BULK MATERIALS BULK MATERIALS HANDLING HANDLING • POWDER • CONVEYING HANDLING • QUARRYING FIBC’S • HILLHEAD • RECYCLING 2018 PREVIEW & WASTE• MANAGEMENT VALVES
FEBRUARY APRIL 2018 2017
TEREX TRUCKS TO SHOWCASE LATEST INNOVATIONS & COMPANY HERITAGE AT HILLHEAD
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HIGHLIGHTS:
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The new coaxial planetary drive
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Dry Flue Gas Scrubbing – made easy!
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The Evolution of Digitalisation from Siemens
The Smart Way to Unload, Convey, Weigh & Mix ®
MODU-KLEEN BIN VENT FILTER
SWITCH RECEIVER
CONVEYING LINE
®
BLENDCON SILO BLENDER
TM
BULKBUSTER BULK BAG UNLOADER
STORAGE SILO
STORAGE SILO
STORAGE SILO
TM
VIBRA-JET BIN AERATOR
BULK BAG
®
GYRO BIN ACTIVATING FEEDER TM
DYNA-SLIDE HIGH PRECISION AIR-ACTIVATED FEEDER
WEIGH HOPPER
®
BAGBUSTER BAG BREAKER ®
BELLA TWIN SHAFT FLUIDIZED ZONE MIXER
®
BLENDCON AIR BLENDING HEAD
TRANSPORTER MANUAL HOSE SWITCH
Less degradation
Cost effective
Move your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear.
Our high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation and maintenance. Initial cost is surprisingly affordable too, thanks to our modular design concept and ease of installation.
Proven capability Dynamic Air dense phase pneumatic conveying systems have been proven in over 15,000 installations worldwide. They handle a wide range of materials and bulk densities at rates from less than a hundred kilograms per hour to 400 tonnes per hour, over distances exceeding 1500 metres.
Sixteen concepts Each Dynamic Air system is custom designed from one of our sixteen different conveying concepts. So you get a conveying solution that fits your process perfectly, without compromises.
BellaTM Twin Shaft Fluidized Zone Mixer
GYRO EXTM Bin Activating Feeder
Dynamic Air Ltd. Milton Keynes United Kingdom Phone: +44 (0) 1908 622344 E-mail: sales@dynamicair.co.uk
www.dynamicair.com
Dense Phase Transporter, J-Series
BulkBusterTM Bulk Bag Unloader
Issue 125
CONTENTS 4
NEWS
11 VALVES 15 FIBC’S BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: editorial@bulksolidstoday.co.uk advertising@bulksolidstoday.co.uk Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday
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BULK MATERIALS HANDLING
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HILLHEAD SHOW 2018 PREVIEW
26 QUARRYING 28 CONVEYING 30
BUYERS GUIDE
CIRCULATION To receive a copy free of charge, please send your details to subs@bulksolidstoday.co.uk SUBSCRIPTIONS Subscriptions are available via www.bulksolidstoday.co.uk/subscribe No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements. SOME MANUFACTURERS & SUPPLIERS HAVE MADE A CONTRIBUTION TOWARD THE COST OF REPRODUCING SOME PHOTOGRAPHS IN BST.
ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2018
www.bulksolidstoday.co.uk Bulk Solids Today
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COMPANY NEWS
VORTEX ANNOUNCES NEW REPRESENTATIVE AGENT IN FINLAND
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ortex Global Limited, a solids and bulk handling components company, is pleased to announce the appointment of Industri-Textil Job AB as its new representative agent in Finland. Industri-Textil will service solely the Finnish market. Industri-Textil Job AB is a major brand owned by the Job Group. The Job Group has realized significant recent growth as a result of its culture for innovation. The group is known for offering an extensive range of market-leading products and services – primarily, those focused on filtration and other “clean tech” solutions. In addition, they are widely known for their hi-tech textile offerings. “We are very excited to represent Vortex’s high quality products in Finland,” shared Tommi Kyllästinen, area manager at Industri-Textil Job AB. “Vortex’s product lines are well-suited for our product portfolio. The quality of the products we manufacture is very important to us,
and we are proud of our results. We seek that same level of quality in the products we represent. Both Vortex and Industri-Textil are renowned for their high quality, professionalism and know-how in the dry bulk industry. By working together, we are able to offer the Finnish market greater knowledge and more comprehensive product offerings to assist customers in their processes.” Industri-Textil will utilize Vortex valves and loading equipment to complement the Job Group’s
filtration technologies. These efforts will improve filtration capabilities and overall efficiencies in facilities throughout Finland. “Industi-Textil has a proven history working in the dry bulk solids industry in the Finnish market and further afield,” said Laurence Millington, managing director of Vortex Global Limited. “Vortex has always strived to increase our opportunities within the Scandinavian markets, and IndustiTextil is well-placed to make this happen.” www.vortexglobal.com
CONSPARE BOLSTERS ON-SITE SERVICE OFFERING WITH APPOINTMENT OF HYDRONIX SPECIALIST
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oncrete production specialist ConSpare has expanded its on-site service offering by appointing Ian Hatch to its Capital Department. Ian joins Nottinghamshire-based ConSpare as Hydronix Specialist, responsible for installation and maintenance services for its range of moisture measurement equipment. Hydronix is the world’s leading manufacturer of digital microwave moisture measurement equipment, which enables concrete producers to manufacture the highest quality concrete at the lowest possible cost. Its unique digital sensor technology ensures accurate and reliable performance. Ian will oversee the installation of Hydronix equipment, calibration of sensors, operator training and system optimisation and troubleshooting. He brings concrete industry 4
Bulk Solids Today
experience and expertise within the field of batch process control, having previously specialised in remote and on-site support, installation and training for both software and hardware. His work in the concrete industry forms part of a wider career in application support, spanning more than 20 years. Steve Peterson, ConSpare’s Engineering Director, said: “We’re really pleased to have Ian on board. His appointment highlights continued investment in our range of on-site services for concrete producers. “His skillset and experience complements our existing team perfectly and further expands our onsite support for Hydronix equipment. “Hydronix is a key tool in
improving the concrete production process, particularly in terms of improving product quality and reducing waste. I’m sure our customers will value the additional support we can provide, allowing them to focus on making the best concrete possible.” For more information about ConSpare’s full range of moisture measurement equipment, visit www.conspare.com.
COMPANY NEWS
HOPPECKE ADDS TO ITS GROWING TEAM
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emonstrating its determination to deliver unrivalled customer service, leading specialist in industrial battery systems Hoppecke has made three new key appointments. As part of its investment in a dedicated nationwide team, Hoppecke has appointed Craig Brennan as account manager and Michael Wignall and Ian Sheils as field engineers. They join Hoppecke with the aim of ensuring the company’s products and services continue to meet everchanging customer demands. Jason Howlett, Hoppecke’s Regional Managing Director – Northern Europe, says: “The three join us with strong track records of delivering results in customerfocused business environments within the industry and we are delighted that candidates of such calibre see
Hoppecke as their go-to employer.” In the UK, Hoppecke has invested heavily in employee engagement and incentive programmes and believes its success lies in its people. Jason continues: “We benefit from a team that is engaged, prepared to voice its concerns and comes up with ideas to improve the way we do business. Our employees are committed to the long-term success of Hoppecke and its customers and that professional attitude will take us all forward into a successful future.”
Hoppecke is committed to getting as close to its customers as possible and offering carefully attuned services across all aspects of energy management. If anyone is looking for a new opportunity in this field they should contact Lynne Morris, HR Manager at Hoppecke on 01782 667305. www.hoppecke.co.uk
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Bulk Solids Today
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COMPANY NEWS
PROSEAL CROWNS 20TH ANNIVERSARY YEAR WITH QUEEN’S AWARD Tray sealing specialist Proseal uk has marked its 20th anniversary year by winning a Queen’s Award for Enterprise in the category of International Trade. The company received the honour in recognition of its outstanding continuous growth over the last six years.
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ased in Adlington, Cheshire, Proseal designs and manufactures high quality automatic tray sealing machines, conveyor systems, and sealing tools for the food industry and other applications. The award comes after a period in which Proseal achieved strong sales in both its home and export markets, creating many new jobs in the process that have increased the number of employees to over 300 in the UK to nearly 400 worldwide. This impressive growth has culminated, in the last year, with the company’s best ever performance in international trade. The Proseal USA and Proseal Australia subsidiary businesses along with a growing network of thirteen global distributors have helped Proseal gain an impressive 52% of sales in export markets in 2017. The company also enjoys strong business in mainland European countries such as the Netherlands, Ireland, Germany and Spain, and has developed new markets in Southeast Asia, China, Turkey, North Africa, South Africa and South America. As a result of these successes, Proseal now has a presence on every continent except Antarctica. “We’re honoured and delighted to have received the Queen’s Award for International Trade – and the fact that it comes during our 20th anniversary year makes it all the sweeter,” comments Steve Malone, Proseal’s Director, who together with Robert 6
Bulk Solids Today
Hargreaves founded the company in 1998. “Early on we identified that expanding our presence overseas would be critical to our continued growth and the award is testament to this strategy.” Proseal’s impressive performance has been supported by the company’s ongoing investment in research and development, which has seen the introduction of models that have broken new ground in tray sealing technology and opened up new applications. For example, the company developed the first machine to erect, fill and seal cardboard skillets for sandwiches, which has facilitated the move away from plastic packs for many leading retailers. Its advanced sealing technology has also been behind the move in the soft fruit sector from clamshell and clip-on lids to simple thin top sealed film for plastic punnets, reducing packaging materials by as much as 33%. More recently, Proseal has worked with tray manufacturers to develop a sealing system for a new generation of board-based MAP-capable food trays produced from sustainable cardboard that delivers optimal conservation of the packed product. Just as important has been Proseal’s continuing investment
in its people. Training has been a key element of the company’s operation from the very beginning, with comprehensive programmes that have seen many recruits promoted to senior positions over the years. In addition, Proseal has established close links with local colleges to offer work experience and has recently opened its own dedicated training centre to bring on the next generation of engineers. A friendly and open working environment has also underlined this people-centred approach. “We have always prided ourselves on being a warm and welcoming company in which any employee, no matter what their position, can contribute ideas,” continues Steve Malone. “Sometimes this idea will be just the solution we were looking for – so we benefit as a company from this approach and our ongoing commitment to training. “People are at the heart of Proseal – and as this has now led to the Queen’s Award, I’d like to thank everyone for their contributions. Our success will only encourage us more to keep innovating and exploring new opportunities.” Tel: +44 (0) 1625 856600 Website: www.proseal.com
Global sieving & filtration specialists The Russell Compact SieveÂŽ
Improves product quality
Fits into smaller spaces
Compact & mobile design
Eliminates dust & fumes
What makes us specialists..? Customized solutions - Applying innovation to meet your requirements Comprehensive customer service - Technical support & global stocking Specialized testing facilities - Trial your products for total peace of mind Call us on: +44 (0) 20 8818 2000
Email: sales@russellfinex.com
COMPANY NEWS
NEW POWERSCREEN PREMIERTRAK R400X PULLS NO PUNCHES
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he Bristol and Avon Group (B&A Group) have become one of the first major transport and waste management companies to receive the new Powerscreen® Premiertrak R400X which was launched last year. Supplied by Blue Machinery (Southern) the new machine has been hard at work at the company’s new aggregate facility at Hallen near Bristol. B&A Group, is an established, family owned company providing transport services, supply of aggregates and waste management solutions to a broad range of clients in the south west region for over 30 years. Recently the B&A Group have invested more than £7million in a new state-of-the-art, 11-acre aggregate recycling facility. With a further 11 acres purchased in 2017 and ready to develop in line with the Groups expansion plans to become the largest soil and stone treatment facility in the South West region. This new and exciting development in Bristol is Bristol & Avon Groups new headquarters, centralising all operational activities including a 4-bay workshop, lorry park and bespoke offices, made from shipping containers and designed by the awardwinning Mackenzie Wheeler Architects and built by Urban Space Management. The B&A Group are currently advancing plans to include facilities for a soil washing plant and waste transfer station As part of the on-going investment in plant and machinery and to keep their fleet fresh and maximise on residual values B&AG have invested in a new Powerscreen® Premiertrak R400X 8
Bulk Solids Today
which has replaced a three-year old Powerscreen® R400 Jaw Crusher. ON-SITE PROCESSING: Material is delivered to the aggregate processing area by an extensive fleet of B&A Group trucks where the new machine is currently employed on processing this incoming feed of C&D recyclable materials which consist mainly of concrete, brick rubble and tarmac. All materials are then pre-prepared before being fed into the Powerscreen® Premiertrak R400X to make the required recycled products. The end products are produced in-line with market demands and the current blue-chip company contracts B&A Group must fulfil, which ultimately sees them produce a range of recycled material from 6F type to MOT type 1 and single size materials for use in fill, sub-base, road base and pipe bedding. THE POWERSCREEN® PREMIERTRAK R400X: The Premiertrak 400 has been one of the strongest machines in the Powerscreen® range and the new R400X builds on that legacy improving ease of use, maintenance, serviceability and on-site safety to ensure this is a class leading machine. Capable of circa 400tph the machine supplied to B&A Group incorporates a hydraulic release jaw, hydraulic jaw flipper plate, magnet and side fines conveyor. Providing high output and
excellent reduction capability the R400X is controlled remotely by umbilical connection and features the Powerscreen® Pulse™ Telematics System which has revolutionised the way you can improve your crushing operation. Available online anywhere and at any time the Pulse™ Telematics System provides comprehensive information on the GPS location, start and stop times, fuel consumption, tonnages, cone settings, wear ratings, operating hours, maintenance status, and much more. A user-friendly interface displays information clearly for ‘at a glance’ metrics and diagnostics. This allows the operator to ‘take action’ before damage occurs, in addition predetermined maintenance intervals are signalled, and error messages are displayed in plain text messages. OUTSTANDING PROFESSIONALISM: With a reputation built on outstanding professionalism, attention to detail and efficient service, B&A Group can now have the confidence in their investment in Powerscreen® equipment. An OEM with a rich heritage of design and manufacturing excellence and a leading force in the crushing and screening heavy plant sector. Powerscreen® machines cover the full range of material processing requirements with mining equipment, quarrying equipment and mobile crushing and screening machines for the mining, quarrying, demolition and recycling industries. www.powerscreen.com
COMPANY NEWS
BONFIGLIOLI 711C 2 B SERIES, THE NEW COAXIAL PLANETARY DRIVE A dedicated solution for winches.
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hanks to its compact dimensions, the 711C 2 B new coaxial planetary drive, which provides an output torque of up to 25.000 Nm, allows a perfect fitting inside the winch drum. This design is a lighter and more cost-effective solution compared to the standard one. The 711C 2 B oil seals, gears profile and bearings are robust and produce less vibration, thus offering a durable and reliable solution. The gearbox flange design facilitates the assembly, can sustain harsh environments with ambient temperature from -25° up to 50° and simplifies maintenance, thanks to its lifetime lubrication, which requires no oil changes. External oil cooling ports are available, to operate even at high ambient temperatures. In this case, the gearbox can be provided with gear oil temperature sensor setup, allowing a better monitoring of the gear oil temperature. Last but not least, the drive is directly connected to the electric motor (3 600 rpm) and its design makes him perfectly quiet. We design, create and develop solutions alongside our customers, showing them our capacity to listen and understand their needs by supplying tailored-made solutions. ABOUT BONFIGLIOLI Bonfiglioli is a worldwide designer, manufacturer and distributor of a complete range of geared motors, drive systems, planetary gearboxes and inverters, which satisfy the most challenging and demanding needs in industrial automation, mobile machinery and renewable energy. Bonfiglioli serves more industries and applications than any other drive manufacturer and is a market leader in many sectors. Established in 1956, Bonfiglioli operates in 21 countries, with 14 production facilities and over 3,600 employees worldwide. More information is available at www.bonfiglioli.com
Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort. Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof
Tuf-Lok (UK) Tel: +44 (0) 1706 822512 Email: sales@tuflok.co.uk • www.tuflok.com Bulk Solids Today
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COMPANY NEWS
FORTIS IBA LTD SELECT TEMA AND LIWELL® TO UPGRADE SCREENING TECHNOLOGY AT ITS HAMPSHIRE IBA PROCESSING FACILITY
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ortis IBA Ltd has recently invested in a Liwell® Flip Flow Technology Screen for their A303 IBA Processing Facility in Hampshire. The A303 facility currently processes 120,000 tonnes of bottom ash from Energy from Waste Facilities each year, transforming the ash into a sustainable recycled aggregate which is used in construction projects. Fortis IBA Ltd, resourced the project internally, undertaking extensive research within the European materials separation technology markets prior to the investment. It was critical to ensure that the investment would significantly increase metallic extraction rates and improve processing efficiencies, whilst enhancing the engineering properties of the final IBA Aggregate products. A series of trials were carried out using a number of different screening and separation solutions from the UK and Europe. After a lengthy evaluation process, Tema (Machinery) Ltd were selected to carry out further detailed trials at the A303 IBA Processing Facility using their mobile version of the Liwell® Screener. The trials proved highly successful in meeting the expectations and requirements of Fortis IBA Ltd. The Fortis team were subsequently invited to the Liwell factory in Germany to negotiate and agree final specifications. Supplied by Tema (Machinery) Ltd who are based at Woodford Halse, near Daventry, the Liwell® 2.0 x 6.0m double deck flip flow screening machine (Model LF2.0-5.76/18DD) was installed at the Barton Stacey site, close to the A303 in Hampshire at the end of December 2017. The investment in the Liwell® Flip Flow Screener followed extensive on-site testing with the Hein Lehmann test facility with the design and build contract awarded to European Active Projects Ltd.(EAPL) of Southampton with final commissioning taking place in mid-January. MORE EFFICIENT RECOVERY: Simon Parry-Jones, Sales Engineer for Tema (Machinery) Ltd, commented, “Initially, the remit was to clean the 10
Bulk Solids Today
feed material entering the plant, but more specifically the feed to the -5mm Eddy Current Separators (ECS) which required frequent cleaning, which was impacting on process continuity and costs.” Simon, continued, “We invited Terry Moore, General Operations’ Manager at Fortis to visit a similar facility in Germany to see many Liwell® screens operating on IBA and to draw on the German experience working at very small separations.” “However, it became apparent to Fortis IBA that cleaning the feed on its own would not be justification for the investment and sought an improvement on the metals recovery at Barton Stacey. The test facility was again hired in to look at the possibility of separations much smaller than was thought possible with this material and the Liwell® screen proved they could make those reductions in separation size and recover more metals.” Terry Moore, General Operations Manager – Fortis IBA, commented, “We are continually looking at new ways of developing our processes to improve our metallic recovery rates and overall processing efficiencies. We produce high-quality IBA Aggregates and the introduction of the Liwell® screen has refined our processes further. Successfully
separating smaller IBA fractions improves recovery rates and reduces maintenance and downtime. We are delighted with the performance of the Liwell® screen and are achieving the anticipated improvements in recovery and efficiency.” HISTORY OF THE LIWELL SCREEN: The Liwell® screen was the first ever flip flow screen, invented by Hein Lehmann some 45 years ago, the innovative technology has seen many attempts to copy it over the years, but this application highlights the advantages the Liwell screen still has over the competition. The Liwell® principle ensures the mat is subject to at least 50g’s acceleration, yet the screen itself is under very little stress, in fact just over 2g when operating. Liwell® machines are known for their longevity and it’s quite common to come across old machines in the second decade or more of their service life. Hein Lehmann and Tema (Machinery) Ltd are sister companies within the wider Steinhaus Group of companies, Tema look after the interest of Hein Lehmann and the Liwell® screen along with Siebtechnik GmbH here in the UK and Ireland. www.tema.co.uk
VALVES
STAINLESS STEEL BUTTERFLY VALVE Posi-flate has introduced an inflatable seated butterfly valve with a highly polished 316 stainless steel housing and disc.
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he Series 486 inflatable seated butterfly valve from Posi-flate features a fully machined 316L stainless steel housing. The single piece disc and shaft is available in a number of materials including 316L stainless steel and hastelloy. The disc may be polished to a mirror finish or coated with PTFE, nylon or other high performance coating. The stainless steel valve is ideal for powders, granules, slurries and liquids and is available in sizes 2” (50mm) to 20” (500mm). Typical applications include loading and unloading of process material, sterile air control, and outlet valves for storage containers or hoppers. It is suitable for many applications, such as food, chemical and pharmaceutical. The inflatable seat design of the Posi-flate butterfly valve provides a better seal by utilizing air pressure to expand the seat against the disc, providing more sealing area and an even pressure distribution against
the disc every time. The seat automatically compensates for wear when it inflates against the disc, extending valve life considerably. Because the Posi-flate disc only makes casual contact with the seat during opening and closing, torque requirements are substantially lower. This ease of movement also allows the disc to come to a perfect 90-degree position every time. Additionally, the smooth profile of the disc helps material flow easier and reduces build-up. For unique fail-safe monitoring, a pressure switch can be utilized to verify a perfect seal. Tel: +44-1908-622366 E-mail: sales@posiflate.co.uk www.posiflate.com
Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost. Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong. • • • • • •
Less friction Low torque Low maintenance Lower actuator costs Longer valve life More reliable Tel: +44 (0) 1908 622366
www.posiflate.com
Bulk Solids Today
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VALVES
SAFEGUARD TECHNOLOGIES FOR DRY BULK MATERIAL HANDLING
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hen designing a system for dry bulk material handling, it is important to consider all possible scenarios a slide gate may face during its life cycle – and equip it to appropriately handle those obstacles as they arise. For this reason and as a safety precaution, it is beneficial for a slide gate to be equipped with both a fail-safe air tank and a vented ball valve. FAIL-SAFE AIR TANKS: HOW THEY WORK In traditional setups, a slide gate would be energized through the following steps: • Plant air is plumbed to provide air supply to the slide gate. • An air line is connected from the plant air source to the slide gate’s solenoid. • The solenoid calculates whether the air supply should feed toward the opening or closing stroke, based on commands received from the operator or from a PLC. • Pressurized air travels through the solenoid and the pneumatic air cylinder, forcing a piston in the pneumatic air cylinder to move either forward or backward. This movement allows the slide gate to actuate open or closed.
With fail-safe air tanks, the same actuation process occurs. However, instead of providing air supply direct from the plant air source toward the solenoid, an air tank is installed between the two. It changes the process in the following ways: • Plant air is supplied to the air tank. • As plant air fills the air tank, that pressure is stored until the tank reaches its maximum storage capabilities. • When the slide gate is signaled to actuate, air pressure is released from the fail-safe air tank, toward the solenoid. Any air pressure that was lost in the air tank is then replenished with new plant air. 12
Bulk Solids Today
Fail-safe air tanks are simply a way to store additional air pressure, in preparation for an emergency. The purpose of a fail-safe air tank is to allow a slide gate to actuate fully closed in the instance of plant air loss. When plant air supply is shut off or lost, fail-safe air tanks have a one-way “check” valve that prevents stored air pressure from leaking backward, toward the plant air source. Then, the fail-safe’s stored air is automatically forced toward the solenoid and through the pneumatic air cylinder, so that the slide gate fails closed. FAIL-SAFE AIR TANKS: WHY THEY ARE IMPORTANT Fail-safe air tanks are beneficial to safeguarding your manufacturing process because they close a convey line’s moving parts. This forbids materials from moving any further in the manufacturing process until plant air is restored. The alternative is an open system that cannot be controlled. This creates many concerns, including: • Bad batches by allowing materials to skip over manufacturing stages. • Damaged product by allowing materials to travel through the convey line at inappropriate velocities. • Damaged equipment from excessive material impact. • Product loss from material spillage at the end of a process. Fail-safe air tanks are also intended to address safety concerns. If the cause of plant air loss is unknown, maintenance technicians must perform inspections to determine where the error(s) may have occurred. If inspection requires technicians to work near a slide gate, it is important for the gate to be actuated fully closed. Otherwise, if a maintenance technician is still working near a partially open slide gate once plant air is restored, the blade may actuate fully closed and cause serious injury. Continued on page 14
VALVES But even if a fail-safe air tank has actuated a slide gate into the full close position, once plant air is restored, the gate will immediately become live – allowing it to again start opening and closing quite rapidly. To avoid this additional risk, it is critical for all slide gates to be complemented by a vented ball valve. VENTED BALL VALVES: HOW THEY WORK If plant air or electricity are lost, a pneumatically-actuated slide gate will be impacted in the following ways: • If electricity is lost, the slide gate’s solenoid will become inactive. Most Vortex slide gates are built with a single-coil solenoid so that if electricity is lost, the gate will fail into a closed position. However, because plant air remains live, once electricity is restored, the slide gate will immediately begin cycling again. • If plant air is lost, the slide gate’s air cylinder will be deprived of air pressure and thus, will not have access to the energy necessary to actuate. Once plant air supply is restored, air pressure will be immediately accessible to the air cylinder, which allows the slide gate to suddenly regain normal functionality. If maintenance technicians are working near the slide gate during either of these conditions, a once idle slide gate may immediately begin actuating and cause serious injury. For this reason, “vented ball” valves are essential to plant safety protocol. Ball valves are used to prohibit plant air supply from moving toward a slide gate’s pneumatic air cylinder – regardless of if plant air is active or disengaged. Typical ball valves are successful in blocking off the pressurized side of the air line, but are hazardous in that they do not “bleed” residual air from the process side of the air line. If sufficient air is stored on the process side of an air line during upset condition, a pneumatic air cylinder may be pressurized enough to still be capable of actuating the gate – even after a ball valve has been applied.
To prevent this additional hazard, Vortex sources vented ball valves. The primary difference between typical ball valves and vented ball valves is that vented ball valves are designed with a “vent” to exhaust any residual air from the process 14
Bulk Solids Today
side of the air line. This ensures that even if residual air does become trapped in the process side of the air line, it will be quickly exhausted so that air pressures are too weak for the slide gate to actuate out of command. Once plant air is restored, the closed vented ball valve blocks the pressurized side of the air line to forbid air supply from reaching the air cylinder until a maintenance technician physically re-opens the ball valve.
VENTED BALL VALVES: WHY THEY ARE IMPORTANT For safety reasons, many ball valves also feature a locking mechanism so that only authorized individuals are capable of operating the ball valve. Thus, vented ball valves are arguably the most important lockouttagout safety mechanism to consider when using slide gates in a manufacturing process. In fact, Vortex recommends vented ball valves so highly that for safety and legal purposes, a vented ball valve is always quoted alongside each Vortex product. WHY YOU SHOULD HAVE FAIL-SAFE AIR TANKS & VENTED BALL VALVES IN YOUR MANUFACTURING PROCESS Based on the topics discussed, if: 1. A fail-safe air tank is used to ensure a slide gate will fail into the full-close position. 2. A vented ball valve is applied to bleed residual air from the process line and to restrict air supply from continuing toward the gate once plant air is restored. Then, there is no risk for the slide gate to actuate during maintenance – which is a great asset for employee safety and management piece-of-mind. For many years, these simplistic devices have been utilized in manufacturing operations worldwide to avoid material waste and system damage, and to better control hazardous working conditions. By investing in safeguard technologies today, companies will benefit tenfold over expensive alternatives, such as lost production, equipment replacement or repair, or lawsuits for employee injury or loss of limb. For more information on fail-safe air tanks, vented ball valves, and other safety accessories, visit www.vortexglobal.com
FIBC’S
AUTOMATING RUBBER COMPOUNDING
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terling Systems & Controls, Inc. is pleased to announce it has developed and implemented the capability to automate the ingredient batching of the rubber compounding process. Using a hybrid ingredient bulk material batching system that combines minor bin and bulk bag ingredient batching, Sterling Systems has been automating rubber compounding and replaced the slower, labour intensive manual batching with an efficient, fast and accurate automated system. For the purposes of automating rubber compounding the minor ingredient batching system is customized and can be configured with virtually any number of bins and bulk bag stations. In one installation, the compounder used 10 Ingredients (7 bins and 3 bulk bags) that directly fed existing containers. These batches were weighed via a gain-in-weight system on the Roller Conveyor, also provided by Sterling Systems & Controls. Further customisation included a Dust Collection System for dust control during the automated ingredient batching. The overall system provided also included dust collection ducting, a pallet platform, a stairway to gain access to the work and pallet platform, and a rolling stairway to gain access to untie the bulk bag ingredients. The automation and control for the system includes a PLC control panel, a PC enclosure with an industrial grade PC, a panel mounted 17” flat screen monitor, a NEMA12 keyboard, and a smart uninterruptable power supply (UPS). The custom batching control software provided by Sterling Systems & Controls, Inc. is easy to use, has virtually unlimited storage of formulas and ingredients, and much more. Sterling Systems & Control also included its WebCentral supervisory control application. WebCentral is a browser-based application that allows you to access the database of a Sterling Systems batching control system application without the need for any software to be installed on the remote PC’s. It allows you to add and remove ingredients, create and manage recipes, manage ingredient and product inventories, setup a batching schedule, and print reports. By simply using a web browser WebCentral can be accessed by any PC that is networked with the Sterling batching control system. Sterling Systems & Controls, Inc. has 40+ years of experience providing efficient solutions for process equipment, batching, micro, minor and bulk weighing, bag unloading systems, as well as plant automation. Sterling’s designs utilise the latest technology to provide specialized data management, raw material management, along with production data tracking. Sterling’s systems can
optionally be interfaced by remote users using our unique WebCentral™ supervisory control application. For more information contact Sterling Systems & Controls at 1-815-625-0852, sci@sterlingcontrols.com, and at www.sterlingcontrols.com.
Bulk Solids Today
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FIBC’S
DRY FLUE GAS SCRUBBING - MADE EASY!
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he Bulk Powder Handing Industry is known to be problematic and therefore requires safe, reliable, durable equipment. At Trantec, our most recent challenge was to design, manufacture and supply a FIBC (Flexible Intermediate Bulk Container) or ‘Big Bag’ Discharger for a new client who use combustion as part of their industrial process. Industrial processing is an important part of economic development however, it can have a negative effect on the environment. Industrial combustion releases harmful gases, such as carbon dioxide and sulphur dioxide into the atmosphere, polluting soil, air and water. This process can cause health issues, climate change and much more. However, by implementing new systems into this process, emissions from industry can be significantly reduced, which is why our client came to Trantec. As part of their project, our client wanted to introduce Dry Flue Gas Scrubbing into their process, to reduce the carbon emissions. Dry Scrubbing is an extremely 16
Bulk Solids Today
effective way of neutralising acid gases from combustion sources by adding an alkaline material, such as lime or sodium bicarbonate into the gas flow. A safe, efficient way of introducing the alkaline material into this process is by using equipment such as a FIBC Discharger. THE CHALLENGE Our challenge was to design, manufacture and supply the FIBC Discharger with metering feeder seamlessly integrated into the process system. Modular in design, our FIBC Discharger would deliver high accuracy, environmentally friendly dosing of Sodium Bicarbonate, whilst maintaining complete safety. Trantec, based in Clayton-le-Moors in Lancashire, have over 20 years of experience supplying equipment for the Materials Handling Industry, producing custommade powder handling solutions to industries worldwide. Rapidly expanding over two decades, Trantec grew from a small, family-run business into one of the
FIBC’S UK’s leading manufacturers of metering, dosing, and filling equipment, supplying industries such as food, pharmaceutical, chemical, plastics and environmental. We were therefore well placed to assist our new client with their project. THE SPECIFICATIONS Modular in design, our FIBC discharger would ensure complete discharge of the FIBCs (Big Bags) under controlled, dust free conditions. Configurations are determined by product flow properties and application specifications, it was therefore important that we worked closely with our client during the design process to establish what the material and the machinery specifications were. The material (Sodium Bicarbonate) - an estimated bulk density of 600-800 kg/m3. The angle of repose was estimated at 45 degrees with an operational temperature of 25 degrees C. There was no moisture or fat/oil content and it was not hazardous or corrosive. The machinery requirements – an estimated throughput of 2 kgs/hr with accuracies of +/- 3%/ hr. The storage capacity of the metering feeder was estimated to be 10 litres with an IP rating of 55. The contact and non-contact materials were to be made from mild steel, painted with inside welds as laid. THE SOLUTION The FIBC Discharger would consist of – • Support Dish with Floor Mounted Frame • Lifting Frame designed, and proof load tested to 1000 Kgs SWL, complete with FLT channels, painted yellow. • Tensioning Support Side Frames with telescopic twin arms, spring loaded to urge the FIBC upwards, elongating it to aid product discharge. • Neck Access Door, hinged with door peripheral seal and closure catch. • Adaptor Chute and Feeder Extension Hopper. • Silicone Membrane seal mounted in upper section of support dish to provide extra sealing capability. The integrated Metering Feeder would consist of – • Product Containing Chamber, providing approximately 10 litres of storage capacity • Auger Screw 25mm in diameter (driven by AC direct drive motor and gearbox).
• Product Agitator (driven by AC direct drive motor and gearbox). • Removable Front Access Panel with feed tube approximately 100mm long from feeder to front panel. • Replaceable Double Set Nitrile Shaft Seals THE BENEFITS • Modular design can be seamlessly integrated into your existing system • Cost Effective Solution to your Material Handling requirements • Safe Handling of ‘Big Bags’ • Environmentally Friendly (Dust Free) • Easy and safe to use • Low Maintenance • Robust, Durable construction For materials that are difficult to discharge from the big bag, an optional Discharge Aid can be fitted, for example pneumatic Massage, comprising of 2 off Pneumatic Rams mounted on side frames astride the FIBC to push the sides and break up the material, including a simple “blind” pneumatic control system to accept input from main plant PLC. For applications requiring the delivery of materials for the food & pharmaceutical industries, an alternative construction of stainless steel 304 or 316 would be used for all contact parts, in compliance with all EC and FDA food contact regulations. For further information, please contact Gareth Harrison on +44 (0)1282 777566, or email sales@trantec.info. You can also visit our website at www.trantec.info. Bulk Solids Today
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BULK MATERIALS HANDLING
DOOSAN GETS HEAVY AT MULTIMODAL 2018
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oosan, the leading manufacturer of robust high performance forklift trucks, will be exhibiting alongside its wholly owned subsidiary, Rushlift GSE, the airport ground handling specialists, at Multimodal 2018 (hall 4, stand 7050), the UK’s premier freight transport, logistics and supply chain exhibition at the NEC, Birmingham, 1-3 May 2018. On the stand, Doosan will be showcasing its heavy lifting capability with its latest D160 diesel 16 tonne counterbalance model – part of its powerful diesel engine truck range – designed to deliver high-end torque at low RPM for reduced fuel consumption. Importantly, Doosan’s revolutionary G2 diesel engine is fully compliant with all current Euro Stage lll/lllB/lV emission regulations, without requiring a Diesel Particulate Filter (DPF). Doosan has an extensive range of over 200 models of counterbalance, reach and warehouse trucks, with capacities spanning 1.3 to 25 tonne, over power sources of electric, gas and diesel. Everything a freight logistics business needs in terms of handling performance to keep goods moving. Paul Watson, UK Commercial Director for Doosan, 18
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says: “The freight transport sector is a primary focus for both Doosan and Rushlift GSE. We have a strong, robust range of heavy lifting trucks capable of meeting the diverse needs of the logistics market – from container stuffing to loading/unloading of vehicles. Our industry leading Doosan G2 diesel engine delivers the power to get the job done and our electric heavylifting counterbalance trucks are just as able.” He adds: “Airside, Rushlift GSE is a leader in the field with its specialist knowledge of ground handling equipment and services – having just recently secured one of the aviation industry’s largest contracts to supply 449 ground support vehicles to a major carrier based at Gatwick.” Doosan Industrial Vehicles is one of the world’s leading manufacturers of forklift trucks. As an important part of the $21 billion global Doosan Group – a conglomerate with a 120-year history – the forklift truck division has the extensive resources needed to lead in product design, performance, ergonomics, energy and safety. Visitors to the show will have the chance to win an iPad mini. All it takes is a business card to enter the prize draw. www.doosanforklifts.co.uk
BULK MATERIALS HANDLING
NARROW AISLE LAUNCH AC LITHIUM-ION FLEXI MODEL
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arrow Aisle Ltd has announced that models across its top-selling Flexi range of articulated forklift truck-based intralogistics solutions are now available with the option of lithium-ion battery power. Thanks to developments in lithium-ion battery technology, Flexi AC Lithium trucks require zero battery maintenance. And, fast battery charging times ensure that truck uptime is optimised: the Flexi AC Lithium range features heavy-duty batteries that can be fully charged within one or two hours, even if the battery is fully discharged. In addition, the Flexi AC Lithium battery’s ability to distribute consistent power levels each hour means maximum warehouse throughput efficiency is achieved even during the longest and busiest shifts. “We are delighted to be able to offer the market the Flexi AC Lithium range. When it comes to running a modern warehouse, productivity is key which is why more lift truck users are appreciating the benefits of lithium-ion battery technology,” says Narrow Aisle’s commercial director, John Maguire. John Maguire believes that the growth in lithium ion-powered forklift trucks is coming at the expense of other established power sources – most notably LP Gas and Diesel engine powered units. “Sales of LP Gas-powered warehouse based trucks have been declining for a while for several reasons,” he says. He continues: “Compared to battery electric power, LP Gas is expensive and the time taken to change or refill each gas bottle means that truck downtime can be a problem at some sites, unless a bulk tank can be justified. “In addition, the control systems and catalytic converters required to reduce the risk of carbon monoxide poisoning from LPG emissions add significantly to a truck’s operating costs. “And, there are many differing emission control and operational noise level standards and rules across the world which make the manufacture and operation of engine powered trucks more and more difficult in many markets.” Narrow Aisle is offering a free consultancy service to users of all makes of LPG-powered articulated forklift trucks to allow the benefits of switching from LPG to lithium-ion battery power to be compared. The company has also launched a scrappage scheme that gives operators of LPG-powered articulated trucks the chance to make significant savings should they choose to upgrade their old LPG forklifts to new Flexi AC Lithium or electric models. “Our scrappage scheme means we’re offering companies the chance to take older less efficient forklift
trucks out of their fleets and replace them with the latest ultra-efficient Flexi AC Lithium technology in the most cost-effective way possible,” added John Maguire. For details of the new Flexi AC Lithium range or information regarding Narrow Aisle’s LPG truck scrappage scheme, visit www.flexi.co.uk
High Efficiency Drying or Cooling of Bulk Solids The Bella dryer/cooler offers thermal efficiencies to 80 percent or better because air flows around material while it is suspended in the weightless zone. The result is a more consistent material.
Dynamic Air Ltd. • +44 (0)1908 622344
www.dynamicair.com Bulk Solids Today
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HILLHEAD SHOW 2018 PREVIEW
THE EVOLUTION OF DIGITALISATION FROM SIEMENS
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iemens will be showing how digitalisation is evolving to provide better value to the customer, with solutions based around integrated, intelligent drive systems and the use of smart data on its stand (PA2/PB1) at Hillhead. DRIVE SYSTEMS GO DIGITAL: TURNING DATA INTO VALUE Digitalisation enables integrated drive systems (IDS) to take full advantage of all of their strengths. Instrumentation, motors and converters generate enormous volumes of data – from the field to the management level – which can be collected and evaluated. Analysing this data provides valuable insight to optimise production, assess the condition of machines and facilitate the ideal planning of maintenance work. The result is an increase in plant reliability and availability. IQ FOR OPTIMAL PERFORMANCE SIDRIVE IQ/SIMOTICS IQ are new introductions by Siemens that make drive systems ‘intelligent’, for maximum reliability and availability, better productivity, efficiency and performance, and far more effective maintenance. SIDRIVE IQ makes drive equipment intelligent by combining smart motors and software and turning the resulting data into real customer value. Having your motor call your mobile to report a fault or request maintenance is one thing that really smart data can do for you. Using Siemens’ SIMOTICS IQ, any abnormal behaviour in operations can be identified faster and failure statuses predicted instead of responded to. SIMOTICS IQ gives low-voltage motors a ‘voice’ to help boost the transparency of production processes and manage operations more effectively. OEMs and end users in the minerals, aggregates and mining industry are looking at highly automated modular equipment to enhance cost efficiency and improve operating flexibility. Digitalisation has a vital role to play, as it will drive the integration of systems, suppliers and partners along the value chain, unlocking new opportunities along the way through tools like digital twins to aid operational excellence and rapidly develop new business models. From exploration, engineering and simulation, right through to advanced process control, forecasting and quality management, this integration will enable faster reactions and improve flexibility, lowering CAPEX and OPEX costs. As artificial intelligence evolves, it will develop self-maintaining robots and systems. Overseeing 20
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it all will be cyber-security systems for risk-free data exchange and operations. MindSphere is the Siemens Cloud for Industry, and the hosting platform that lets you understand the data from machines; connecting physical machines and infrastructure to the digital world for improved productivity and efficiency. On the Siemens stand at Hillhead there will be the opportunity to experience the COMOS engineering platform, including simulation, SIMIT, Walkinside, plus documentation management, technical file creation and XHQ real time operation intelligence. CEMAT ALSO EVOLVES The CEMAT control system for automation was introduced by Siemens over 40 years ago and the latest version (9.0) can manage interconnectedness from components in a single cement plant, all the way through to connections between different plants. It can facilitate unmanned operations so orders become more accurate, stockpile utilisation is better and energy consumption lower. Knowing more about your assets, including power consumption, the location of mobile equipment, conveyor capacity in cost per tonne per hour, and the ongoing condition of each asset are all essential to improving the performance of a mine or quarry operation. Siemens experts will be available at Hillhead (stand PA2/PB1) to talk about SIDRIVE IQ and SIMOTICS IQ, as well as integrated, intelligent drive systems and how to create digital twins to test equipment (such as mill drives, winders and conveyors) and optimise performance before any actual resources are invested, saving time and reducing costs. www.siemens.com/IDS
HILLHEAD SHOW 2018 PREVIEW
FIRST UK SHOWING OF BOBCAT R-SERIES EXCAVATORS AT HILLHEAD Stand No: CE18
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he Bobcat stand at Hillhead 2018 will show models from the company‘s very latest compact loader, compact excavator, telehandler and attachment ranges, including the first appearance in the UK of the new Bobcat R-Series compact excavators from 2-4 tonne. Another product being shown for the first time at Hillhead is the new TL30.70 compact telehandler from Bobcat, providing a maximum lift capacity of 3 tonne and a maximum lift height of nearly 7m. Bobcat will also be continuing celebrations of the 60th Anniversary of the world famous Bobcat skid-steer loader at Hillhead. Over the last sixty years, Bobcat’s commitment to outstanding quality, workmanship and innovation has helped to maintain its market leadership, so that one in every two skidsteer loaders sold today is still a Bobcat machine. NEW R-SERIES COMPACT EXCAVATORS The new range of five R-Series compact excavator models – the E26, E27z, E27, E34 and E35z – offers a best-in-class mix of high digging forces, superb stability and smooth controllability of working functions complemented by low weights for easy transportation. Excellent machine fit and finish plus new ground-breaking design features will make the new Bobcat R-Series unique on the market. The new excavators introduce many state-ofthe-art features and offer enhanced levels of quality and robustness. They utilize newly developed flexible machine platforms that allow different configurations of models and specifications to suit a wide range of applications and customer needs. In addition, while taking engineering and productivity to unheralded heights, the development team for the new machines has ensured they offer greatly enhanced operator comfort and functionality and the best fit for key applications. While keeping proven, easy to maintain mechanical injection engines, all models meet the upcoming European Stage V engine emission regulations. NEW TL30.70 COMPACT 7 M TELEHANDLER The new TL30.70 compact 7 m telehandler from Bobcat is designed for a wide range of applications found in the construction and rental industries.
The TL30.70 provides an excellent compact and costeffective alternative to larger 7 m models, especially where working spaces are tight and increased manoeuvrability is required. In addition, performance is not compromised as the TL30.70 offers an outstanding maximum reach of 4 m with a load of more than 1 tonne. At the maximum lift height, users can lift up to 2 tonne of weight, which is sufficient to place a pallet of heavy bricks in most conditions. The compactness and stability of the TL30.70 will make this machine a perfect tool for easy pick and go or for lifting materials to height on housing and commercial property developments. The new TL30.70 is part of the Bobcat range of 12 user-friendly telehandler models, covering maximum lifting capacities between 2.6 and 4.1 tonne with lifting heights from 6 to 18 m. All the models in the range are covered by a three year/3000 hour warranty as standard. BOBCAT – A LEADER IN ATTACHMENTS Hillhead will also demonstrate why Bobcat is a leader in attachments with the widest portfolio on the market. Several attachments will be on display that form part of a large array available from Bobcat for use with the company’s compact loaders, compact excavators and telehandlers. Bobcat offers customers so many advantages in the attachment market, including the company‘s OneStop-Shop approach; the service support of the vast Bobcat dealer network and engineering approval, ensuring that all Bobcat attachments are optimized for efficiency, performance and greater productivity. For more information about Bobcat and Bobcat products, visit www.bobcat.com
Bulk Solids Today
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HILLHEAD SHOW 2018 PREVIEW
MECALAC TO EXHIBIT LATEST RANGE AT HILLHEAD 2018 Mecalac Construction Equipment UK Ltd, a global leader in compact equipment design and manufacture, will debut its latest range of excavators (now available for distribution in the UK) on stand A23 at this year’s Hillhead exhibition (26-28 June 2018).
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he portfolio which includes the recently-launched MWR, demonstrates the perfect combination of performance, flexibility and speed. The pioneering range is manufactured at Group Mecalac’s global headquarters in Annecy, France. Alongside revealing the UK range of Mecalac products now available, an exciting new site dumper development will also be presented. Developed at the company’s UK headquarters in Coventry, this new product aims to pave the way in safety-critical rental equipment. Paul Macpherson, UK Sales and Marketing Director at Mecalac Construction Equipment UK Ltd, said: “Although we’re keeping specifications close to our chest, the new Mecalac site dumper is set to be the
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most exciting addition to our range yet.” Completing the Hillhead line-up, the Mecalac team will be on hand to discuss three new safety technology packages, designed to aid operators. Macpherson added: “As one of the UK’s most renowned construction exhibitions, we’re looking forward to showcasing our latest products, updates and equipment technologies with thousands of engaged visitors at Hillhead 2018. Being part of the show provides the perfect platform to speak with existing and potential customers about our exciting plans for the future.” For more information on Mecalac’s latest range of compact construction machinery, visit www.mecalac.com or call 02476 339400. For more information about Hillhead 2018, visit www.hillhead.com.
HILLHEAD SHOW 2018 PREVIEW
TEREX TRUCKS TO SHOWCASE LATEST INNOVATIONS AND COMPANY HERITAGE AT HILLHEAD Terex Trucks will exhibit the old and the new at Hillhead 2018 with its Gen10 TA300 and its R17 hauler – which dates back more than 40 years.
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erex Trucks is set to return to Hillhead once again – this time, to showcase the latest TA300 alongside the vintage R17 hauler. “We are excited to be at Hillhead this year, it’ll be a good opportunity to show customers what the Terex Trucks brand is all about,” says Paul Douglas, Managing Director of Terex Trucks. “Having the R17 on our stand gives visitors a rare opportunity to take a glimpse into the history of hauling. Terex Trucks’ heritage can be traced back to 1934 when the world’s first off-road dump truck was created. It’s not often that you get to see a 40-year-old truck that’s still in working condition; we hope this highlights the level of quality we build into our machines. Of course, our current machine, the TA300 articulated hauler, will take pride of place too and shows that we remain committed to creating quality trucks that are built to last.” A STRONG PARTNERSHIP Occupying stand N14, Terex Trucks will be joined by its official UK dealer, TDL Equipment, which will be located on stand A7. “Since the very beginning, TDL’s ethos has been to provide local support on a national basis – and that’s something we still strive towards today,” says John Black, Sales Director at TDL Equipment. “This, together with our partnership with Terex Trucks, means that we are able to offer haulers to our customers that help them to provide an enhanced level of service to their own customers.” With 476 exhibitors and 18,601 visitors from 71 countries, the 2016 Hillhead show was quite literally record-breaking – and the 2018 show is set to be even bigger. It will take place from June 26th - 28th at Tarmac’s Hillhead Quarry near Buxton, Derbyshire. THE OLD AND THE NEW Based in Scotland, Terex Trucks has been building robust haulers at its Motherwell site since 1950. Taking pride of place on the Terex Trucks stand will be the new TA300 articulated
hauler and the R17, which dates back to the early 1970s. Achieving a payload of 28 tonnes (30.9 tons) and powered by a fivecylinder Scania DC9 EU Stage IV compliant engine, the TA300 hauler is designed to withstand the toughest conditions at quarries, infrastructure developments and commercial projects. With a maximum torque of 1,880 Nm, the machine has great traction and an effective power-to-weight ratio to ensure material is moved quickly and cost-effectively across all kinds of terrain and in any type of weather. Additionally, the machine features an ergonomically designed cab, complete with plenty of space and a commanding view for maximum operator comfort. More than 40 years old, the R17 13.5 tonnes (14.9 tons) hauler represents the history of Terex Trucks. Originally, the engine was manufactured in Cumbernauld and the machine itself was built in Motherwell. A team of apprentices have been working hard at the Motherwell factory to restore the machine back to its original glory. With the work now complete on the truck, visitors at Hillhead will be able to appreciate the historic craftsmanship of the R17 for themselves, from the simple yet effective operating system to original features such as the driver’s seat and engine. www.terextrucks.com Bulk Solids Today
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HILLHEAD SHOW 2018 PREVIEW
NEW DOOSAN PRODUCTS IN ANNIVERSARY YEAR AT HILLHEAD 2018
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oosan Infracore Construction Equipment will be showing the company’s latest generation of excavators, wheel loaders and articulated dump trucks (ADTs) for the quarrying, mining and construction markets on the company’s stand number Z4 and in the demonstration areas at the Hillhead 2018 Exhibition at Hillhead Quarry in Buxton, Derbyshire in the UK from 26-28 June 2018. Hillhead is the platform for the UK launch of several new products being shown at the exhibition for the first time, including a new version of the company’s successful DA30 30 tonne ADT and new features in the large Doosan wheel loaders. Hillhead will also celebrate Doosan’s achievements since 1978, when the first machines in the company’s construction equipment range were introduced, growing successfully over the next 40 years to position itself today as a top global player and to produce more than 400,000 units for markets worldwide in the same period. To mark this, the Doosan machines 24
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at Hillhead will bear Anniversary stickers that the company is putting on all machines for sale in 2018. The changes in the new DA30 ADT model are signified by a new colour scheme for the machine that also aligns it with other products in the Doosan Heavy range. Most of the changes are aimed at enhancing operator comfort and the controllability of the machine, but there are also changes in the driveline and electrical systems.
HILLHEAD SHOW 2018 PREVIEW NEW HYDRO-GAS SELFLEVELLING SUSPENSION The most important development is in the suspension of the DA30 which is being upgraded to a hydro-gas self-levelling system to provide outstanding performance and superior shock absorption for better driving comfort, especially when the truck is being driven when it is empty. To complement this, the operator will now benefit from a Grammer Actimo XXL seat in the cab as standard with its own independent low-frequency pneumatic and wide scissors-type suspension. The Grammer seat is not the only change in the new state-of-art operator’s cab on the DA30 which has been redesigned to provide better ergonomics and more operator comfort. The dashboard has a completely new layout and soft-touch material composition that is easier to clean and features a new display as well as a high quality finish and appearance. The cab also offers new safety and performance functions with a more comfortable control panel with a power cut off switch and an LED indication lamp which indicates when it is safe to switch off the power cut off. Other features include a new easy-to-use lever for retarder steering, a new more precise brake system for increased sensitivity and performance, an extra hand grip on the right hand side, a USB charger and a 12V/24V power socket, together with more convenient compartment storage and electrically adjustable mirrors as standard. On the outside of the cab, a new all-round hand grip rail has been installed for improved safety for moving round the outside of machine for cleaning and other tasks. Doosan has also introduced a new position and solution for the power cut off switch. According to Doosan, in the new version of the DA30, there will be lower running costs involved as there are a reduced number of service points with fewer different oil types in the driveline and increased intervals for transmission oil change. In addition, the new cab tilting system enables the service technician to lift and close the cab in just a few minutes. With these new features incorporated, the DA30 establishes a unique benchmark in load carrying performance, fuel efficiency, enhanced controllability and high operator comfort, together with improved reliability, durability and reduced maintenance and servicing costs. NEW FEATURES ON LARGE DOOSAN WHEEL LOADERS Doosan has announced a wide range of new safety and ergonomic features on all six large Doosan wheel loaders including the DL300-5, DL350-5, DL4205, DL450-5, DL550-5 and DL580-5 models. A number of the new features are aimed at increased safety and visibility in and around the operator’s cab.
For example, a new handrail has been installed around the cab roof with three holding points, allowing operators to move very safely all around the cab to clean windows and to perform other tasks. Inside the cab, there is a new ergonomic joystick control with a progressive thumb wheel added for the auxiliary hydraulic line (3rd valve). The progressive thumb wheel ensures that no additional lever is needed, providing the easiest combination of movements to manage the 3rd valve operations. FNR control has been relocated on the back of the joystick, via a three-position rocker switch, which is much more convenient and intuitive to use. To make life more comfortable and easier for operators, Doosan has added a rolling sunshield on the rear window to avoid any disturbance from sunlight during operations. The cup holder has also been relocated to the front right of the cab and a new double hanger hook allows both a helmet and a jacket to be hung inside the cab. The operator has the benefit of additional convex mirrors installed on the lateral mirror frames. The wider angle and additional visibility provided by the convex mirrors along the side of the machine ensure safer manoeuvring of the wheel loader on site and in the quarry. Along with the new features in the large wheel loaders, Doosan has implemented a restyling for all the models in the company’s wheel loader range. The new styling scheme involves a change of colour (from orange to dark grey) for the front lift arm, front frame and front and rear axle components on the machines. The more dynamic curved lines of the new styling are designed to reinforce the robustness and power of the Doosan wheel loader range. www.doosanequipment.eu Bulk Solids Today
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QUARRYING
MOBILE BULK SCREENER FOR MARBLE POWDER Francis Flower check-screen pulverized marble during loading of delivery tankers from bulk loading silos
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ormed in 1953, Francis Flower is a family business which has grown over 60 years to become a specialist in minerals management, storage and processing. Originally a quarrying and lime-burning business, Francis Flower now provides a range of high-quality recycled powdered minerals, limestone powders, super-fine white marble powders and other products for the agricultural and construction industries, as well as paints, plastics, food and pharmaceutical manufacturers. A key feature of Francis Flower’s business ethos is sustainability. The company recovers, reclaims and recycles mineral by-products from other industrial processes. This reduces the need for mineral extraction and landfill, helping to deliver sustainable environmental solutions for the future. For example, the super-white marble powder used in Francis Flower’s Fordacal range of fillers and extenders is made with 100% recycled marble. Using marble offcuts from Northern Italy, these exceptionally white, pure calcium carbonate fillers and extenders are used in a range of applications, where the purest white colour is of paramount importance. However, the recycled marble must be processed to achieve this quality, and a key factor in guaranteeing a consistent particle size is sieving powdered minerals to remove oversize contamination and ensure accurate sizing. Francis Flower utilizes Russell Finex separation equipment for this part of its process. The marble by-product is imported from Italy via Avonmouth Docks, near Bristol, UK. It is then transported to Francis Flower’s Gurney Slade site, Somerset, U.K, where the marble is pulverized and processed before being shipped for use in a range of applications. Having already applied a Russell Compact Sieve® to check-screen powders during big-bag filling in another production line, Francis Flower decided a further mineral powder sieving system would be needed to qualitycheck the marble powders during tanker loading. Lee Dursley, Plant Manager at Francis Flower said, “Following the successful application of Russell Finex equipment in our bag-filling line, we decided to employ a
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Russell sieving machine to screen selected silos of powder during tanker loading. It was important to find a solution that would be compact and mobile due to the nature of lifting into position above the tanker. The sieve also needed to meet the high capacity demands of tanker loading.” Francis Flower required a sieve capable of meeting the desired 30-minute loading time for a 28-tonne
QUARRYING tanker. With its considerable screening capacity, the company was confident that the Russell Compact Sieve® was the smart choice for this application. The 1200mm-diameter Russell Compact Sieve® is applied between the loading silos and delivery tankers to screen the marble powder before it is shipped. However, to allow for easier connection and loading to each tanker, the sieve unit is transported and elevated into position above the tanker using a telescopic handler. The Russell Compact Sieve® range is used in various industries to remove oversized contamination from bulk powders and granulates. These vibratory screeners are ideal for high-capacity screening where space is limited, or in instances where a mobile solution is necessary. The units fit neatly into production and filling lines to check-screen incoming or outgoing materials. An innovative design means these screeners are less than half the height of a traditional sieving machine, and a wide range of sizes and customizations are available to meet specific requirements. Mr Dursley concluded, “The Russell sieve proved the ideal solution for our requirements. The unit is quick and easy to setup and transport into position when needed. It more than meets our required throughput, and the sieving accuracy allows us to ensure a consistent quality of powder for our customers.” www.russellfinex.com
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Bulk Solids Today
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CONVEYING
DYNAMIC AIR OFFERS 16 DIFFERENT PNEUMATIC CONVEYING CONCEPTS • Four different vacuum conveying systems • Twelve different pressure conveying systems.
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ach system has its own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Because each and every material to be conveyed reacts differently under a given set of operating conditions, it is extremely critical to match the system operating characteristics to the material to be conveyed in order to achieve the most desired conveying performance and to provide the best value to you, the customer. Dynamic Air’s 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. Dynamic Air can convey many materials with conveying velocities as low as 50 feet per minute (0.25 m/sec) using the HDP 6000 dense phase pneumatic conveying system and, using the LDP 2000 dilute phase pneumatic conveying system, Dynamic Air can convey at velocities well over 7000 feet per minute (35 m/ sec). Plus Dynamic Air’s conveying capacities range from just a few hundred pounds (100 kg) of material per hour up to 400 tons per hour and conveying distances exceeding 5000 feet (1500 m) in length. In addition, Dynamic Air’s pneumatic conveying systems become highly efficient when they employ the unique patented DC-5™ Air Saver technology and are unmatched for performance and reliability. These systems can handle even the most difficult of materials, plus they significantly reduce the energy requirements and convey material at much lower conveying line velocity with higher conveying line densities and reduced dynamic loading. When Dynamic Air’s DC-5 Air Saver technology is employed on lower pressure systems using less than 15 PSIG (1 barg), in many applications the conveying line velocity can be lowered well below the normal saltation velocity. Depending on the material being conveyed, energy requirements can be reduced and system performance and reliability drastically improved. THE RESULT: Gentle handling of heavy abrasive and nonabrasive materials that cannot tolerate degradation. 28
Bulk Solids Today
For many fragile crystalline and granular materials there is no finer material handling process. Dynamic Air’s 16 different pneumatic conveying concepts can offer a more gentle treatment of system components as well. Because of lower velocities, system wear and related breakdowns are minimized. Dynamic Air Pneumatic Conveying Systems Are: • Energy and labour efficient • More reliable, because of our DC-5 Air Saver technology • Flexible to design in tight plant environments • Easy to install with minimum disruption to existing plant production • Clean - because the system totally contains the material conveyed • Friendly to the environment • Equipped with fewer moving parts • Lower in initial investment costs • Lower in maintenance http://www.dynamicair.com/systems.html www.dynamicair.com
CONVEYING
FOR SMALL HEADROOM: PNEUMATIC DENSE PHASE CONVEYING SYSTEM GERICKE PTA/PHF 20 The advantages of pneumatic dense phase conveying systems are well known. Minimum air consumption, high product loading and throughput, little wear on the piping and preserving the product quality. Pressure vessels require in general a certain height to be installed, which is not always available. As an alternative, rotary valves are used, with all negative side effects as air leckage, wear and product attrition. Gericke has developed a small conveying pressure vessel, which, with its 20 liter volume, requires only the headroom of 660 mm!
T
he smallest sender Gericke PTA/PHF 20 performs although with a throughput of 1.5 m3/h and up to 50 meters. It is equipped with a level probe and the additional air volume control makes the conveying even more efficient. The dense phase conveying can be carried out either as product-gentle plug conveying or thrust conveying. The Gericke STP 61 machine controller ensures trouble-free and fast commissioning and maximum conveying efficiency. Furthermore, communication with higher-level control systems is possible via interfaces such as Ethernet / IP, Profibus DP, Profinet RT and Modbus/TCP. Due to the very compact design with a required height of only 660 mm, the PTA/PHF 20 conveyor sender is particularly suitable for installation under sack tipping and big bag stations, dust filters or storage containers. The sender requires very low maintenance as it has no rotating parts. Thus, it is also suitable as a replacement of more maintenance intensive rotary valves, which are used for lean phase conveying systems. Depending on the product characteristics, throughput rates of up to 1.5 m3/h and distances of up to 50 m can be achieved. As a continuous double-conveyor system even throughputs of up to 8 m3/h are possible. Depending on the requirements,
different versions of the conveyor system are available, such as food grade, high-temperature or wearresistant versions and for explosive products. The compact conveyor transmitter PTA / PHF 20 is suitable from fine powders up to granules of 15 mm. Even very light products with bulk densities of 0.1 kg/l up to very heavy steel balls of 5 kg/l have already been conveyed successfully. Examples of conveyed products include sand, milk powder, nuts, salts, metal powders, additives, filter dusts and blasting agents. www.gericke.net Bulk Solids Today
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BUYERS GUIDE Aero Mechanical Conveyors
Conveyors & Elevators
Mixers & Blenders
“Often copied NEVER matched�
Suppliers of the Original EnteconŽ Aero Mechanical Conveyors Other Products: • Sack Openers • FIBC Fill / Discharge Tip or Automatic • Pneumatic Conveyors
Sales office for UK & ROI: SGH Equipment - EnteconÂŽ Agent
Tel / Fax: 01270 651611
E: sales@sghequipment.co.uk • www.sghequipment.co.uk
Bulk Storage & Handling
MANUFACTURERS OF SILOS, TANKS AND CONVEYING SYSTEMS Redbrook, Barnsley S75 1HR Tel: 01226 730037 Fax: 01226 730066 Email: info@eb-equipment.com Web: www.eb-equipment.com
Bulk handling with complete confidence Designers and UK manufacturers of: • Bucket elevators • Chain & flight conveyors • Screw conveyors & bin dischargers • Belt conveyors
Dynamic Air Ltd. Milton Keynes, England
+44 (0) 1908 622344 www.dynamicair.com
www.perryengineering.com Tel: 01404 891400 Fax: 01404 891402
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www.kasoneurope.co.uk
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Screw Feeders, Mixers & IBC Systems
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Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706
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www.ajax.co.uk email: solids@ajax.co.uk
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Posi-flate Milton Keynes England +44 (0) 1908 622366
www.posiflate.com
Intermodal dry bulk logistics for polymers, chemicals & minerals Cost effective Environmental savings Reduced C02 emissions
www.InterBulkGroup.com
InterBulk GROUP
Bulk Solids Today
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BULKEX 2
0
1
8
Shaping the future Exhibition • Technical Conference • Awards Dinner Nottingham 17-18 October
High profile speaker programme
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To exhibit or sponsor 01787 226995 bulkex.co.uk
Delegates register free at
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