING CERTICATES AHEAD OF THE CHARTER
On the cover: DISA Equipment T/A Doosan Tel: (011) 974-2095, Email: darrelh@doosan.co.za www.doosan.co.za
Contents CMA News Cover Story
SAIMH Beltcon 19
4 6
24
Conveyor Drives
25 Design Considerations on Capacity Upgrade of 6km Downhill Conveyor System
10
LEEASA News Lifting
Market Forum Endorsing Bodies
11 Mobile LMI Unit
•
CMA (Conveyor Manufacturers Association)
•
LEEASA (Lifting Equipment Engineering Association of South Africa)
•
16 Slashing Pre-sink Time 18 Setting the Benchmark
SAIMechE (SA Institution of Mechanical Engineering)
•
Fire Suppression
•
SAIMH (SA Institute of Materials Handling) also mailed to members of the RFA (Road Freight Association)
8
Always Ready for Action! Trailers and Wagons in One Line
37
Academic Research
12 The Future of SA Mining
Local Content Verification 14 Stepping Up to the Plate
Lifting
21 Prevention Systems
Copyright
All rights reserved. No editorial matter published in “Bulk Handling Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.
Our e-mail address is bulkhandling@promech.co.za Visit our website on www.bulkhandlingtoday.co.za
The monthly circulation is 3 673
Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Advertising Sales: Linda Patricio DTP: Anne Rotteglia Administration: Belinda Siegruhn Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas. Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)
BULK HANDLING TODAY
October 2018
3
From The Chairman’s Desk
T
his month we pay tribute to two very special people who have a close connection to and are Honorary Members of the CMA, Graham Shortt and Alan Exton. These two gentlemen retired after a lifetime serving the industry but are still passionate about promoting the excellence of belt conveyors. They have redirected their energies into educating the next generation as well as performing a consulting function to end users and designers. Graham Shortt retired from Anglo American twelve years ago and has been lecturing the CMA Diploma Course in the Design and Maintenance of Belt Conveyors for the last eleven years. In that time over 380 candidates have attended this intensive 6-day training course of which 260 have achieved a Diploma. Graham has also written many technical documents, including the training material used on the Diploma course, and has served on various committees and working groups over the years Alan Exton retired from Nepean Conveyors and immediately threw his energies into consulting and education and training. Alan has actively participated on various Committees, for example he chaired the Working Group that drafted the Safety Guideline and is currently Chairman of the Beltcon Organising and Technical Committee. Alan is also the author of the training material he uses on the courses he lectures, namely the CMA Conveyor Certificate 3-day and Beltsman Certificate 1-day courses.
4
BULK HANDLING TODAY
October 2018
Jay Pillay
When asked what candidates most enjoyed about the courses they attend, the answer is always being taught by someone who has such passion for his subject! Another milestone was achieved this year. Chris Townsend has been Company Secretary to the CMA for twenty-five years this month. Her first task as Company Secretary was to take the Minutes at the October 1993 Members’ Meeting alongside Brian Bell who was the newly elected Chairman. Chris has worked with many CMA Chairmen over the years: Brian Bell, Alan Exton, Max Schenck, Simon Curry and now yours truly! Jay Pillay Chairman
conveYor Manufacturers association
Membership at October 2018 All members subscribe to the CMA Code of Ethics
Graham Shortt
Alan Exton
Chris Townsend
Brian Bell
Acrow Limited Actom Afripp Projects Altra Industrial Motion South Africa (Pty) Ltd Bauer Bearings International Belt Brokers Belting Supply Services BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CedoTech cc Closeal Manufacturing Collisen Engineering ContiTech South Africa (Pty) Ltd Conveyor & Engineering Equipment CT Systems David Brown Gear Industries DRA Projects SA (Pty) Ltd Dunlop Belting Products Dymot Engineering Company ELB Engineering Services Fenner Conveyor Belting (South Africa) Flexco SA (Pty) Ltd FLSmidth Roymec Giza Technologies (Pty) Ltd Habasit South Africa (Pty) Ltd Hägglunds Drives South Africa Hatch Africa (Pty) Ltd HMA South Africa (Pty) Ltd Hosch - Fördertechnik (SA) International Belting & Marketing (Pty) Ltd Iptron Technology KevConBelt (Pty) Ltd Lesa Mining Equipment and Conveyor Belt Lorbrand Martin Engineering Megaroller Melco Conveyor Equipment Merlin consulting (Pty) Ltd Moret Mining Nautilus Projects (Pty) Ltd Nepean Conveyors OE Bearings Oriental Rubber Industries SA Osborn Engineered Products Pegasus Industrial Services cc Regal Beloit South Africa Rema Tip Top South Africa Ringspann South Africa Rossi Gearmotors (Pty) Ltd Rula Bulk Materials Handling SENET SEW Eurodrive Shaft Engineering (Pty) Ltd SKF South Africa Tenova Takraf ThyssenKrupp Industrial Solutions South Africa (Pty) Ltd Timken South Africa (Pty) Ltd Transvaal Rubber Company Voith Turbo Weba South Africa (Pty) Ltd WorleyParsons RSA Zest Electric Motors
Inaugural Manufacturing Exhibition Promech Publishing is an official media partner of the Local Manufacturing Exhibition 2019 (LME) in conjunction with the South African Capital Equipment Export Council (Saceec), and with Specialised Exhibitions Montgomery. Endorsed by the Premier of Gauteng, David Makhura and the MEC for Economic Development, Lebogang Maile, the LME will be an interactive, educational and practical showcase of South Africa’s most outstanding local manufacturing capabilities. The manufacturing sector offers the potential to significantly accelerate South Africa’s economic growth and development. With a specific focus on Gauteng, the LME will showcase leading local industries to thousands of potential national and international investors. “Saceec has been working closely with the Gauteng Provincial Government, which has identified key sectors of the economy that have the potential to address multiple imperatives such as greater economic inclusion and additional employment opportunities,” says Eric Bruggeman, CEO of Saceec. “The manufacturing sector is considered one of Gauteng’s largest economic sectors and with its labour-intensive characteristics and other socio-economic benefits, it has the power to create jobs and export opportunities faster than any other sector,” he concludes. The inaugural LME will take place May 21-23, 2019 at the Johannesburg Expo Centre, Nasrec. To secure your place at the Local Manufacturing Exhibition (LME), visit www. localmanufacturingexpo. co.za
BULK HANDLING TODAY
October 2018
5
cover storY
Always Ready for ACTION! The DX220LCA-2 is Doosan’s new entry into the 20 to 22 ton excavator class, developed with advanced design features for greater productivity in daily operation – even in the harshest conditions on African soil.
“
Not only do these robust machines boast pristine manufacturing standards, but Doosan’s advanced technologies have been introduced in the latest excavator series, to ensure optimum fuel efficiency, precision control and greater operator comfort. Added to this, is the advantage of a more reasonable total cost of owning and operation (TCO),” says Darrel Holton, managing director, DISA Equipment (Pty) Ltd T/A Doosan, part of the Capital Equipment Group (CEG) of Invicta Holdings Limited. “What’s notable is the DX220LCA-2 excavator can perform the same challenging operations, with lower fuel consumption, than other ma-
chines of the same class, boasting increased work efficiency.
No fuel wastage
“In fact, fuel consumption has been improved by up to 12%, compared with other machines in this class. This has been achieved by combining quality components and a high-efficiency engine, known for reliability, low fuel consumption and easy maintenance. Doosan’s newly designed main control valve (MCV) ensures even greater fuel efficiency than the previous model.” Doosan’s new engine and pump matching technology also contributes to reduced fuel consumption and minimal exhaust fumes. Other attributes include the
Fuel consumption has been improved by up to 12%, compared with other machines in this class
6
BULK HANDLING TODAY
October 2018
cover storY
optimised lever control and auto idle facility which allow the operator to take a break and leave the control joystick fixed, keeping both the engine and pump in standby mode, preventing fuel wastage. Enhancements to the main pump – which include optimised cylinders and higher system pressures -also contribute to improved fuel economy
A rotor type of pre-cleaner in DX220LCA-2 excavators filters out particles larger than 20 mircros with over 99% accuracy. Doosan has designed a high capacity water separator to improve engine durability and a large reserve tank, with UV protection, has reduced failure risks.
The engine power of these excavators is a maximum of 109kW at 1 800rpm, with a maximum torque of 66 kgf.m at 1 400rpm.
A larger cooling module ensures extended service life of every machine and a new vertical fuel level sensor provides highly accurate information about the fuel level. The new separate design of injection and discharge of the grease valve for the idler cylinder, reduces the risk of failure in valves.
Impressive space
The newly designed frames, undercarriage, swing bearing, sprocket roller and reinforced heavy-duty boom and arm offer greater durability. To protect the base of the arm, reinforced bars have been added and the arm centre and end-boss have been strengthened. A new general purpose (GP) bucket is installed onto the machine as a base spec, with open-type side cutters for improved loading operations. The H class bucket has a maximum capacity of 1,40 m³. The optimum use of space in the cabin is impressive. The newly-designed monitor clearly displays all relevant information for different operation scenarios and with the new joystick buttons, the operator can easily select specific features. For example, the breaker button is activated when this button is pushed, the eco-zone mode button is selected for the most fuel-efficient sector and the power mode is selected for more demanding tasks.
Support throughout
The Doosan team offers a technical advisory, maintenance and support service through its national branch and distributor network. The company provides a quick delivery of parts throughout southern Africa to ensure minimum downtime of every machine. Doosan earthmoving equipment, which is manufactured in South Korea, encompasses track, wheel and mini excavators, articulated dump trucks (ADT’s), as well as wheel loaders and various attachments.
A walk around the machine shows that easy access to all components, including the engine oil filter, radiators and grease inlets, enables quick maintenance procedures and prevents contamination to the surrounding environment.
Quick delivery of parts throughout southern Africa to ensure minimum downtime of every machine
DISA Equipment T/A Doosan Darrel Holton Tel: (011) 974-2095, Email: darrelh@doosan.co.za www.doosan.co.za
BULK HANDLING TODAY
October 2018
7
After welding, there are five buffer positions in front of the painting area. A heavy-duty platform from Vollert transports the trailers and wagons weighing up to 25 tons from there to the robot blasting cabin.
The blast cabinet is followed by the passage through the priming, painting and drying cabins.
Trailers and wagons in one line Since April 2018, the Brazilian manufacturer Randon has been manufacturing trailers and freight cars in Araraquara on a 500m long combined welding, painting and assembly line utilising with heavy-duty conveyor technology.
T
he Brazilian manufacturer Randon has built a 500m long combined welding, painting and assembly line for trailers and railway wagons in São Paolo. Vollert has developed a heavy-duty material flow concept consisting of 13 combined rope conveyor drives, two moving distribution transfer platforms and the control system for the individually timed forward feed. From April 2018, trailers and wagons are being welded, painted and assembled in a combined line over a length of 500mm approximately. Different wagon and trailer lengths of 9 to 22 m are feasible. Randon's product portfolio includes oversized sugarcane double trailers. “It is now possible to achieve a short clock cycle and
8
BULK HANDLING TODAY
October 2018
a calculated capacity of up to 18 wagons per work shift”, explains Jochen Keinath, project manager at Vollert. At full capacity, wagons and trailers can be completed every half hour.
In a single line Initially, the frame structures set up on dummy buggies are still fed manually into the system. Vollert’s automatic conveying line starts at a weight of 10 tons within the welding range at the end of the line, the total weight of the workpieces can reach up to 25 tons. A total of 13 rope conveyor drives, handle the buggies forward movement after each work step. For this purpose, the drives are arranged one behind the other to allow individual forward feed at the
conveYor Drives
Exit from the dryer takes place on a second heavy-duty transfer table, which distributes the trailers and wagons on two parallel assembly lines for mounting the wheelsets.
workstations At the end of a conveying section, the rope conveyor transfers the workpiece over to the next section. "Rather than using a single rope conveyor for the entire conveyor line, the single drive concept allows for individual dwell times of the workpieces at the respective workstations,� explains Jochen. “In addition, five buffers are located before the painting area that follows."
Painting and assembly zone The painting area spans over a length of approximately 190m. It starts with the distribution centre equipped with five buffer spaces and a heavy-duty transfer platform, which handles the distribution of trailers and wagons on demand.
A total of 13 rope conveyor drives ensure that the buggies are transported further after each work step. The drives are arranged one after the other to enable an individual feed at the workstations.
The workpieces enter into the robot blasting cabin, and are moved from there by means of the rope conveyors first to the primer station, then to the painting station and finally through the dryer cabin where at the end, two more buffer positions are placed and a second transfer platform. From here, the conveyor line continues on two parallel assembly lines, each about 90m long, where the wheelsets are fitted to the trailers and wagons. The extension of a second paint line is in the planning stage, so that this area can operate as a double-lane line, if needed.
www.vollert.de
BULK HANDLING TODAY
October 2018
9
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 650 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 Tel: 074 900 8378 • www.leeasa.co.za Secretary: Arni Sommer • email: arni@leeasa.co.za
BULK HANDLING TODAY
February 2012
Lifting
Milton Mhlanga is the leading lifting machine inspector at Kelmeg Lifting Services
W
hen it comes to lifting, rigging and lashing, Kelmeg Lifting Services (KLS) is one of South Africa’s leading manufacturer and supplier, and a company within the Commercial Products division of Bidvest. For the past 26 years, KLS has provided customers in all industry sectors with excellent lifting equipment and outstanding after sales-support. “We have recently expanded our service offering to include a mobile Lifting Machinery Inspection (LMI) unit. This will be accompanied by a registered lifting machine inspector, who is fully equipped to perform lifting machine inspections, load tests, repairs and maintenance; as well as the recertification of repaired equipment,” says Rodney Young, General Manager of KLS. “All of which will conveniently be conducted on site at the customer’s convenience,” he advises.
Certificates on site
The LMI unit is equipped with a mobile load test rig; as well as repair and maintenance facilities, including a range of spares, and the issuing of load test certificates on site. “This means that lifting tackle which complies with the required SANS specifications can be issued with the necessary certification on completion of the inspection or test, on site.” He explains, “Inspections on lifting tackle are a legal requirement in terms of the Driven Machinery Regulation 18 of the Occupational Health and Safety Act 85 of 1993, 2015; as well as chapter 8 of the Mine Health and Safety Act, Act 29 of 1996, which dictates that all lifting tackle must be inspected by a competent person at intervals not exceeding three months. Lifting machinery has to be subjected to a thorough
Mobile LMI unit examination as well as a ‘proof load’ in accordance with the standard to which the machine was manufactured, by the Lifting Machine Inspector (LMI) of a Lifting Machine Entity (LME), to determine the serviceability of the lifting machinery, at intervals not exceeding 12 months.”
Valuable service
Milton Mhlanga, KLS’s leading Lifting Machine Inspector (LMI), who has over 20 years of accumulated lifting industry experience, explains that mobilising this valuable service will result in improved efficiencies – not to mention expedited maintenance and inspections for KLS’s customers. This service is underpinned by the company’s commitment to continuously expanding its product and service offering, while maintaining the most stringent levels of professionalism, quality and service excellence.
The provision of the mobile LMI unit is a natural progression through which we can more efficiently meet our customers’ legal compliance and safetyrelated requirements “Our aim is not only to provide a comprehensive range of lifting and rigging equipment to our customers; but to add further value by combining our long-standing industry knowledge and expertise with innovative execution strategies.” “To us, the provision of the mobile LMI unit is a natural progression through which we can more efficiently meet our customers’ legal compliance and safety-related requirements, in order to provide a one-stop-solution to the challenges faced on site,” Rodney concludes. www.renttechsa.co.za
BULK HANDLING TODAY
October 2018
11
acaDeMic researcH
The future of SA mining Rio-Carb MD, Martin Maine, has commissioned academic research into the South African mining industry.
M
artin Maine, Managing Director of RioCarb of Alrode, a chromium carbide (CrC) wear-solutions provider, has identified a gap in the mining sector in the form of a lack of local beneficiation in the second-tier supply chain in the South African mining industry. Failure to galvanise foreign direct investment and innovation as a critical contributor to the future growth and development of the local economy has resulted in, for example, a large proportion of local mining equipment containing ‘re-imported’ raw materials.
Dr. Mngadi will liaise extensively with local stakeholders, especially the Government Department of Mineral Resources, to ensure that the research findings reflect the needs of the South African landscape In response, Martin has commissioned academic research into the current state of the South African mining industry to establish how we can utilise our own natural resources to stimulate economic growth from grassroots level. The research will focus specifically on how to develop the current South African mining industry to add imperative value to its mineral reserves. “Developing the industrial capability in these areas will generate employment and accelerate skills development, not only for the local communities themselves, but for the entire supply chain. This will also assist mining houses in complying with their local procurement and employment obligations in terms of Broad-Based Black Economic Empowerment (B-BBEE),” he highlights.
Future growth
Celebrating its 37th anniversary this year, Rio-Carb is ideally positioned to promote such high-level research, being fully independent, and unaligned with any major corporate interests. “One of our major thrusts is to become more involved with the development of our industry. The market is simply not big enough to sustain future growth. The best means to guarantee its viability is to promote the long-term growth of the South African mining industry itself,” Martin highlights. Entitled ‘Utilising South Africa’s natural resources to catalyse economic transformation from the grassroots’, the academic research will be conducted by Dr Anele Mngadi, in conjunction with prominent international academic institutions, led by Harvard University. Currently a nominee for Chancellor of the University of the Witwatersrand (Wits), Dr. Mngadi has extensive economic and financial management experience in Sub-Saharan Africa, China, the Middle East, Australia, the US, and Switzerland over the past 28 years.
Economic sectors
Whereas most suppliers and OEMs are currently based in the larger metropolitan areas, there is a great need to establish supply, engineering, and sub-contracting companies closer to existing mining operations.
She is a renowned turnaround strategist specialising in economic development deriving from various economic sectors. She holds a cocktail of Economic, Commercial, Legal, and Financial Management qualifications, including Masters in Business Administration and Commerce, and Doctorates in both Finance and Public Policy from leading tertiary institutions globally.
A long-time stalwart of the mining industry in South Africa, Martin has extensive experience in physical metallurgy, and has participated in an
As part of her research, Dr. Mngadi will be accompanied on a whistle-stop tour of major South African and Namibian mining operations
Closer to the mines
12
array of international conferences and seminars. Twice President of the South African Institute of Welding (SAIW), he has been involved with many of South Africa’s flagship infrastructure projects, including Sasol ll and lll, Koeberg, and Gariep Dam.
BULK HANDLING TODAY
October 2018
acaDeMic researcH
by Rio-Carb General Manager, Sias Suurd, who himself holds a Bachelor of Mechanical Engineering, and Honours in Design Engineering, from the University of Pretoria, and a Master’s in Business Administration from the University of Stellenbosch. Dr. Mngadi will liaise extensively with local stakeholders, especially the Government Department of Mineral Resources, to ensure that the research findings reflect the needs of the South African landscape, and dovetails with the revised Mining Charter. “We perceive a great need in South Africa for this level of research, which will help create an enabling environment for second-tier companies in the mining supply chain,” Sias stresses.
Local beneficiation
“It will also give us a bigger picture of local ben-
eficiation, and how best to promote and nurture this fundamental requirement. Beneficiation of our vast mineral wealth is the best means to grow the economy, eradicate poverty, reduce unemployment, and mitigate social unrest. For Rio-Carb, if we build the country, we build the company,” Sias argues. As an example, he highlights that South African companies were in a position to manufacture their own CrC plate not even ten years ago. Currently, this is mostly imported, albeit manufactured from raw materials exported from South Africa, such as iron, manganese, and chrome. “Local beneficiation will place us in the position of becoming a net exporter of CrC plate to the international market,”he concludes. Rio-Carb www.riocarb.com
BULK HANDLING TODAY
October 2018
13
Local content verification
Stepping up to the plate
Gravity concentration spirals are manufactured in the Spartan factory
Engineered ceramic solutions are manufactured at Multotec's factory in Pretoria North
Jannie de Jonge, Chief Operating Officer at Multotec
Polywedge panels are supplied for highly abrasive applications
South African mineral processing equipment manufacturer Multotec has taken the step of having its local content verified by the South African Bureau of Standards (SABS), in line with the requirements of the draft Broad-Based Socio-Economic Empowerment Charter for the Mining and Mineral Industry, 2018.
A
t the end of the verification assessment in July, Multotec Group chief operating officer Jannie de Jonge commended the work of the technical teams from the SABS and Multotec, who had pursued the creation of this ‘prototype’ process as a starting point for promoting local content in mining goods. Whereas mines’ procurement requirements have in the past been linked mainly to the B-BBEE ownership of suppliers, the new draft Mining Charter proposes
14
BULK HANDLING TODAY
October 2018
a more direct measurement of local manufacture embodied in the products themselves. “Following the publication of the National Development Plan, the Department of Trade and Industry (DTI) and the Department of Mineral Resources (DMR) have put more emphasis on the promotion of the South African manufacturing industry,” says Jannie. These proposals were incorporated by the Department of Mineral Resources in the 2018 draft of the Mining Charter.
Local content verification Over five years The amendments propose that 70% of all goods procured by mines are required to be “South African manufactured goods”, which are in turn defined as “goods with a minimum 60% of the value added during the assembly or manufacturing of the product is created in the Republic.” It is also proposed that this plan is phased in over five years, giving suppliers time to align themselves and become compliant if they wish to continue supplying mines. The Multotec Group decided to become more proactive in this process after a DTI-SABS presentation early this year to the South African Mineral Process Equipment Council (SAMPEC) – part of the South African Capital Equipment Export Council (SACEEC) – where the benefits of the local content requirement were outlined. “South Africa’s manufacturing sector has shrunk considerably in recent years, and this localisation drive is part of efforts to support and grow local manufacturing and job creation,” Jannie explains.
Action better than words The Multotec Group decided that action would be better than words, so showed its support for the spirit of these local manufacturing requirements by investing in having its products verified. While there were reasonable standards in place against which such verification could be initiated, there were aspects of the requirements and processes that were still not clearly defined. “Both Multotec and the SABS agreed that we needed to create a prototype of how this verification process could work, which would need practical engagement. We committed to go through the process to see what was involved and what we could learn and to provide useful feedback to the SABS and the DTI. The learnings gained from the process and the experience gleaned by all involved are priceless.” The Multotec Group has invested millions of Rands over the four decades since its establishment in 1978 in state-of-the-art manufacturing plant and equipment and is actively engaged in training initiatives to ensure that the skills are developed and maintained to put these investments to best use.
Injection moulded panels manufactured in Spartan are supplied to customers across the world
Accountability “We certainly appreciate seeing this recognition from government for our own progress to date,” says Jannie. “Despite the uncertainty of the outcome, and the rules and definitions still being under review and open for comment, we are committed to the process and supporting the initiative by the DTI and DMR to prioritise local content.” However, he emphasises that this process will need to be embraced with a significant responsibility and accountability to the industry by local mining suppliers. “The key focus among all stakeholders, including local manufacturers, must be the sustainability and success of our mining sector, so we need to ensure that we can supply world class products at competitive prices to the mining industry."
The mining industry is under severe cost pressure and is not in a position to absorb higher prices from suppliers Promoting competitiveness The concerns expressed by the Minerals Council South Africa (previously the Chamber of Mines) that some of the elements of the Draft Charter do not promote competitiveness, must be taken seriously. “The mining industry is under severe cost pressure and is not in a position to absorb higher prices from suppliers,” Jannie warns. “Local manufacturers are therefore obliged to continue becoming more competitive themselves, and to improve productivity as a strategic priority going forward. We must all understand and accept that for mining in South Africa to be competitive, it must have an efficient and competitive supply chain.” He also firmly believes that the promotion of local manufacture can gain momentum and can itself attract substantial foreign direct investment to enable local expansion and improvement. Multotec, Vivienne Murray Tel: (011) 923-6000 Email: marketing@multotec.com www.multotec.com
Millions of Rands has been invested over four decades in state-of-the-art manufacturing plants
A global specialist in polyurethane, rubber and wedgewire screen panels
BULK HANDLING TODAY
October 2018
15
Slashing Pre-sink Time
T
he modernisation and expansion programme called for two 23-metre-span overhead travelling factory cranes, with capacities of 30 tons and 15 tons, and one 20-ton all-weather portal crane with a span of 26 metres.
Robust usage
The world’s fifth largest mine, Oyu Tolgoi in Mongolia, will use advanced techniques enabled by pioneering crane design to fast-track the pre-sink phase at Shaft 6.
LMI ACADEMY cc. Merseta Accreditation No: 17-QA/ACC/0637/11 Reg. No. 2001/075895/23
P.O. Box 5907,Weltevredenpark 1715 E-MAIL: info@lmi-academy.co.za website: www.lmi-academy.co.za Training offered at the LMI Academy or on site. • • • • •
Lifting Machinery Inspector Qualification (LMI). Registered CPD Training. The Rigging trade. DMR 18 training. Tackle training. For further details contact: +27(011) 475 5876 Member of: LEEASA No. 810051
16
BULK HANDLING TODAY
October 2018
The cranes, which will be used to handle newly filled power cable drums, are both robust and feature-rich, sporting hand-held remote controls for operation from factory floor, control cabins for alternative operation from elevated vantage points (open cabins on the factory cranes; closed on the portal machine), variable frequency V belt drives on the hoists, and load cells to protect design limits and warn operators via LED lights when these limits are being approached. The portal crane also features Condra’s patented storm brake. Three companies competed for the order. Though prices were similar, lower overall operating costs achieved through rapid spare parts delivery and an effective and efficient maintenance service tipped the scales in Condra’s favour. The company holds substantial stock of locallymanufactured spares, routinely delivering these parts to any point in South Africa within 24 hours. By contrast, European companies with local representation need several weeks to ship spare parts to South Africa.
First-hand experience
Aberdare Cables has experience of Condra’s service through Load Mass Crane Services, the Port Elizabeth-based company behind the operation of an initial Condra crane installed some years ago, and the company which also installed, commissioned and maintains the three new machines. Two of these cranes will lift completed cable drums coming off the production lines into a covered storage area. Outside, a portal crane manages the open air storage facility. The remaining two machines, a 15-ton crane of identical span and similar configuration, and a 20-ton double-girder portal crane with a wider span of 26 metres, are at an advanced stage of manufacture. In terms of incorporated technology, there are variable frequency drives on all hoists, adapted and set to allow lifting speeds that can be altered
Lifting
at will from very slow to very fast, maximising productivity by minimising handling time.
The Condra portal is radically different from the level-luffing type of crane traditionally used for pre sinking European crane manufacturers are only now beginning to introduce V-belt drives such as those incorporated in the Aberdare Cables hoists, whereas Condra has offered the reliability and lower maintenance costs afforded by this type of drive for more than five years. The company is tipped to secure further orders resulting from the Aberdare Cables expansion programme, when open ground is converted into additional factory space. Condra, Tel: (011) 776-6000 Email: sales@condra.co.za
voith.com
Your service and solution Driveline expertise Our products and services include: • TurboBelt Drive Package • TurboBelt Controller with Intelligent Logic
• •
Onsite Service and Maintenance Condition Monitoring
For more information: Email: Info.vtza@Voith.com
BULK HANDLING TODAY
October 2018
17
Lifting
Setting The Benchmark Overhead cranes and services supplied by RGM Cranes are recognised as the gold standard for reliable and safe lifting within the Gauteng region. Having served the area for more than thirty years, the company remains focussed on providing its services to Africa’s largest industrial and mining hub.
A
ccording to managing director, Alex Dowling, rather than dilute its focus through a national footprint, RGM Cranes chooses to service Gauteng, a region that has more cranes in a single industrial area than can be found throughout the entire City of Cape Town.
Crane experts
This kind of focus ensures a concentration of skills and the ability to deliver professional services to its clients timeously.
"Our strength and longevity through turbulent economic circumstances is testament to the hard work put in on a daily basis by our incredible team."
Our strength and longevity through turbulent economic circumstances is testament to the hard work put in on a daily basis by our incredible team. As a premier turnkey service provider, services range from conception, design, manufacture and installation of, as well as, repairs, maintenance, upgrades and conversions of any type of lifting equipment. The company has ISO: 9001 accreditation for quality management that governs all processes within the supply chain.
18
BULK HANDLING TODAY
October 2018
“From the foundations of your new building right down to the smallest lifting point or shackle, we provide every conceivable lifting item to our clients. From the ground, up to the crane and from the crane back down to the load” says Alex.
Alex continues that all fabrication is carried out at the company’s 10 000 sqm purposebuilt premises according to all relevant BS and SANS specs. RGM Cranes also entered into a partnership with the Turkish based company Güralp Crane and Machine in late 2015 and has experienced tremendous success through the company’s robustly designed machinery and advanced electrical systems. Working conditions in Turkey bear many similarities with sub-Saharan Africa making it a lot simpler for the design team at Güralp
Lifting
to fully understand the specific requirements for overhead cranes in South Africa.
Lifting products
Güralp introduced the GMD range of wire rope hoists into the Turkish and European market more than 10 years ago and has enjoyed success with the range of noticeably strong FEM rated hoisting units. The GMD range features maintenancefriendly design coupled with advanced electrical systems for hoist and load monitoring. The hoists boast ABM drive units from Germany that stand up to harsh lifting conditions. Cost of ownership is a critical factor in today’s economy and Güralp ticks this box emphatically with comparably affordable spare parts. The Güralp end carriage offering is one that has had an enormous impact in South Africa and around the world. From 112mm up to 630mm diameter wheels and in both single and double bogie arrangements, utilising GGG70 sphero cast wheels as a standard, these end carriage systems are among the best available in today’s market. Inverter control reduces both brake and gearbox wear and is 30% more energy efficient than conventional contactor-controlled drives. The single girder end carriages have a hinged design to counteract
minor long travel rail wear or misalignment making these end carriages a very attractive option. There are important criteria involved in the purchase of an electric chain hoist and the Güralp GMD range excels in all key areas. The compact hoisting unit boasts significant headroom coupled with an attractive design. Hoisting chains are supplied by Pewag of Austria, the strongest available chain in the world today. Low voltage control keeps the operator safe together with a slipping clutch that also prevents overwind and overload. RGM Cranes, Scott Turner Tel: (011) 422-3690 Email: scott@rgm.co.za www.rgmcranes.com
BULK HANDLING TODAY
October 2018
19
The Local Manufacturing Expo Aims to:
21 – 23 MAY 2019
Promote local manufacturing
EXPO CENTRE, NASREC,
Demonstrate Southern Africa’s export potential
JOHANNESBURG, SOUTH AFRICA
Provide access to global markets
A Showcase of Southern Africa’s Manufacturing Capabilities Who Will Exhibit?
Networking opportunities Develop public / private partnerships Public / private sector collaborations Identify industry challenges and opportunities for growth
Manufacturers across a variety of sectors, including:
Agriprocessing
Automotive
Business Process Outsourcing
Capital Equipment
Chemicals
Construction
Engineering
Food and Beverage
Furniture
ICT and Electronics
Metals
Mining
Plastics
Textiles/ Clothing/ Footwear
Transport
www.localmanufacturingexpo.co.za In association with:
Endorsed by:
Implemented by:
Brought to you by:
h
Fire suppression A triple-action fire-suppression system uses high-pressure water mist to suppress fire and cools down the compartment to prevent reignition
The patented discharge piston allows for complete discharge regardless of vertical or horizontal orientation
Prevention systems
A
ccording to the Managing Director of Fogmaker South Africa, John Russell, mining contractors are under pressure from mining houses to have their machines fitted with fire prevention systems. “When it comes to choosing the right technology, we are seeing a distinct move by both mining companies and contractors to adopt water mist technology as the preferred fire suppression system. “In fact, two blue-chip mining companies have decided to change to water mist technology from powder or foam as the preferred fire extinguishing method. They are recognising the numerous advantages offered by this type of system related to extended lifecycle, low total cost of ownership, and, most importantly, safety. “In addition to fast and efficient fire suppression, the low maintenance system prevents reignition and is easy to clean up and reset after discharge.”
The recent roll out of fifty fire suppression units for fitment to a fleet of above-surface mining machines to a large mining contractor operating at a diamond mine which had lost machines to fire in the past. Triple whammy John describes the low-weight, low-maintenance Swedish-manufactured Fogmaker system as ‘simplicity’ itself. The system makes use of the purest extinguishant, water, combined with 3% Aqueous Film Forming Foam (AFFF), to attack all three components in the fire triangle namely heat, oxygen and fuel. Using high-pressure (100 bar) water mist, the system effectively suppresses the fire and cools down the compartment to prevent reignition. John points out
that the use of water in the form of mist (50-micron droplets) presents an additional firefighting benefit different from any other fire-fighting agent. “The significant number of droplets, together with the large combined surface area, effectively blocks radiant heat by absorbing and scattering heat radiation, which helps to reduce fire damage within the engine compartment. As high pressure and consequently high discharge speed is required to ensure that the mist reaches the flames and penetrates the outward flows induced by the fire, the system is fitted with special highpressure nozzles. These nozzles ensure good penetration of droplets into the fire as well as efficient cooling and oxygen depletion due to the respective fast vaporisation and the expansion of vaporised droplets. The patented discharge piston allows for a complete discharge regardless of the orientation of the bottle, vertically or horizontally, leading to a versatile installation footprint. This, together with a compact, neat design, enables the system to be fitted in confined, internal compartments, avoiding hindrance to general machine maintenance.
Absolute minimum As there is no powder or mess to clean-up after actuation, resetting of the released suppression system is easier and faster than powder or foam suppression systems. “After a discharge, it’s a simple matter of replacing the detector hose and refilling the piston accumulator, thus keeping costs and downtime to the absolute minimum,” John explains. Every diesel engine-operated machine presents a potential fire risk, with implications for people safety, uptime and productivity as well as repair and replacement costs. This automatic fire suppression system is therefore ideally suited to any industry where diesel machines are being operated. John confirms the recent roll-out of fifty fire suppression units for fitment to a fleet of above-surface mining machines to a large mining contractor operating at a diamond mine which had lost machines to fire in the past. Fogmaker South Africa www.fogmaker.co.za
BULK HANDLING TODAY
October 2018
21
TRACE Inte is a globa anti-br or leading pr party risk
TRACE due diligence solutions are based on internationally accepted best practices and our experience and familiarity with the compliance needs of multinational companies. Services range from a denied parties screening to enhanced due diligence, including TRACE Certified Due Diligence.
International, Inc. globally recognized ti-bribery business organization and g provider of third risk management solutions.
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.
Tel: (011) 867-0902
.
.
Company Affliates as info@saimh.co.za at May 2017 Fax: (011) 867-0036 Email:
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
find out if you qualify to #joinourtable at pps.co.za
.
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 PPS is an authorized Financial Services Provider.
24 (011) BULK HANDLING Tel: 867-0902TODAY Fax:October (011) 2018 867-0036 Email: saimh@global.co.za www.saimh.co.za
BELTCON 19
Design Considerations on Capacity Upgrade of 6Km Downhill Conveyor System Dharma Raj H
GSSV Suresh
This paper focuses on the drive upgrade of two downhill regenerative conveyors running in one of the existing projects of NMDC Ltd (Bailadila Iron Ore Mine, Bacheli, Chhattisgarh State, India) for conveying additional load. A technical audit was conducted and it was recommended to replace the old drive and braking system with state of the art variable speed drives and a soft braking system on the slow speed side.
T
his would enable the conveyors to be upgraded to handle a design load of 3 000 tph by increasing the belt speed up to 4 m/s while keeping all the conveyor structures, belting and other components the same. Accordingly, a study was undertaken to recommend minimum design parameters for those conveyors and a report compiled listing the considerations and requirements.
existing belting; take-up tension, additional safety features; drive house sizing and handling facilities; and discharge chute modification requirements is presented.
Brief of downhill conveyor system
The downhill conveyor system (DCS) of Bld. 5, Bacheli Complex was commissioned in 1977 and transports crushed iron ore from hilltop to foothill, crossing two hills.
This paper discusses the design considerations and engineering solutions recommended for the proposed capacity upgrade of The DCS is 6 km long and consists of conveyors 24, 27, the selected downhill regenerative conveyors. A comprehensive brief including design criteria; power demand/regeneration for various loading cases; selection of drive components (motors, variable speed drives, gearboxes, low speed side hydraulic disc brakes having a soft braking option; couplings; pulleys etc); static and dynamic behaviour, suitability of Figure 1. Equipment and facilities at downhill conveyor system Parameter
Conveyor 28
Conveyor 29
Belt Width
1050 mm
1000 mm
Horizontal Length
2.5 km
2.4 km
Drop [-] (approx.)
(-) 101 m
(-) 211 m
Max. Slope (approx)
10 Deg. (down)
6 Deg. (down)
Belt Speed
3 m/s
3 m/s
Drive Motor (3.3 kV, 50 Hz, 1000 RPM, 3 phase, slip ring induction motor)
450 kW – 1 No. at tail end 150 kW – 1 No. at head end
450 kW – 3 Nos. at tail end 150 kW – 1 No. at head end
Braking System (limited to max. 2100 TPH)
DC injection electrical braking system and a mechanical disc brake on high speed side.
Special Features
(a) Belt turn-over device (b) Motorised take-up winch with load cell for automatic belt tensioning and correction.
Table 1. Brief specification of downhill conveyors 28 and 29
BULK HANDLING TODAY
October 2018
25
Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine well-appointed and equipped business suites. Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages. Secure parking, business centre, fibre optic broadband AV, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.
www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 1401 41 St. Albans Ave, Craighall Park
BELTCON 19 28, 29, 31, 32 including traveling tripper – 33 between the stockpiles. The upgrade involves verification of all these conveyors in the stream for handling a design load of 3 000 tph. However, this paper focuses on conveyors 28 and 29 considering their critical nature and the advanced engineering involved. Figure 1 shows the equipment and facilities of the downhill conveyor system. Key profiles (not to scale) of conveyors 28 and 29 are also shown for reference (distances and levels are given in metres).
Parameters of downhill conveyors 28 and 29
Each of the two critical regenerative downhill conveyors 28 and 29 are about 2.5 km long with steel cord belting ST 2250 and ST 5000 respectively. Conveyor 29 runs through a 2.1 km long tunnel. The existing drive and braking system (1992) of these two conveyors is of 3.3 kV slip ring induction motor and DC injection electrical braking system with hydraulic disc brakes on the high speed side having PLC based closed loop control. For stable operation, feed to conveyor is restricted to 2 100 tph at 3 m/s due to braking limitation and non-availability of old equipment spares. A brief specification of these two existing downhill conveyors of the DCS is given in Table 1 for reference.
New overland conveyor system – not a viable option
The option of laying a new parallel overland conveyor system was studied as an alternative solution since the existing system had completed 40 years of successful service. However, the following limitations ruled out a new overland conveyor system: Length of downhill conveyor system increases by 2.6 km Regenerative power of about 1 MW would be lost as overland conveyors have to rise and travel a long way to clear the hillocks
Thus, the capacity upgrade of the existing downhill conveyor system was considered to be a feasible option for implementation.
Design criteria
The following are the properties of material conveyed and environmental conditions considered for design verification of the downhill conveyors: Material conveyed
Steel grey haematite iron ore, crushed
Design capacity
3 000 tph
Bulk density
2 200 to 2 800 kg/m 3
Surcharge angle
20°
Maximum lump size
150 mm
Temperature range
10 to 45 °C
Conveyor runs in the existing structure and path
Belt speed, carrying capacity and fill factor
The maximum capacity possible with the existing speed is about 2 400 tph and 2 300 tph for conveyor 28 and 29 respectively. Therefore, in line with the audit report recommendations it was decided to achieve the design capacity by increasing the speed. Accordingly, speed vs carrying capacity is worked out based on the CEMA method for arriving at optimum speed and a graph is plotted in Figure 2. Restricting the fill factor level up to 80% is considered as a safe limit on carrying capacities. It can be seen that the carrying capacities of conveyors 28 and 29 are about 3 200 tph and 3 000 tph respectively at the belt speed of 4 m/s. Further, operating these conveyors at 4 m/s speed is considered to be in the comfortable range as NMDC is operating downhill regenerative conveyors, which are running at 4 m/s and more. Considering these factors and NMDC’s experience, speed of the conveyor is selected as 4 m/s for carrying a load of 3 000 tph.
The number of conveyors would increase resulting in additional transfer houses, drive systems, pulleys etc, increasing operational and maintenance activities
Conveyor analysis
High legged trestles up to 74 m (approximate) may be needed to support the conveyor gallery, which makes the system complicated
Fully loaded (FL) belt at 3 000 tph load at 4 m/s belt speed Empty belt at 4m/s belt speed
The overland conveyor would pass through an active mining area of another operating mine
All decline sections loaded (DL) at 3 000 tph load at 4m/s belt speed
Higher magnitude of capital investment.
All incline sections loaded (IL) at 3 000 tph at 4m/s belt speed.
The belt conveyors in question were studied and analysed for the following loading conditions:
The conveyors were studied for these loading conditions with various friction factor values. The frictional factor values are hypothetical idler friction factor as per DIN standard and predicted based on existing conveyor characteristics. A reasonable check on the friction factor based on the power demand/generation
Figure 2. Speed vs carrying capacity at 80% fill factor
BULK HANDLING TODAY
October 2018
27
BELTCON 19
values obtained during the conveyor audit was carried out. The friction factor effected by the conveyor design software was also compared. Further, the calculations were verified with software results. Ambient temperature and motor efficiency was also considered while selecting the friction factor. For a conveyor with the characteristics as shown in Table 2, the Figure 3. Elevation of conveyor 28 standard value of friction factors should range from 0.01 to 0.02 as per DIN standard.
the conveyor as per CEMA (7th edition) method is given in Table 3 for reference.
As per the technical audit conducted on the conveyors during 2006, the recorded values of power demand/regeneration at different loading conditions were noted and compared with theoretical calculations. It was noted that the friction factor during normal running condition varied from 0.0115 to 0.014.
With Table 3 in mind, these conveyors were studied for the following combinations of loading conditions and friction factors:
The design report recently commissioned on a similar downhill conveyor considered a DIN factor of 0.012 for fully loaded and decline loaded conditions and 0.022 for empty and incline loaded conditions.
Static analysis (at 4 m/s speed)
The friction factor applied by the software while analysing Characteristic
Value assumed
Internal friction of material conveyed
Medium to high
Belt conveyor alignment
Medium
Operating conditions
Medium (dusty environment)
Idler diameter
152.4 mm
Carrying idler spacing
1m
Return idler spacing
2.5 m
Belt speed
4 m/s
Troughing angle
35 deg.
Ambient temperature
10 to 45 °C
Table 4 conveyor loading conditions were analysed for the following operational conditions: Normal motor stop, dynamic analysis (braking by variable frequency drives and mechanical brakes are applied once the conveyor is stopped) and proportional stop, dynamic analysis (complete braking by disc brakes) Operational start and dynamic analysis; the drives are controlled to accelerate the belt in a smooth manner following the predetermined ‘S’ curve.
Route and profile of conveyors 28 and 29
Table 2. Characteristics of conveyor Load case
Friction factor assumed by software for conveyor 28
Friction factor assumed by software for conveyor 29
FL (3 000 tph)
0.0129
0.0127
Empty
0.0188
0.0180
DL (3 000 tph) 0.0128
0.0127
IL (3 000 tph)
0.0182
0.0203
Table 3. Load case and friction factor applied by software Loading condition
Friction factor used
FL (3 000 TPH)
0.012
Empty
0.023
DL (3 000 TPH)
0.012
IL (3 000 TPH)
0.023
Table 4. Load case and friction factor considered for analysis
The conveyors continue to run in the existing corridor and alignment. Tail end extension of 17 m (approx.) and 23 m (approx.) is planned for conveyors 28 and 29 respectively for installing a new drive system. Conveyor 28 travels about 2.5 km with a drop in elevation of 101 m from the receiving point (conveyor 27 discharge chute) to discharge point (tail end of conveyor 29). Along the route, the conveyor negotiates 19 vertical curves. The elevation of conveyor 28 is given in Fig 3. Conveyor 29 travels about 2.4 km with a drop in elevation of 210.9 m from the receiving point (conveyor 28 discharge chute) to discharge point (tail end of conveyor 31). Along the route, the conveyor negotiates one vertical curve. The conveyor travels in a tunnel of about 2.1 km length. The elevation of conveyor 29 is given in Fig 4. The drive system of both the conveyors are located in their respective tail ends. Conveyor 28 houses one number 450 kW drive at the tail end and one number 150 kW drive at the head end. Conveyor 29 houses three number 450 kW drives at the tail end and one number 150 kW drive at the head end. For both the conveyors, the load receiving point is located after the tail pulley. The material is fed through a discharge chute. The return side of both conveyors include belt turn-over at head and tail ends. Motorised winch take-up with load cell for automatic belt tensioning and correction is provided near the head end of both conveyors.
BELTCON 19
Motor power
Power demand/regeneration is calculated to select the suitable capacity drive motor(s). Calculations are performed using basic formulae manually and verified using software program for the CEMA 7th method and the DIN method. Power demand/ regeneration is worked out by sum- Figure 4. Elevation of conveyor 29 ming-up power required to overcome the various resistances produced by the conveyor system. The method used for manual calculation follows the basic principles of conveyor design as presented below. P = P1 + P2 + P3 + P4.kW
1
Power consumed by all moving parts of the conveyor. P1 = (C R L/367) (3.6 A v).kW Power required for moving the load horizontally. 3
Power required for lifting/lowering the material. P3 = Q H /367.kW
4
Power consumed by conveyor accessories. P4 = Psk + Psc.kW
A – Mass of moving parts, kg/m v – Belt speed, m/s Q – Conveyor carrying capacity, t/hr H – Lifting/lowering of material, m
2
P2 = (C R L/367) (Q).kW
L – Conveyor horizontal centre to centre distance, m
5
Where
Psk – Power for skirt board, kW Psc – Power for scrappers, kW For the sake of simplicity, power required for accelerating material in the feed zone is not considered, as this does not contribute significantly to the total power requirement and for regenerative conveyors, P4 is considered as zero. Results of calculations performed for power demand/regeneration of conveyor 28 are tabulated (Table5).
C – Length correction factor
Results of calculations performed for power demand/regeneration of conveyor 29 are tabulated (Table 6).
R – Idler friction factor
Drive system assembly and arrangement
Power demand (+) / Regeneration (-) [kW] Loading condition
Manual calculation
CEMA 7 th Method (Software results)
CEMA 7 th Method (User friction factor)
DIN method (Software results)
FL
(-) 425
(-) 386
(-) 413
(-) 371
Empty
(+) 285
(+) 224
(+) 270
(+) 237
DL
(-) 850
(-) 830
(-) 849
(-) 815
IL
(+) 788
(+) 732
(+) 761
(+) 725
Table 5. Power demand/regeneration of conveyor 28 Power demand (+) / Regeneration (-) [kW] Loading condition
Manual calculation
CEMA 7 th Method (Software results)
CEMA 7 th Method (User friction factor)
DIN method (Software results)
FL
(-) 1312
(-) 1254
(-) 1277
(-) 1233
Empty
(+) 327
(+) 264
(+) 330
(+) 290
DL
(-) 1437
(-) 1394
(-) 1415
(-) 1374
IL
(+) 460
(+) 417
(+) 486
(+) 442
Table 6. Power demand/regeneration of conveyor 29 Loading condition
Conveyor No. 28 (kN-m)
Conveyor No. 29 (kN-m)
FL
186
369
IL
256
392
Table 7. Braking torque requirement
From these calculations, considering the maximum power regeneration of about 1 437 kW from conveyor 29 and additional drive motor service rating of 10%, the installed drive power requirement is about 1 581 kW. In order to ensure uniformity and standardisation of drive components among the conveyors, three identical drive assemblies with 550 kW motors are proposed for conveyor 29 and two identical drive assemblies with 550 kW motors are proposed for conveyor 28 at their tail ends. Braking torque requirements to stop the conveyors in 30 seconds are shown in Table 7. Each drive assembly consists of a VFD controlled inverter duty LT induction motor (690V) of 550 kW at 1 000 rpm, a gear reducer of reduction ratio 1:20, disc brake of 220 kN-m braking torque capacity (selected based on motor torque) at the low speed side, low speed and high speed couplings. The motor, brakes and gearbox compo-
BULK HANDLING TODAY
October 2018
29
BELTCON 19
Figure 5. Drive arrangements proposed for downhill conveyors 28 and 29 at tail end
Figure 6. Running tensions of conveyor 28, FL (3 000 tph) condition
nents are intended to be mounted on a machined drive base platform. Drive base frames will be connected with pulley frames for better rigidity. The drive system will be installed at the tail end of the conveyors and the proposed arrangement is symbolically illustrated in Figure 5.
Static analysis
Running tensions of conveyor 28 for various loading conditions were worked out (CEMA 7th Method with user defined friction factor) and the result of fully loaded belt condition is shown in Fig 6.
Based on the tension results, the safety factor at which the existing belt ST 2 250 continues to operate is shown in Table 8. Running tensions of conveyor 29 for various loading conditions were worked out (CEMA 7th Method with user defined friction factor) and the result of fully loaded belt condition is shown in Fig 7. Based on the tension results, the safety factor at which the existing belt ST 5 000 continues to operate is shown in Table 9. Note that the maximum running tensions of both the downhill
Loading condition
Maximum running tension (N/mm)
Safety factor
Loading condition
Maximum running tension (N/mm)
Safety factor
FL (3000 TPH)
291
7.74
FL (3000 TPH)
591
8.45
Empty
163
13.78
Empty
255
19.61
DL (3000 TPH)
363
6.19
DL (3000 TPH)
592
8.45
IL (3000 TPH)
160
14.03
IL (3000 TPH)
256
19.56
Table 8. Safety factor of conveyor 28 belt
30
BULK HANDLING TODAY
October 2018
Table 9. Safety factor of conveyor 29 belt
BELTCON 19
Figure 7. Running tensions of conveyor 29, FL (3 000 tph) condition
When the start is called for, the drives are given a zero speed command. The brakes are then released over five seconds, transferring load from the brakes to the drives. The master drive then follows the speed ramp specified in Figure 8 for providing good starting control under all load conditions. The minimum acceleration time is proposed to be set at 60 seconds. Figure 9 shows the starting tensions of conveyor 28 while starting in fully loaded (3 000 tph at 4m/s) condition.
Figure 8. Starting curve
conveyors after capacity upgrade are less than the existing maximum running tensions for which the conveyors are designed.
Figure 10 shows the starting tensions of conveyor 29 while starting in fully loaded (3 000 tph at 4m/s) condition.
Stopping Control – Dynamic Analysis
Starting Control – Dynamic Analysis
Considering the criticality and braking effort required to stop the conveyors, a secure, robust braking system is adopted.
The conveyors are to be powered by variable frequency drives (VFDs) of required capacity (suitable for regenerative conveyor application). VFDs provide good torque control and allow for an extended controlled start under any loading condition. The system will be configured with one of the drives acting as a master following a demand speed profile, while the other drives will act as torque followers.
During normal stopping, the VFDs simply ramp the system to 3% of speed within a pre-set time interval and thereafter, the mechanical braking system applies brakes for stopping the conveyors. This mode is used under normal conveyor operating conditions and thus load to mechanical brakes is minimised. This reduces the heat generation and mechanical wear of the mechanical brakes. The minimum stopping time is proposed to be set as 30 seconds and velocity ramp is shown in Figure 11.
The starting behaviour of the conveyors is studied for all the loading cases in various starting conditions.
BULK HANDLING TODAY
October 2018
31
BELTCON 19
Figure 9. Starting tensions of conveyor 28
Figure 10. Starting tensions of conveyor 29
32
BULK HANDLING TODAY
October 2018
BELTCON 19
During a power failure condition, VFDs will be powered by uninterrupted power supply (UPS) and the regenerative energy will be dumped to a large resistor bank (ie, energy is dumped through chopper circuit to the suitably sized dynamic braking resistor made of Fecral wire grid resistor and provided with natural air cooling). The conveyor will be ramped to stop in the pre-set time interval. Thus, VFDs ensure smooth stopping of the conveyor and reduce conveyor dynamic tensions to a greater extent. This ensures increased life of conveyor components including the belt. In the event of power and VFD controller failure, a brake
controller modulates the brakes and brings the conveyor to rest in 30 seconds. In the unlikely event of brake controller failure as well, the brake dumps 50% torque immediately and bleeds to full torque over 10 seconds. The conveyors have a robust, redundant braking system to stop the conveyor under all loading conditions. Spring applied hydraulically-released fail-safe disc brakes with a soft braking option are envisaged per drive at the low speed side. The disc brakes are proposed to be mounted in the pulley shaft through hubs. One working and one stand-by hydraulic power pack for the brakes for each conveyor are envisaged. Two callipers per disc are provided. The brakes can control the conveyor in normal, power failure, VFD controller failure, brake controller failure and emergency mode of stopping, and during conveyor over speeding. Use of the soft braking option ensures application of braking torque over a pre-set period of time in a controlled manner.
Figure 11. Velocity ramp during stopping
PLC based brake controllers (one working and one stand-by) are envisaged for monitoring various features and the functions of the braking system, like monitoring of braking time, maximum speed, nominal speed, hydraulic pressure, brake pad temperature and other features like constant deceleration, controlled start-up ramp, controlled
Figure 12. Stopping tensions of conveyor 28
BULK HANDLING TODAY
October 2018
33
BELTCON 19
Figure 13. Stopping tensions of conveyor 29
Figure 14. Key plans of proposed drive houses for downhill conveyors
release of brake, key board locking and password function, alarm, event logging, control of electric motor hydraulic unit, battery back-up etc.
operation of the conveyors. On completion of construction, the new drive system will be connected by extending the tail ends of the respective conveyors.
Figure 12 shows the stopping tensions of conveyor 28 when stopping the conveyor while fully loaded (3 000 tph at 4m/s) normal condition.
Drive houses are suitably sized for accommodating the drive system and ensuring space for maintenance and men movement. Truck approach is provided and an EOT crane of capacity 15/5 tonnes is envisaged in both drive houses for handling requirements.
Figure 13 shows the stopping tensions of conveyor 29 when stopping the conveyor while fully loaded (3 000 TPH at 4m/s) normal condition.
Drive houses and motor control centres
A well-equipped new drive house and motor control centre are planned for each conveyor at the tail end. These new drive houses will be constructed independently, away from the existing drive houses and without disturbing the day-to-day
Drive house key plans for both conveyors, showing overall dimensions are given in Figure 14.
Discharge trajectory
Trajectories of discharged materials for both conveyors were plotted in Figure 15 (dimensions shown are in metres) based on BIS 11592 and the increase in distance of fall at chute
BELTCON 19
was considered to take up the necessary modification works in the discharge chutes.
Conclusion
This paper summarises the important design considerations to be made in a brownfield capacity up-grade of a downhill conveyor system by striking a balance between the Figure 15. Discharge trajectories of falling materials capacity augmentation requirement and existing constraints.
Truck approach is provided and an EOT crane of capacity 15/5 tonnes is envisaged in both drive houses for handling requirements The front end engineering design helped in understanding the basic requirements of downhill conveyor systems. The static and dynamic analysis results of different operating and loading conditions helped in understanding the transient behaviour of downhill conveyors thus arriving at the safe operating parameters and sizing of drive components.
This paper was first presented at the Beltcon Conference in 2017. Copyright is vested with IMHC. www.beltcon.org.za Raj H Dharma and GSSV Suresh NMDC Limited (India) Email: hdraj@nmdc.co.in, gssvsuresh@nmdc.co.in
The engineering carried out from the owner’s side facilitated an estimate of upgrade requirements in advance and forms a baseline for meticulous execution and seamless integration through an EPC contractor.
DEMAG V-GIRDER CRANES – NOW AVAILABLE UP TO 50 TON LIFTING CAPACITY.
Visit us at Electra Mining Africa 2018 10-14 September 2018 Hall 5, Stand E28
+27 11 898 3500 www.demagcranes.co.za
BULK HANDLING TODAY
October 2018
35
MARKET FORUM
Revolutionary modular rope hoist For the first time, a rope hoist can be built either in a C-design or co-axial design utilising one basic technology. The extraordinary wide range of possible DMR applications can be extended thanks to smart interfaces and corresponding fittings and accessories. Demag’s Modular Rope Hoist offers many options, such as five different sizes with load capacities of up to 50 tons; a choice of motors; a foot-mounted hoist, low-headroom travelling hoist, double-rail crab or a standard-headroom travelling hoist as well as a smart SafeControl system, conventional contactor control or provided by the customer.
“Flexibility and productivity, as well as its long service life and cost-effective operation are key characteristics of our DMR,” says Richard Roughly, Senior Manager Sales & Marketing of Demag Cranes. “Consequently, the impressive modular rope hoist concept also offers sophisticated technical details.”
The coupling between the motor, which weighs much less than previous models, and the gearbox absorbs sudden motor forces for a longer rope hoist service life. The DMR gearbox, which requires 30% less oil, provides for long maintenance intervals thanks to its efficient oil lubrication. Its enclosed design offers protection against external factors. Richard Roughly Tel: (011) 898-3500 Richard.Roughly@demagcranes.com www.demagcranes.co.za
In Durban and going strong In December 2017, Transnet SOC Ltd ordered seven Liebherr Reachstacker LRS 545, which were dispatched from the manufacturing site in Sunderland, Great Britain, in February this year. Thanks to the professional on-site assembly by qualified Liebherr service engineers in Durban, South Africa, all seven units were already in operation by March. Within a short period after the commissioning of the new reachstackers
in daily business, Transnet SOC Ltd appears impressed by the remarkable performance of the seven latest Liebherr machines. Moreover, the machines have proven to be highly reliable as they have been in permanent 24/7 operation for more than six months straight. “The decisive factor for the purchase of a Liebherr machine was to find a reachstacker that could withstand the difficult maritime environmental
conditions such as dust and salt that prevail in the port of Durban and defy them permanently. In addition, it was necessary to find an engine that could cope with the deficient quality of diesel fuel in Africa. "A very satisfactory solution for these requirements was found, the LRS 545," says Nene Thubelihle, Regional Supply Chain Manager KZN for Transnet SOC Ltd. www.liebherr.com
BULK HANDLING TODAY
October 2018
37
MarKet foruM
A BIG HITTER
be imported from China by GEM has already been pre-sold prior to delivery. In addition, a major Zambian copper mine has ordered four units on a trial basis, which has been so successful that it has ordered an additional six units. “The SY75 will definitely carve a niche for itself in the market, due to its reliable power source and impeccable back-up from GEM,” Andre notes. The Isuzu 6WG1X engine delivers a maximum torque of 2 138Nm at 1 500rpm. “Hence the excavator has sufficient horsepower to get the job done quietly and efficiently and, perhaps most importantly, without breaking the bank.” The Isuzu engine brand is known particularly for its durability and fuel economy, and is an integral part of Sany’s strategy to source only the best and most cost-effective components for its equipment. For example, Kawasaki pumps are also used to ensure constant hydraulic flow.
What is believed to be the largest excavator in Africa has been launched by Goscor Earth Moving (GEM), part of the Goscor Group, and official distributor of Sany. The SY75 is a primary loading tool for the mining industry, from opencast to alluvial diamond mining.
(ADTs), as well as for stripping top soil and free digging, Andre Steenkamp, General Manager of the Sany range under GEM, explains, "For example, the 4.2m3 bucket means that a 40t ADT can be loaded in less than seven passes. This is a highly affordable, large excavator.”
The 75t excavator is ideal to load blasted material onto articulated dump trucks
Such has been the success of the SY75 to date that only the second unit to
In addition, the SY75 features a selfdiagnostic system that flags any technical issues quickly, thereby reducing downtime. The standard warranty allows for carefree digging for the first yearand-a-half, or 3 000 hours, whichever is achieved first. Goscor Group, Debby Marx Tel: (011) 230-2600 Email: dmarx@goscor.co.za www.goscor.co.za
Underground belt protocol In terms of its ongoing contribution to improved firefighting methodologies for the mining industry, the I-Cat Fire Division has compiled a totally new protec-
tion protocol for underground conveyor belt protection, including redundancy protection. The protocol has been tested against various test scenarios identified
in a risk assessment. I-CAT, Tel: 086 112-4228 Email: environmental@i-cat.co.za www.i-cat.co.za
BULK HANDLING TODAY
October 2018
39
High securtiy welded mesh
Pallisade
Gates
Gate Automation
Razor wire and more ....
What is High Security Weld Mesh HIGH Security Weld Mesh is wire fused and welded at a Horizontal distance of 76.2mm and a vertical distance of 12.7mm also known as 35B/3510 where 3 denotes 3”(distance between vertical wires), 5 denotes 0.5” (distance between horizontal wires), and B or 10 denotes gauge of wire
Salient Features • Difficult to Climb: The spaces between the Horizontal wires are too narrow for fingers to have grip • Impregnable: Extremely difficult to cut with a hand cutter as the beak of a wire cutter will not be able to penetrate the horizontal wires • Excellent Replacement option to Solid Wall as: 1. More economical than a solid wall 2. Faster to install than a solid wall 3. CCTV Camera has a clear view • Further upgrade possible with electric security system • Anti-corrosive & low maintinance
Standards
• Manufactured according to BS EN 10016-2 • Wire Sizes in accordance with BS EN 10218-2 • Tolerance on Mesh Size in accordance wiht EN 10223-7 • Tolerance on Panel Size in accordance with EN 10223-4 • Welding Strength in accordance with BS EN 1461 • Zinc Coating in accordance with EN 10245-1 • Anti Corrosion in accordance with BS En 3900 E4/F4
Tensile Strength • Wire has a tensile strenght of min 550 MPA
MARK: 083 454 6488
Email: mark@palifence.co.za
www.palifence.co.za
MARKET FORUM
Building Maintenance Units A specialist supplier of suspended access systems, Riggers Steeplejacks makes extensive use of fischer construction fasteners, Milwaukee power tools, and Stabila measuring tools, all distributed exclusively by leading local supplier Upat, to enable it to offer complete solutions to its clients. Riggers Steeplejacks was established in 1970, with offices in Alberton North in Gauteng, Pinetown in KwaZulu-Natal, and Cape Town in the Western Cape. It is a market leader in permanently-installed systems, commonly known as building maintenance units (BMUs). The company’s systems are designed, manufactured, installed, and maintained in compliance with a number of industry codes and regulations, namely SANS 51808, SANS 50795, SANS 1903, SANS 10295, Driven Machinery Regulations
DMR 18, and Construction Re g u l a t i o n s 2014. Riggers Steeplejacks Project Director, Hentie Wessels, reveals that the company has to date installed over 2 000 anchor points for rope access suspension using the fischer M12 express anchor, which can hold up to 1.2t. “Our engineer specified the fisher brand due to its strength and ease of installation. We also use fischer M10, M12, M16 and M20 anchors extensively on
the brackets of our units.” Hentie adds that the correct installation of high-quality anchors is essential for safety-critical operations such as rope access and working-at-height. Upat, Tel: (011) 624 6700 www.upat.co.za
Ahead of schedule Murray & Roberts Cementation reports that work is well underway on its contract at Kalagadi Manganese Mine in the Northern Cape. This underground mining contractor, which formed a joint venture with BCM Underground Mining (Pty) Ltd, is tasked with building up production to the shaft system’s nameplate capacity within the first 18 months of the five-year contract. Thereafter the scope is to operate the mine for the balance of the contract term. Kalagadi Manganese Mine, owned by Kalahari Resources, is situated northwest of Hotazel on three farms which overlay an estimated 960-million metric tons of manganese ore. The mine has been designed to produce 3 million tons of manganese ore at a grade between 36 to 38%. The mining method used will be room and pillar.
this and is well positioned to ensure appropriate best practice systems are put in place. The mine is a two-shaft system with a main man/material shaft and a separate ventilation shaft. The main shaft with a nine metre diameter will reach a working level of 281 metres and a loading level of 317 metres. The ventilation shaft is to a depth of 323 metres and has a 6,7 metre diameter. Included in the development phase, which is well underway, is the completion of the required underground infrastructure that
will support the ramp up and sustainable production at the mine into the future. This will include conveyor systems, crushers, settlers and workshops as well as the sliping of silo number 1 to ensure it has the requisite throughput capacity and the sliping of the RAW to Level 261 which will facilitate access to the second tipping area. Murray & Roberts Cementation Allan Widlake Tel: (011) 201-5000 EmaiL: allan.widlake@murrob.com www.cementation.murrob.com
Processes and procedures were implemented in accordance with base line risks assessments conducted that took all factors into account. Significantly, Murray & Roberts Cementation has extensive experience on full turnkey projects like BULK HANDLING TODAY
October 2018
41
MARKET FORUM
N2 upgrade “Our 440t mobile cranes were deployed on the N2 Mtunzini-to-Empangeni upgrade project in KwaZulu-Natal for main client Sanral. Construction commenced in 2016 with completion due in 2019," says Branch Manager of Concord Cranes Richards Bay, Bella Mollentze. The 34 km stretch of road between Mtunzini and Empangeni is known to the locals as the ‘road of death.’ Over the years, there have many countless accidents and hundreds of lives have been taken. Concord Cranes, specialists in mobile crane hire, rigging and specialised transport solutions, was involved in the project in order to provide the cranage needed to erect 30mlong bridge beams over a dry riverbed, each weighing 52t. The company placed a total of 76 beams at various crossings, just two days before flooding. Subsequent to the flooding, 44 beams, 22m in length and each weighing 16t, were placed on the last bridge. All bridge sections were completed in July 2018 and the actual road building has continued. Concord Cranes will also be providing the client with a turnkey project solution which will include the supply of cranes, riggers, specialised rigging equipment and extendable trailers to transport the bridge beams. Concord Cranes, Marcus Wilkinson Tel: (011) 805-8071 Email: marcus@concordcranes.com www.concordcranes.com
ABSOLUTE MATERIAL FLOW CONTROL
CHUTE SYSTEMS & SOLUTIONS • Optimum material flow • Up to 80% decrease in material degradation
• Reduced dust and noise levels • Virtually maintenance free
Tel: +27 (0) 11 827-9372 email: info@webachutes.com
www.webachutes.com
42
BULK HANDLING TODAY
October 2018
• Greatly reduced spillage • Significant reduction in belt damage
MarKet foruM
Spring cable reeling drums New innovative Conductix Wampfler SR-Express spring reeling drums are available from Powermite. Telefonika mining cable, Conductix Wampfler cable reeling drums, downshop and festooning systems, Mennekes and Ampco plugs, connectors and sockets as well as crane accessories complete Powermite’s line-up. Powermite is part of the Hudaco group of companies and is a leading supplier of electrical and mechanical equipment for moving machinery in the southern African region. Powermite (a division of Hudaco) Rolf Lung Tel: (011) 271-0000 rolf.lung@powermite.co.za www.powermite.co.za
Never looked back One of the Western Cape’s fastest growing civil construction companies, JVZ Construction, attributes a large portion of its success to the procurement of reliable and durable equipment that has enabled it to complete projects effectively and timeously. As a result of its on-time performance and high standard of work, the company has enjoyed unprecedented growth from a one-man show in 2006, to a largescale contractor with a workforce of approximately 150 staff and capability of undertaking R200-million projects on its own, by 2018. Speaking at a recent construction and
farmer’s open day in Wellington, founder and director of JVZ Construction, Johan van Zyl says, “ELB Equipment has been a major influence in my business from the beginning when I purchased my first Terex 860 backhoe loader. The company’s sales representative in those days, Abrie Visser and Cape Town branch manager, Gert Mouton, were there with sound advice, a large equipment selection and finance solutions that has helped us to grow. “Due to the service we received from ELB Equipment and the performance and versatility of the Terex TLB 860, I decided to standardise on ELB Equipment
wherever possible. As a result, when the business grew and there was a requirement for an excavator, I did not hesitate to contact ELB Equipment, whereupon Abrie recommended we purchase one of the company’s efficient Sumitomo excavators. And we have never looked back with the Sumitomo’s proving to be among the best excavators I have ever worked on with superb economy and durability.” Wakefield Harding Tel: (011) 306-0700 Email: wakefieldh@elbquip.co.za www.elbequipment.co.za
Part of JVZ Construction’s growing fleet supplied by ELB Equipment
BULK HANDLING TODAY
October 2018
43
Piecing together your success.
12415/E
We understand that you’ve been building your career piece by piece, and that all those hours, projects and plans allow you to live the lifestyle you deserve. Partner with PPS, and let us help you ensure your success is more than the sum of its parts. Proud sponsor of the SAICE Young Engineer of the Year. Visit pps.co.za to find out more about our financial solutions for graduate professionals. PPS is an authorised Financial Services Provider.
MarKet foruM
Collaboration is key Having an in-house Projects Department to focus on the specific requirements of project houses, OEMs, and other tender-related project activity, is starting to bear fruit for drive and automation specialist SEW-Eurodrive South Africa, which has clinched a major order for five M-Series industrial gear units for a mining operation in West Africa. The Projects Department, headed up by Andreas Meid, oversaw this entire project from receipt of the initial order to successful installation and commissioning at the mine, in addition to any back-up service and technical assistance required. It is this capability to offer complete solutions packages, as opposed to standalone products, in addition to the necessary aftermarket support, that has resulted in SEW’s Projects Department showing consistent growth year-on-year. “We pride ourselves on our on-time delivery in particular, which is a clear differentiator for us in a highly competitive market,” Andreas comments
The Projects Depar tment also has a drawing office, and a mechanical engineer to compile any calculations that are needed. It focuses mainly on Greenfield projects related to conveyors, agitators, and mixers in mineral-processing applications. “Based on the enquiries received, we work in conjunction with the specific project house or OEM to offer a complete solution for their mining clients. In other words, our products essentially allow them to complete their portion of the work in hand,” Andreas explains. Such collaboration between suppliers
and related companies is a growing trend in response to a tough business environment, and clients’ need to reduce costs by installing the latest technology. “We specialise in integrated solutions. A lot of clients tend to regard SEW solely as a gear unit supplier, but we offer a host of ancillary services that can add significant value, reduce risk and downtime, and improve efficiency,” Andreas concludes. SEW-Eurodrive, www.sew-eurodrive.co.za
Lowering cycle times
12415/E
When planning and implementing loadhaul mining contracts, the importance of close cooperation between contractor and customer cannot be over-emphasised, says Graeme Campbell, commercial and operations manager of Raubex Group company, SPH Kundalila. “It begins with the customer providing relevant and accurate data, so that the contractor can make the right calculations, but it goes much further than this,” says Graeme. “When both parties are focused on improving cycle times, the project efficiency can be significantly improved, and the cost reduced.”
He highlights that contractors will not be able to achieve the required cycle times if the customer causes any delays. But, on the other hand, it only takes small improvements to shorten cycle times and reduce the cost per tonne. This result should provide enough motivation for a constructive partnership. “There are basic principles of earthmoving that influence cycle times, which include ensuring ideal conditions both on-site and off-site,” he adds. “On site, the loading area should be level and stable underfoot, while the haul road needs to be a well-maintained, quality
surface with as few stops as possible. “Conducive off-site conditions mean that all activities must be accurately recorded, information on tonnes handled and hours worked per shift must be regularly provided, and there must be constant feedback on health, safety and machine status,” he concludes.
SPH Kundalila Jeremy Petter Bowyer Tel: (021) 527- 5200 Email: jeremp.p@sphgroup.co.za www.sphkundalila.co.za
MARKET FORUM
Fit-for-purpose
tions. All chain comes standard with a 12-month warranty on materials and workmanship, while extended warranties can be arranged.
Leading supplier BI has supplied a large order of Kobo chains to cement producers in the North West and the Western Cape. This consisted of bucket elevator, coal reclaimer, and hot pan conveyor chain. In total, BI supplied 80m of coal reclaimer chain, 93m of bucket elevator chain, 90m of elevator chain, and 120m of hot pan conveyor chain. The bucket elevator chain was supplied to cement producers in both the Western Cape and the North West, while the pan conveyor chain and reclaimer chain was supplied exclusively to its Western Cape client.
standard, with larger link tolerances, depending on the application, Kobo Southern Africa Business Development GM Naigel Pera explains.
These chains are ideal for the corrosive and abrasive environments of cement plants. They are available clad or
The bulk of Kobo engineered-class chains are manufactured to order, and are designed for fit-for-purpose applica-
BI has been the exclusive distributor of G e r m an - e n gi neered Köbo chains in Southern Africa since March 2017. Köbo has been producing sprockets and chain wheels since 1894, and is well-known for its innovation across multiple industries. The company has ISO 9001:2008-certified manufacturing facilities in Germany, Poland, and China. BI, Tel: (011) 899-0000 Email: info@bearings.co.za www.bearings.co.za 24 Hour Hotline: 083 250 9191
Going up
46
Relative newcomer to the tower crane and hoisting sector, Crane & Hoist SA has secured an order for the supply and erection of a Potain tower crane for the new Stor-Age Self Storage facility being constructed in Craighall Park, Johannesburg.
“It is all very well being able to supply pieces of materials handling equipment, but it is critical to be able to support these sophisticated machines in the field,” Louw says. “And to make sure the erection of the tower crane complies with all the legislative requirements.”
Louw Smit, sales director of Crane & Hoist Equipment SA, says that the company was able to offer the
A Potain MDT 98 tower crane was selected for this particular project as it will provide a 1,2t lifting capacity at a 55
end- user the most appropriate tower crane for the project and at the right price with full back- up support over the duration of the eight month hire period.
metre radius allowing optimum materials movement on this fast track project. Significantly, this top slewing modular tower crane can be easily adapted for individual sites and brings optimum
BULK HANDLING TODAY
October 2018
performance coupled with flexibility to a construction site. Crane & Hoist SA Louw Smit Tel: 083 413-7524 Email: Louw@che-sa.co.za www.che-sa.co.za
dŚĞ ƐƐŽĐŝĂƟŽŶ ŽĨ ^ŽƵƚŚ ĨƌŝĐĂŶ YƵĂŶƟƚLJ ^ƵƌǀĞLJŽƌƐ
QuanƟty Surveying… …at the heart of every successful construcƟon project
Find out more… info@asaqs.co.za
T 011 315 4140/1 F 011 315 3785
www.asaqs.co.za
P O Box 3527 Halfway House 1685 I Suite G6 Building 27 Thornhill Office Park Bekker Road Vorna Valley Midrand •
•
•
•
Conveying Excellence with High-End Conveyor Belts Every conveyor belt, every climate zone and every topography calls for perfect conveyor belt technology. ContiTech provides knowledge, experience, a globally encompassing and competent network and a broad product range to give your conveyor belt applications a technological lead. More than 140 years of rubber expertise make us a strong partner, enabling our customers to benefit from the synergies within the Continental corporation. We implement innovative conveyor belt technology reliably, sustainably and safely from development to commissioning and after-sales service.
conveying excellence
+27 (0) 11 248 9300 www.contitech.co.za
Bulk Handling.indd 1
2016/02/03 8:44 AM