Bulk Handling Review Mar 2019

www.bulkhandlingreview.com

VOLUME 24, ISSUE 2 | MARCH/APRIL 2019

In this issue: Grain handling feature Dust control safety Designing better chutes

BUILDING THE WORLD’S FOOD INFRASTRUCTURE

IN CONJUNCTION WITH

Australasia’s largest dedicated bulk handling conference & exhibition MELBOURNE

1-3 APRIL 2020

Media partners AUSTRALIA

Association Partner

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REVIEW

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bulkhandlingexpo.com.au

AUSTRALIA

CONTENTS MARCH/APRIL 2019

AUSTRALIA

REVIEW

Published by:

REVIEW

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11-15 Buckhurst St South Melbourne VIC 3205 T: 03 9690 8766 www.primecreativemedia.com.au Publisher Christine Clancy E: christine.clancy@primecreative.com.au Assistant Editor William Arnott E: william.arnott@primecreative.com.au Subeditor Amy Morison E: amy.morison@primecreative.com.au Business Development Manager Luke Ronca E: luke.ronca@primecreative.com.au Client Success Manager Janine Clements E: janine.clements@primecreative.com.au Design Production Manager Michelle Weston E: michelle.weston@primecreative.com.au

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30

46

8 M etso sells off grinding media business

26 Fenner Dunlop builds local brand through acquisition

56 Hydraulic solutions for harsh situations

10 QLD Government streamlines approvals for $1.4B Sconi project

28 M ethodology for increasing the throughput of existing belt conveyors

58 Roy Hill extends conveyor belt life

13 China’s biggest bulk expo to showcase major brands

30 Keeping conveyor belts on track

15 Women in Industry award nominations open

34 The advantages of flexibility in the bagging of bulk products

18 Tip Top Training Academy graduates join the workforce

36 Why ESS’s new Air Cannon systems are a real blast

22 Stacked up: How Nepean is building a conveyor revolution

54 Flat out like a lizard: thyssenkrupp’s new mobile stacking bridge

60 S WR’s measurement management 61 Bulknet boosts productivity by breaking bulk blockages 62 B ULKTalk: Best practice in chute design - Part two 66 A SBSH Member Profile: Timothy Donohue

GRAIN HANDLING 38 From Port to Pub: Upgrading Geelong’s malt exports

42 Finding needles in a haystack: Selecting the right electromagnet

41 VEGA’s radar sensor solution for bulk solids

DUST CONTROL

Art Director Blake Storey

44 Eye of the storm: Vortex Global’s new ship loading spout

50 Transfer point optimisation key to productivity improvements

Design Kerry Pert, Madeline McCarty

46 Ask an Engineer with Jenike & Johanson: Should I be concerned about the explosive potential of my process dusts?

53 Keeping dust down in concrete batch plants

Subscriptions T:03 9690 8766 E: subscriptions@primecreative.com.au

COVER STORY Growth by the numbers: AGI’s strategy for success

www.bulkhandlingreview.com www.bulkhandlingreview.com

VOLUME 24, ISSUE 2 | MARCH/APPRIL 2019

The Publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from the advertisers and contributors against damages or liabilities that may arise from material published. © Copyright – No part of this publication may be reproduced, stored in a retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.

In this issue: Grain handling feature Dust control safety Designing better chutes

4 І Australian Bulk Handling Review: March/April 2019

BUILDING THE WORLD’S FOOD INFRASTRUCTURE

Australian Bulk Handling Review: March/April 2019 І 3

Agricultural infrastructure company Ag Growth International (AGI) provides the equipment and technology required to facilitate the global movements of material needed to grow, harvest, process and transport crops. Its platforms of grain, fertiliser, food, feed and seed are available across six continents, brought together by seven components: storage, handling, structural processing and controls, engineering and project management.

AGI speaks to ABHR about the business strategy it uses to continue growing within the industry.

For the full story, see page 16.

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EDITORIAL

KEEP YOUR DUST DOWN Dust emissions constitute a significant operating,environmental and occupational health hazard that is unacceptable to the modern Bulk Materials Handling Industry.

The ESS Dust Suppression systems generate a spray of fine water droplets to encapsulate dust particles to prevent the material from becoming airborne outside chute areas.

The ESS Dust Suppression system is suitable for use with most dust producing materials where the process will allow for small amounts of added moisture.

The ESS Dust Suppression system is: - Simple, Safe and Easy to Maintain as all maintenance is performed from the outside of the chute.

- Low Maintenance when the Quickfit Nozzle is combined with an appropriate filter, decreasing blockages and maintenance.

- A Low Water Consumption Unit as it uses 2 litres of water a minute over a range of pressures. Making it suitable for drier environments.

- Supplied in Kit Form, comprising 2, 4 or 6 Quickfit nozzles, a manifold, push fit hoses and fitting.

Proudly Manufactured in Australia

Growing industries Agriculture is a vital part of Australia’s economy, making up three per cent of our Gross Domestic Product, according to estimates by the National Farmers Federation. The food we grow helps sustain our growing population, and what we don’t eat we export to regions such as Asia and Europe.

Today’s farmers paint a very different picture than those of the past, embracing some of the planet’s most advanced technology. Our farmers are adapting to a more digital world, using the power of data and connectivity to improve our productivity levels.

One company that is leading the way in this space is Ag Growth International (AGI), which has been involved in Australia for more than 36 years. With a changing climate and extreme weather events putting more pressure on farmers, AGI’s focus on providing the infrastructure needed to feed the world is more important than ever.

You can read more about how the business is growing in Australia on page 16.

This issue of ABHR also explores how the industry is handling dust control. According to the World Health Organization, airborne dusts are a concern in the workplace as they are often associated with a range of respiratory illnesses. Whenever someone inhales dust, they are at risk of occupational disease.

Dusts can also potentially be explosive, presenting further risks to people and equipment. Grant Wellwood from Jenike & Johanson explains the different safety risks and explosive potential of dust, and what can be done to minimise it on page 46.

There’s also a follow up piece to January/February’s BULK Talk, where Rio Tinto’s Steve Davis explains some of the best practice in chute design on page 62.

In the next edition we’ll be featuring stories on motors, gears and drives, along with silos and storage. Please get in touch if you would like to be involved.

Christine Clancy Publisher - ABHR

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NEWS

Metso sells off grinding media business Metso has sold its grinding business to Moly-Cop, a portfolio company of American Industrial Partners FINNISH MINING AND RESOURCES COMPANY Metso has completed the sale of its grinding media business, which includes Metso Spain Holding, S.L.U, and operations in Bilbao, Seville and Spain, to American business Moly-Cop. The turnover of the divested business in 2018 was approximately 60 million euros ($AU95 million).

Around 80 employees have been transferred from Metso to Moly-Cop. Metso Minerals and Consumables President Sami Takaluoma said Metso’s growth strategy in the consumables business is to focus on developing a global offering.

8 І Australian Bulk Handling Review: March/April 2019

“We are confident that our customers and our grinding media team will benefit from this transaction and from the combination of our strong regional know-how with Moly-Cop’s global capabilities,” Mr Takaluoma said.

Moly-Cop is a major manufacturer of grinding media used primarily by copper, gold and iron ore producers to break down ore in the primary phase of mineral concentration.

Moly-Cop CEO Jim Anderson said the acquisition is a great match for Moly-Cop and its strategy moving forward.

“Metso’s operations and team align perfectly with our global manufacturing network, and this transaction will further enhance our industry-leading value proposition to our customers,” Mr Anderson said.

BELOW: Around 80 employees have been transferred from Metso to MolyCop

NEWS

QLD Government streamlines approvals for $1.4B Sconi project Two million tonnes of ore per year is expected to be processed at the Queensland Sconi Project, which has been declared a prescribed project.

LOCATED IN GREENVALE IN NORTHERN Queensland, the Sconi project aims to produce nickel, cobalt, and scandium for use in battery manufacturing, electric vehicles and other high technology applications.

It estimates average annual production of 8,500 tonnes of cobalt, 53,500 tonnes of nickel sulphate and 77 tonnes of scandium oxide for at least 18 years.

Declaring a prescribed project helps to streamline

approvals and enables the Coordinator-General to intervene in the approvals process to ensure timely decisions are made for the project.

The proponent, Australian Mines Limited (AUZ), has also set a mandate to invest $500,000 each year into the region for training and skills development for process workers, with youth and indigenous programs to feature.

Queensland Premier Annastacia Palaszczuk said the project would create up to 500 jobs during its two-year construction period, with more than 300 full-time equivalent jobs for the 18-year operational period.

Minister for Infrastructure and Planning Cameron Dick said GRAIN Australian Mines Limited will provide upgrades to the local Greenvale infrastructure.

“There’s over $1 billion of capital expenditure proposed, and Queensland companies will be prioritised for this work, which AUZ should be commended for,” he said.

“This prescribed project status will help streamline approvals and fast-track delivery for AUZ.”

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BELOW: The Sconi project aims to produce nickel, cobalt, and scandium for use in battery manufacturing and electric vehicles.

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Boom belt now lasts six times longer Roy Hill is a margin focused iron ore business, aiming to

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EVENTS

China’s biggest bulk expo to showcase major brands The largest international bulk material conveying and handling exhibition in China is set to take place on May 29-31, 2019.

DEMAND FOR HIGH-END BULK material conveying and handling equipment is set to increase in China as its manufacturing sector maintains its current position.

This is one of the key reasons why the fifth China International Bulk Material Conveying and Handling Expo (CBME) plans to bring some of the top companies from more than 30 different countries under the one roof.

The event is dedicated to showcasing the latest industry trends and technological developments, with more than 8000 decision makers and buyers attending from the coal, mining, logistics, cement and steel industries.

CBME is the largest event of its kind in China, attracting more than 20,000 visitors from countries including Germany, USA, Australia, Canada, France, Italy, Russia, Brazil, Chile, Sweden and Finland.

Representatives from more than 500 mining companies, 300 coal companies, 200 cement companies and 30 bulk ports will also be attending.

Among them are world-class exhibitors, which will be featuring their conveying equipment, stacking, reclaiming and handling equipment, power and drive devices, and conveyor support equipment.

Exhibitors at the event will include leading suppliers of technology and equipment, with representatives from BEUMER, ZPMC, Voith, Cargotec, Rema Tip Top, Flexco and more attending.

“This year is the first time for Liebherr to exhibit at such a large-scale bulk handling exhibition like CBME. This year, we will grandly launch series of transporters, loaders, scrap handlers, port cranes, and mining dumpers, for professional visitors at CBME,” Liebherr Group CEO, Andreas Boehm said.

“This is a great success for us. We will keep striving and growing in the bulk material conveying and handling field.”

TAKRAF Tenova Mining Technology Director Rene Wharf said the event provides a great platform to display new technologies and create a significant amount of business opportunities.

“TAKRAF’s brand and products have benefited

greatly from the publicity we achieved at CBME. We also met several important customers on the show floor, helping us build connections with our clients.”

Huadian Heavy Industries, a designer and manufacturer of engineering technical products related to bulk material conveying, will be attending the event after experiencing positive benefits from exhibiting in previous years.

“This event gathers together most of the leading and key business decision makers in the industry,” Huadian Heavy Industries Vice President, Department of Electrical Engineering, Gu Sheng said.

CBME will take place during May 29-31 2019 at the New China International Exhibition Centre in Beijing, jointly organised by the Metallurgical Mines’ Association of China, The Non Ferrous Metals Society of China, China Association of Plant Engineering, and the Beijing Hiven Exhibition Company.

ABOVE: CBME aims to connect key decision makers across the bulk conveying and handling industry.

For more information, please visit en.bjcbme.com or contact donna@hwexpo.com

Australian Bulk Handling Review: March/April 2019 І 13

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EVENTS

Leadership nominations open Nominations for the widely anticipated Women in Industry Awards are now open for 2019.

AS A MEDIA PARTNER TO WOMEN IN Industry, Australian Bulk Handling Review is encouraging leaders in the sector achieving excellence in the waste and resource recovery to put their name forward as a nominee.

The Women in Industry Awards recognise outstanding women from across the mining, engineering, manufacturing, road transport, logistics, infrastructure, rail, bulk handling and waste industries.

The awards aim to raise the profile of women within industry, as well as promote and encourage excellence.

Juliet Maynard, winner of the 2018 Safety Advocacy Award, said that the Women in Industry Awards provide great “recognition of the impact women are having not just in our business but also in our industry”.

Julie Russell, of Russell Transport, said that the Women in Industry Awards provide a forum or a voice for women to share, challenge and measure themselves.

“Having a community that understands you, where you have come from and the challenges you have faced – because they have also experienced similar – helps give you strength and the drive to continue on your own journey,” she said.

Reflecting on taking home the Social Leader of the Year Award in 2018, April Whittam, of Aurizon, said she was taken aback when her name was announced.

“My fellow Women in Leadership nominees in the category are outstanding in their fields and their

RIGHT: Nominations for the Women in Industry Awards are open until 29 March, 2019.

contributions to their communities exceptional. Upon reflection, winning the award has been two-fold.

Firstly, it has meant that the work that I contribute on a daily basis is having a positive change in our communities and the strategy and programs are well regarded and effective.

“Secondly, I was honoured winning the award celebrating Women in Leadership. The mining, transport, logistics sector is predominantly male so to stand out in a field that I am passionate about has been both very humbling and rewarding,” she said.

Gita Pendharkar, of Melbourne’s RMIT University, Winner of Mentor of the Year in 2018, said that the award was a special achievement for her as it was highly competitive.

“It is an excellent recognition of my 26 years of hard work of teaching, mentoring and academic services to the community,” Ms Pendharkar said.

“Recognising capable and successful women in various industries (especially traditionally maledominated ones) is an excellent step towards promoting gender diversity in Australia and these awards are a great platform to achieve this. I would like to give thanks to the organisers, sponsors and everyone involved in making the Women in Industry Awards a success.”

Women in Industry will take place on Thursday, 6 June 2019 at The Park, Albert Park, Melbourne.

Nominations will remain open until 29 March 2019.

Nominations are open in the following categories: • Social Leader of the Year • Rising Star of the Year • Business Development Manager of the Year • Industry Advocacy Award • Safety Advocacy Award • Mentor of the Year • Excellence in Manufacturing • Excellence in Mining • Excellence in Engineering • Excellence in Road Transport.

It is free to submit a nomination, and an individual can be nominated in up to three separate categories.

For more information, head to: bit.ly/2UV5ZYA

Australian Bulk Handling Review: March/April 2019 І 15

COVER STORY

Growth by the numbers: AGI’s strategy for success Agricultural infrastructure company Ag Growth International speaks to William Arnott about the three critical numbers that make up its 5-6-7 strategy.

AUSTRALIA’S AGRICULTURAL INDUSTRY produces an abundance of food, with a significant amount exported to other nations.

This is according to the Prime Minister’s Science, Engineering and Innovation Council (PMSEIC) 2010 report Australia and Food Security in a Changing World. It found that although Australia accounts for less than three per cent of the global food trade, it produces enough to feed a population of 60 million.

However, as the projected global population is set to reach 9.2 billion by 2050, the report says existing and emerging food production constraints and the anticipated impact of climate change could lead to conditions deteriorating.

Professor Peter Langridge, PMSEIC Chair says in the report that global food security will demand the development and delivery of new technologies to increase food production on limited arable land.

The infrastructure required to feed the world’s people consists of a global network of facilities

16 І Australian Bulk Handling Review: March/April 2019

that store, blend, mix, convey, condition, process and protect the hundreds of millions of tonnes of agriculture inputs and crops flow around the world on a daily basis.

Ag Growth International (AGI) is one company helping to further refine the definition of global food infrastructure, providing the equipment and technology required to facilitate the global movements of material needed to grow, harvest, process and transport crops.

Paul Brisebois, Vice President – Farm at AGI, says the company provides the infrastructure to feed a growing global population, and to do so it relies upon its 5-6-7 strategy.

“Our core vision is to continue to be a global leader in the planning, engineering and manufacturing of full solutions and systems across five platforms: grain, fertiliser, food, feed and seed,” Mr Brisebois says.

“We aim to grow in each of these vertical platforms within food infrastructure.

“We then take these systems and solutions

BELOW: AGI has been involved in the Australian market for more than 36 years.

across the globe, to the six continents we operate on: Australia, North America, Africa, South America, Europe and Asia,” he adds.

Each of these systems is then brought together and delivered for farm and commercial applications through seven components: storage, handling, structural, processing and controls, engineering and project management.

The 5-6-7 strategy was developed by AGI CEO Tim Close to provide a structure for the growth of the business. It has been particularly critical for the company’s acquisition plans, helping to identify potential businesses which align well with AGI. Mr Brisebois says that from a growth perspective, the 5-6-7 strategy has helped improve clarity internally for employees and externally for customers and key stakeholders.

“As we continue to grow, either through research and development or through acquisitions, the strategy focuses us on our goal of providing solutions for our customers and growing our businesses together,” he says.

“Our dealers and commercial customers have also been able to benefit from it, as it helps them make informed partnership decisions.”

AGI’s roots can be traced back to rural western Canada, where the company began with its Batco line of conveyors. It has since acquired more than 25 companies and now employs more than 2,500 staff around the world.

AGI is able to provide turnkey solutions for its customers, which Mr Brisebois says has been a key trend within the industry. “Customers want the simplicity of dealing with just one supplier that can meet all their needs,” he says.

Australian Growth AGI has been involved in Australia for more than 36 years with its Westfield augers and Batco conveyor belts used in farms across the country. The company also assists farmers with storage solutions through its Westeel and MFS brands.

Recently, it has also assisted GrainCorp’s Project Regeneration, which aimed to create a more efficient network of storage sites around Australia’s eastern grain belt. AGI assisted GrainCorp with the expansion and upgrade of its network, helping design and manufacture the facilities.

Peter Forster, AGI’s Australian Business Manager, says inefficiency and high costs within the Australian supply chain hurts growers trying to compete in the global market.

“Geographically, Australia is a vast continent with its regional population spread thin. This, along with ageing infrastructure, has led to the local supply chain becoming one of the most expensive in the world,” he explains.

“However, Australian grain is high quality and significantly sought after in the Asian market. AGI is dedicated to upgrading local infrastructure to drive down costs and help the industry compete globally.

“Our partnerships play a significant role in this.

They allow us to provide customers with face to face expertise and can draw on the support of a major manufacturer,” Mr Forster says.

An example of this can be seen with Allied Grain Systems, which recently completed the Malteurop Geelong expansion.

The company’s dealer network works closely with farms and commercial customers to help upgrade local infrastructure by designing, constructing, assembling and maintaining bulk handling systems.

Monitoring technology is a significant part of AGI’s Australian offering, particularly for keeping materials cool, nutritious and properly fumigated. Aeration, conditioning and monitoring systems allow information to be provided to the customer, which assists in operational decision making.

Mr Forster says the new technology being developed will help take the market to the next level, particularly when it comes to food traceability and supply chain management.

“The Australian market is going through a period of reinvestment. Consumer confidence and food security is becoming an important trend to focus on, especially within periods of drought,” he says.

“As a global company, AGI understands the different effects climate change has on the agricultural industry and is reaching out to invest in farmers around the world.”

“AGI, through its 5-6-7 strategy, expects the Australian market to continue to be a growth opportunity in the future and we aim to continue expanding our portfolio of turnkey solutions and continue to supply the market with Hi Roller belts, Neco dryers, Union Iron elevators, MFS silos and Yargus fertiliser systems.”

ABOVE: The 5-6-7 strategy is based around five platforms, six continents and seven components.

For more information visit www.aggrowth.com

Australian Bulk Handling Review: March/April 2019 І 17

TRAINING

Tip Top Training Academy graduates join the workforce The first batch of trainees from Rema Tip Top’s training academy are now getting real world belt splicing experience as the mining industry prepares for a potential skills shortage. William Arnott reports.

A SKILLS SHORTAGE IS EXPECTED TO continue within the mining sector as the industry competes with other growth industries around the country.

This is according to recruitment agency Hays, which has found the shortages have become a national issue since they emerged in Western Australia and Queensland early 2018. Enrolments into mining engineering and related disciplines have also dropped according to the Minerals Council of Australia, which also warns of an impending skill shortage by 2020 across the sector.

Allan Warren, Head of Training at Rema Tip Top, says the shortage is partially due to an image problem.

“When you think of a skilled tradesperson, it’ll most likely be a carpenter or an electrician with a dog in the back of the ute,” he says.

“It’s harder to sell trade careers in the mining industry and the critical jobs that the industry needs to allow for its growth.”

In particular, he says that conveyor systems are often go overlooked when it comes to their vital role within the industry.

Since their introduction in the early 20th century, conveyors have allowed mining companies to greatly improve their productivity. New Industries WA estimates the mining industry utilises some 55,000 kilometres of conveyor belt across Australia, carrying thousands of tonnes of material every day, and if they were to stop working or require repair, there is a

18 І Australian Bulk Handling Review: March/April 2019

potential for significant productivity delays and lost revenue.

Despite the fact that belt splicing skills are highly sought after in the industry, Mr Warren says they too suffer from poor perception.

“Belt splicing work is difficult and requires unique skills which impacts its attractiveness. A lot of that has to do with the lack of recognition for the trade, which is what we’re aiming to change,” Mr Warren explains.

Despite iron ore tonnage production forecasted to grow to 887 million tonnes by 2019-20 by the Australian Office of the Chief Economist, polymer processing apprenticeship and traineeship enrolments have plunged from a high of 263 per-year in Western Australia in 2002 to averaging below 22 students peryear since 2011.

Rema Tip Top identified the market’s critical need for more high-quality belt splicers and has partnered with its major customers to invest in the growth necessary for the mining industry. Through its own registered training organisation, the Rema Tip Top Academy, it is equipping the next generation of belt splicers by providing the training required to upskill trainees into specialised tradespeople with the best practice skills and safety knowledge.

As part of its offering, the Academy introduced a Certificate III in Polymer Processing, which they hope will achieve national-level recognition from

ABOVE: Trainees are able to learn in a controlled environment as they develop their skills.

an industry-wide body.

Currently, Queensland is the only state in Australia that considers belt splicing a recognised apprenticeship trade qualification, but Mr Warren is looking to change this.

“We are currently lobbying the Western Australian and New South Wales governments to start an apprenticeship scheme,” he says.

“Apprenticeships are different to traineeships, as they usually last for around three to four years for students just out of high school. This gives time to students developing their skills to become a master in the workforce and reduces the drop off rate.”

The polymer processing course takes around 18 to 24 months to fully complete, depending on the trainee’s ability, and focuses heavily on teaching safety, technical skills and accuracy. It is comprised of 21 units that teach students the processes needed for belt splicing including specialised training for fabric, solid woven and steel cord belts.

Trainees go through a rigorous selection process, including an interview to understand their background and any transferrable skills. From there,

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the trainees begin a 10-week training course, where they attend classes at Rema’s Perth facility and learn the theory behind the work.

Skills such as how to use a knife correctly and belt vulcanisation are taught in a controlled environment, to allow students to safely learn without the pressures of being on a site.

Trainees are then mobilised to a mine site in the Pilbara, where many get their first experience working on a fly in, fly out schedule. Trained assessors work closely with the students to help keep them safe, physically and mentally.

Tom Fraser, general manager Rema Tip Top Industry West, says the training course is part of the bigger picture when it comes to the company’s longterm investment into the industry.

“The industry has had a shortage of belt splicers for a long time across the country. There is a gap in the market when it comes to training and many of the specialised employees are now reaching an age where they are leaving the industry,” he says.

“This joint investment and long-term strategic planning in partnership with our major clients both

“The industry has had a shortage of belt splicers for a long time across the country.

There is a gap in the market when it comes to training and many of the specialised employees are now reaching an age where they are leaving the industry.”

TRAINING

BELOW: Knife skills and belt vulcanisation are taught in a safe environment.

makes this program successful through on the job training and creates a sustainable workforce which our customers can have confidence in when hiring.

“Belt splicing is high risk work, so to reduce the risk of incidents we aim to set a new benchmark of training for the sector,” Mr Fraser adds.

The first crop of trainee belt splicers graduated from the training program in October 2018, with a second group beginning their training in January 2019. Rema aims to add around 70 employees through traineeships year on year and expand its offering into areas such as the rubber lining and mechanical trades.

Through recognised prior learning, the RTO is also placing its experienced workers on a pathway to nationally recognised certification and is set to issue a further 68 certificates in 2019.

As part of the graduation process, the company has also named its inaugural trainee of the year.

Remi Carter went through the program in 2018 and has since been employed full time by Rema, where she works on site at its operations with Fortescue Minerals Group.

She began her career working in a manufacturing centre inspecting conveyor belts, which is what inspired her to become a belt splicer.

20 І Australian Bulk Handling Review: March/April 2019

“It was something I was good at and I wanted the chance to get even better at it,” she says.

“I was looking for more opportunities even though some people said it wasn’t a job for a woman.

I wanted to further my career and so I decided I would take the opportunity to learn anyway.

“The course was great, and the site work especially was really eye-opening. The team helped out a lot and I was able to get hands on while learning.

We were out there every day cutting belts or helping prepare for setting up work areas.” Ms Carter adds.

Four more intake programs are planned across WA this year, with one to two to be run in each of Rema’s NSW, SA and QLD training centres.

Throughout this process, there has not been a single drop out, which Mr Fraser says is indicative of its success.

“The feedback we have received from our clients has been fantastic. They’re not only impressed by the quality of the people we are sending over, but with our selection process too,” he explains.

“These are transferrable skillsets that depend on accuracy, attention to detail and proper work safety. They’re important services like any other that requires skilled employees to deliver them.”

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MATERIALS HANDLING

Stacked up: How Nepean is building a conveyor revolution Nepean Conveyors is planning to change the game for materials handling in 2019 by introducing its agile relocatable conveyor system. NSW general manager Bill Munday tells ABHR about the system during a site visit.

OVERLAND CONVEYORS ARE A VITAL PIECE

BELOW: The modules can be adjusted for different idler spacing and roller configurations.

of mining equipment, but they are not known for their mobility. Once in place, sites generally expect conveyors to remain put for several years.

Privately owned original equipment manufacturer Nepean Conveyors plans to disrupt this tradition with its latest project, a relocatable conveyor designed for ease of transportation, assembly and (eventually) dismantling.

The Nepean Relocatable Conveyor system — which will be officially named following an internal competition — has taken over two years of research and design to develop.

It promises to upend the traditional approach to conveyor design on account of its improved mobility, operational flexibility, ease of transport and speed of installation.

Instead of building conveyor parts to meet the needs of freight shipping container dimensions, the Australian and international patents pending Nepean Relocatable Conveyor is itself a half-height high cube portal frame configuration that is certified for standard freight shipping.

This means the conveyor is transportable anywhere in the world as a fully assembled unit.

Not only does this approach allow the conveyor modules to be stacked and loaded for direct transport via sea, rail or road, it also makes the conveyors easier to move, remove, assemble and eventually disassemble as the site requires.

22 І Australian Bulk Handling Review: March/April 2019

The units can, therefore, be stacked on ships, unloaded directly onto trucks or trains and transported to a site’s lay down area for direct assembly.

The frames are 12 metres long, with the unit inside supporting belt widths of up to 1800 millimetres on straight conveyors and 1600 millimetres on curved conveyors. Roof-mounted wind guards are also available for each module in a single curve or straight two-piece configuration.

The modules can be triple stacked on a prime mover and unloaded in one bundle using standard container handling equipment, such as fork lift trucks, reach stackers, frannas and cranes, which can then place each module in line for final connection.

This approach vastly reduces the total install cost per lineal metre by minimising both time and staff requirements during setup.

“One of the areas we really wanted to target was logistics,” Nepean general manager, New South Wales, Bill Munday tells ABHR during a site visit to Port Kembla.

“It can turn into a real logistical exercise moving all this equipment from one site to the next and doing so efficiently. The beauty of having a half-height hi cube shipping container format is that they can be multi-stacked on ships, trains or trucks.

“You can potentially get nine modules per road train at a length of 12 metres per module.”

The unit also minimises ground works. The

frame’s integral legs can be set in place by removing a pin, folding them out and replacing the pin to lock the legs in position.

The foot plates also have holes in them for additional stakes to be inserted, which adds stability and security in cyclone-rated zones. While the exposed design of the frame means the unit lacks the surface area to be blown over, it can potentially slide sideways, so the stakes help to eliminate these issues.

Once the modules are aligned to an installation jig on the ground, which is adjustable for idler spacing and roller configurations, the structure can be super elevated by up to seven degrees and banked around corners.

Alternatively, ground screws are also available for added stability and flexibility. Trestles with independent walkways can also be assembled using these ground screw bases to build the conveyor over water courses or cattle crossings. These options allow for the conveyor pathway to be roughly graded within 100 millimetres.

“All the equipment is pre-designed for a fully functioning conveyor and the container module is just part of the system,” Mr Munday says.

“We have also designed a unique one-piece

head end that incorporates a drive system up to approximately 4000 kilowatts, a loop take-up and delivery jib that can be put on a 200-tonne float to transport around mine sites. It is held in place by large ground anchors — there’s minimal concreting or civil works — you just dig a couple of holes and bury the ground anchor.”

Interestingly, the conveyor is not classified as fixed plant due to the unique way it has been designed. In addition to significantly lowering civil

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ABOVE: The conveyors make use of a half-height frame configuration certified for standard freight shipping.

GRAIN HANDLING AND STORAGE SOLUTIONS www.alliedgrainsystems.com.au

MATERIALS HANDLING

BELOW: The head end of the conveyor.

works and installation costs, the Nepean Relocatable Conveyor’s mobility allows it to be adaptable to changes in mining operations and positions it as a true alternative to mine trucks when it is time to move the conveyor on site.

“If you put in a traditional system over a five-year period, that’s classed as fixed plant and depreciates over those five years,” Mr Munday explains.

“With this type of equipment, because it’s modular and reusable, it’s got a 20-year lifespan, so you can depreciate it over a much longer period. It’s not classed as fixed plant for that reason.”

Nepean’s system is primarily designed for use

24 І Australian Bulk Handling Review: March/April 2019

at satellite mine sites that will benefit from the improved portability of the system, while at the same time providing substantial cost savings and reducing downtime.

“From the testing we are doing out here [in Unanderra], we can ideally install 1200 metres of ROM conveyor in a 10-hour shift,” Mr Munday says.

“Realistically though, we would probably install about 600 metres in that time. It pretty much works out at a metre a minute.”

The system is intended to be hired (though this is open to negotiation with the client) and since its design cuts down on the need for concreting, digging and other civil works associated with traditional conveyor installation, this leads to the significant cost and time savings.

“We have had a number of subcontractors come onsite who have mentioned that other companies that use dump trucks can just slot one of these in place being so versatile, however many they want, whether going straight or round a curve,” Kyle Napoleoni, a project engineer testing a three-roll offset, tworoll return Nepean Relocatable Conveyor unit at a BlueScope site in Wollongong, says.

“The versatility of the design and the handling and adjustment of the legs are majorly beneficial, as is the lateral adjustment in the internal conveyor frames. Everything has been thought about.”

The innovation doesn’t end with the conveyor configuration, however. The head and tail end of the conveyor have also been designed with an eye to improved setup and transport speeds as well.

The all-in-one relocatable head end used for the conveyor trial (compete with jib, drive head and loop take up) at the BlueScope site is powered by Nepean’s in-house Nifty Drive, a rapid deployment conveyor drive system that evolved from the company’s standard underground conveyor equipment range.

The Nepean Relocatable Conveyor system, set for launch in the first quarter of 2019, holds strong potential for international expansion.

Nepean is even in the early stages of adding a fully automated idler change system to the Nepean Relocatable Conveyor through discussions with a Perth startup, delivering possibilities for even more productivity and safety benefits to the relocatable system. With the Nepean Relocatable Conveyor, Nepean promises a strong start to 2019.

“The mining industry has gone through some tough times in the last few years, but we’re starting to come out of that now. We’re seeing much more positive attitudes and can see our business ramping up over the next 12–18 months. We’ve come out of the downturn in an extremely strong position,” Mr Munday concludes.

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Australian Bulk Handling Review: March/April 2019 І 25

ACQUISITIONS

Fenner Dunlop builds local brand through acquisition Fenner Dunlop Australia has acquired a local designer and manufacturer of pulleys and bulk handling equipment. William Arnott speaks to Tim Cleine, Operations Manager at CPA, to find out why.

BY 2008, THE MINING AND RESOURCES BOOM

BELOW: CPA, based out of Carrum Downs in Victoria, designs and manufactures pulleys and bulk handling equipment

was in full swing. Despite the global financial crisis affecting most major markets, Australia managed to avoid the brunt of its impact. According to the Reserve Bank of Australia, this was partly due to increased investment in the sector as well as sizeable resource exports to China.

During this time of investment into the resources sector, smaller companies were able to find gaps in the market and develop these opportunities.

Conveyor Pulleys Australia (CPA) – who design and manufacture engineered conveyor pulleys – was one of these companies.

Tim Cleine, CPA operations manager, had been part of the business from the very beginning and says during the early stages, the company’s staff was small, but dedicated to being successful.

“When we started, our name wasn’t out there on the marketplace. We weren’t established but none of us backed away from the hard work ahead of that was necessary to succeed,” he says.

26 І Australian Bulk Handling Review: March/April 2019

“We were lucky to have a team of exceptionally experienced people. We have more than a hundred years of industry experience combined across the team.

“One of those great people is John Bowman, the man who was put on to run the company from the start. It was a great opportunity for the pulley business, as it was entirely sink or swim, but early on he was given some bad news – he was told he had six months to live.”

John managed to beat cancer and has stayed on with the staff, working with the team to provide consultation and expertise with his 40 years of experience.

During these early stages of development, the business forged a relationship with Fenner Dunlop Australia. As a major client, Fenner Dunlop helped support CPA’s cash flow, to the point where it was able to rapidly expand.

New infrastructure and manufacturing equipment were purchased, which in turn required more space to work. CPA moved its factory to Carrum Downs in Victoria and expanded its range of products and services.

The company was able to double its manufacturing output and increase its capabilities, including the supply of parts such as bearings, shafts, shaft locking assemblies and steel fabrications.

The team also grew, including the addition of experienced engineers skilled in using a computerised design program. This meant CPA could support its products through a quality management system and provide documented conformance verification, such as compliance with AS9000-2000.

Mr Clein says what sets CPA apart from their competition is the fact that they are a local company who know how to speak the language of Australian firms.

“Because we’re based in Australia, we have a deeper understanding of the local industry than firms based in other countries such as China,” he explains.

“The ability to just catch a plane or drive down to get hands-on with whatever needs troubleshooting means we can provide a fast response to fix issues

effecting productivity.

“We have also spent a lot of time developing our costing process, so that when a mining or quarry company runs into an issue, we’re able to get a price for them in a matter of hours,” Mr. Cleine says.

Fenner Dunlop’s acquisition CPA’s market offering had helped the company grow, to the point where it was one of the driving forces behind its incorporation into the Fenner Dunlop Group. In late 2018, CPA was acquired by Belle Banne Conveyor Services (BBCS), which is part of Fenner Dunlop Australia.

BBCS is a supplier of conveyor products, materials handling engineering and maintenance services for the bulk materials handling, mining, ports and heavy industry sectors. Through the acquisition of CPA, and the synergies to be gained with other Fenner Dunlop businesses such as Australian Conveyor Engineering (ACE), Fenner Dunlop expects to expand its range of locally manufactured pulleys.

Stuart Milliken, Fenner Dunlop’s chief financial officer, says the combination of the BBCS brand and

CPA’s products and services will allow the company to offer a range of high-quality pulleys, manufactured in Victoria and continuing it’s ‘Think Global, Act Local’ strategy in responding to its customer needs.

“We will combine the knowledge and expertise of the two businesses to enable CPA to provide the highest level of service and support to its many valued customers,” he says.

With the support of a multinational behind them, Mr Cleine says the team is now able to focus on its core business, rather than the stresses that come with managing a small business, such as cash flow.

The staff have also been given the opportunity to ‘upskill’ now that money can be put into training and development.

“Fenner Dunlop’s team has been supporting us with these additional organisational roles, like contract management and marketing so that we can focus on providing services for our clients.

“It’s great to see the extra faces coming in and helping out. We really feel like part of the bigger Fenner Dunlop team now. There’s a sense of belonging and we are keen to keep growing.”

“We will combine the knowledge and expertise of the two businesses to enable CPA to provide the highest level of service and support to its many valued customers.”

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ENGINEERING

Methodology for increasing the throughput of existing belt conveyors Knowing the maximum capacity of existing conveyors is crucial when owners and operators wish to increase the overall throughput of transporting systems. Aspec Engineering’s Sara Vance and Dr Paul Munzenberger provide insight on the processes behind determining the maximum capacity.

BELT CONVEYORS HAVE ATTAINED a dominant position in transporting bulk materials as they are reliable, safe and have low maintenance and energy requirements. Conveyors are commonly used to transfer bulk materials between key operations, such as from a stockpile to a process plant or from a process plant to a loadout system.

Because of their position in the industry, the capacity of a conveyors is crucial for increasing the overall throughput of their operations. We often get asked “How much more can we put through our system?”

If a belt conveyor has sufficiently sized loading and unloading equipment, then the maximum capacity depends on the limitations of its weakest components.

The first step is to determine the capacity of the main components: • the conveyor drive, •v olumetric capacity (how much can physically fit on conveyor), • idlers (load rating & bearing life), • belt pulleys, • belt, • take-up (belt tension),

BELOW: Figure 1. A comparison of design, actual and upgrade capacities of major conveyor components.

Example of Conveyor Capacity 5000

4500

Capacity (TPH)

4000

3500

3000

2500

2000

Drive

Volumetric Design

28 І Australian Bulk Handling Review: March/April 2019

Take Up Actual

Upgrade

Transfer Chute

• brakes and flywheels and • support structure.

For existing conveyors, the determination of the above parameters is more than just carrying out standard calculations. For example, the conveyor drive performance can be validated against the power draw data from the Supervisory Control and Data Acquisition (SCADA) systems. In some cases, the existing conveyor has been conservatively designed and consumes less power than it was installed with. This excess capacity can be used to convey additional material. The volumetric utilization of the conveyor, at the existing speed, can also be determined through laser scanning or other measurements to determine if any additional material can be loaded on the belt to fill it completely.

Once the capacity of each component is determined, the maximum possible capacity of the conveyor can be identified. If the maximum capacity, using the existing components, is not sufficient to meet the owner’s requirements then the components that fail to meet the requirements can be upgraded.

Taking the reasonable assumption that increasing the width of the conveyor belt is not cost effective, the main way to increase the conveyor’s capacity is to increase the belt speed or to fully utilize the volumetric capacity at the conveyor’s current belt speed. In the first case, there will be an increase in the velocity dependant resistances, and in the latter, there will be in increase in the load dependant resistances.

Either option, or a combination of both, will result in the need for more drive power, or a reduction in the conveyor’s resistances. If the conveyor is required to lift the conveyed material by any amount, there will be an additional requirement to further increase the conveyor’s drive power or to further reduce the conveyor’s resistances so that a greater amount of material can be lifted in a given time.

The main consequence of increasing the drive power requirements of a conveyor is that the conveyor belt tensions will increase due to the additional resistances. This will occur regardless of whether the velocity of the conveyor is increased, or its volumetric capacity is better utilised without a speed increase.

Not only will the increased drive size impose more tension on the conveyor belt, the increased take-up force required to generate the additional pulley traction needed to transfer the power into the conveyor belt will further increase conveyor belt tensions.

Tension requirements can reach the point that a stronger conveyor belt would be required. Increased strength requirements of pulleys and supporting structures may also be needed, and transition lengths and the reaction forces generated in horizontal and vertical curves will also be affected. If the conveyor is long enough, the starting and stopping dynamics

should also be recalculated.

When upgrading a conveyor, it is not ideal to change the rating of the conveyor belt. As such, it may be necessary to employ a range of resistance reduction techniques to allow the existing conveyor belt capacity to be used. The methods chosen will likely depend on what components of the existing conveyor are due to be replaced during the upgrade and the type of conveyor that is being upgraded.

Options for resistance reduction include: using larger diameter idlers which lower rolling resistance, lighter idlers which reduce the acceleration tensions by reducing conveyor inertia, idlers with lower rim drag or operating the conveyor at even higher speeds than intended to reduce the total mass of material on the conveyor and thus the weight dependant drag forces.

If additional resistance mitigation is required it may become necessary to replace the existing belt with a modern, low rolling resistance, conveyor belt that will generate less resistance at each idler station, thereby reducing the drive force and thus lowering the belt tensions.

The issue with using these resistance reduction strategies is that they require specific, and sometimes more expensive, components which carry the risk that in the future someone may want to save money by specifying cheaper replacement components without knowledge of why the specific components were originally used.

As an example, for an asset owner that wishes to improve the capacity of their conveyors, upgrades can be implemented to increase the capacity of the governing components. Given the typical data shown in Figure 1, it may be recommended to replace the drive unit and increase the take-up weight. The new drive unit would need a higher ratio gearbox to speed up the conveyor to increase its throughput and larger drive to provide the additional power. Additional take-up mass is also recommended to transfer the additional power to the conveyor belt. In many cases, the capacity of existing conveyors can be increased with relatively low cost and minimum interruption to its operation.

ABOVE: There is a wide range of methods that can be used to increase a conveyor’s capacity.

Australian Bulk Handling Review: March/April 2019 І 29

ENGINEERED SOLUTIONS

CONVEYOR CLEANING

Keeping conveyor belts on track When a conveyor belt is not properly aligned it can rub and wear against the surrounding structures, which eventually results in severe damage to the conveyor belt, the idler frames and even the conveyor structure itself.

BELT MISTRACKING IS ONE OF THE MOST common causes of belt stoppages and occurs when the conveyor belt is not properly centred on the conveyor frames. There are several simple checks which can be performed to find some of the common belt tracking issues and may uncover underlying mechanical issues.

1. Is the belt in poor or worn condition?

If the belt is badly worn or stretched, shows signs of cracking or wear through the rubber cover, the belt may no longer be straight which makes tracking problematic.

2. Is the belt ripped, torn or damaged?

If the belt has rips, holes or any sort of structural damage to the belt carcass, the belt could catch on idlers or other parts of the conveyor, causing it to run off centre and no longer be straight.

3. Is the belt splice in poor condition?

Inspect the splice and make sure it is in good condition, has no flaps, loose items or abrupt edges that may become caught on idlers or other components.

4. Is the conveyor pulley lagging worn or material

build-up on the pulleys?

If the pulley lagging is worn or material builds up around the lagging, this can alter the effective diameter across the pulley. This will likely lead to the belt wandering off centre, increased instability and may result in the belt running off the edge of the pulley.

5. Has material built-up on the idlers?

Material build-up around the idlers may result in the belt being steered off centre, running to one side and contacting other components along the conveyor.

6. Are all the idlers rotating smoothly?

If idlers cease running or become jammed, the stationary roller may act as a brake on that part of the belt. This can cause the belt to run off to one side.

7. Are the trainers in good condition and effectively training the belt?

Mistracking can also occur if the trainers are in poor condition or not effectively training the belt to run in the centre of the structure. Inspect the trainers closely to spot if they are worn or tired.

In this regular column, experts from specialist bulk materials engineering firm DYNA Engineering solve some common issues associated with materials handling. In this edition, the firm’s managing director Graeme Greaves, explains the latest innovations available to correct mistracking belts and improve productivity by reducing unscheduled conveyor stoppages and downtime.

LEFT: Figure 1. This is an example of one of the most common methods used to correct belt tracking.

30 І Australian Bulk Handling Review: March/April 2019

MAXXFLOW HTC

FLOW MEASUREMENT FOR DRY BULK SOLIDS • Powder • Dust • Granules Tracking Rollers Tracking rollers are designed to minimize belt mistracking and are usually fitted on the return run of the conveyor belt but can also be fitted on the carry side of the belt. Tracking rollers assist in keeping the belt aligned and centred on the conveyor system.

One of the most common methods of assisting to correct belt tracking is a pivot belt tracking frame, which can be seen in figure 1. These frames use the standard conveyor rollers with the addition of a horizontal centre pivot and side guard rollers to steer the belt back towards the middle of the conveyor when the belt wanders to one side.

However, in this type of design, there is often a gap between the belt and the side guide rollers which creates a delay in the response to the movement of the belt.

This may result in an overcorrection in the conveyor belt which will continue to wander from one guide roller to the other.

In extreme cases, the pivot design can be a potential liability. When a severe tracking event occurs, the pivoting frame can move to a point where the pivot reaches its limit and the conveyor belt can be forced up and over the side guide roller, potentially damaging the belt or surrounding equipment.

If the centre pivot becomes worn or seized and consistently rubs and wears against the side guide rollers, it can lead to belt mistracking and premature wear of the edges of the belt when it comes into contact with traditional tracking rollers.

It’s common to see the older style

ABOVE: DYNA-TRAC tracking rollers use diamond grooved rubber lagging for an improved grip.

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CONVEYOR CLEANING

ABOVE: A traditional training roller and frame being held in place by a rope.

tracking rollers, or “trainers” as they’re sometimes called, tied with rope or supported with other devices because they simply don’t steer the belt correctly. The belt keeps tracking off centre, causing the edge of the belt to become damaged and frequently trip the belt drift safety switches.

When issues continuously reoccur, conveyor operators tend to take matters into their own hands and work around these issues as best they can. The work arounds are usually effective for a short period of time, however they are sometimes unsafe and not a long-term solution.

DYNA-TRAC Tracking Rollers DYNA-TRAC tracking rollers are a relatively low cost and low maintenance solution to belt mistracking. Easily installed on most conveyor systems, DYNA-TRAC Tracking Rollers are selfaligning and self-adjusting.

The self-adjusting mechanism uses belt forces provided by gravity, friction and balance to keep the belt aligned and centred while the belt is in motion. The design steers the belt towards the centre of the conveyor without the need for side rollers or pivot frames.

By using conveyor belt forces to adjust the tracking, the tracking roller is constantly adjusting any small changes in the belt alignment, eliminating any delay response typical of traditional tracking rollers. The intuitive steering mechanism streamlines the correct steering response based on the force applied which helps to prevent overcorrection.

Another important feature of the DYNA-TRAC tracking roller is the belt edges no longer need to come in contact with side guide rollers. Side rollers have been made redundant on the DYNA-TRAC due to its design, eliminating potential damage and

C

M

Y

CM

MY

CY

CMY

K

RIGHT: DYNA-TRAC’s tracking roller doesn’t need to come in contact with side guide rollers, eliminating potential damage to the belt.

32 І Australian Bulk Handling Review: March/April 2019

wear to the conveyor belt.

All DYNA-TRAC tracking rollers are supplied with diamond grooved rubber lagging to improve grip on the belt. This improves the steering performance in a variety of conditions including dry, wet and muddy. Diamond grooved rubber lagging enables more positive and reliable tracking than the traditional plain steel rollers.

Additionally, DYNA-TRAC training rollers have enhanced dust sealing which ensures greater service life of the steering mechanism when compared traditional tracking rollers. Traditional tracking rollers frequently suffer from pivot bearing failure due to dust and other contaminates entering the pivot bearing. The redesigned mechanism combined with improved dust sealing, resists the entry of water, dust and other forms of contamination.

DYNA-TRAC Tracking rollers are available to suit conveyor belt widths (in millimetres) of: 400, 500, 650, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2200, 2400, 2600.

Bulk Handling Capability Ad - 1-2 Page.pdf

1

14/12/18

About DYNA Engineering DYNA Engineering is an Australian-owned and operated company with their head office and factory located in Perth, Western Australia.

The company specialises in the design, manufacture and supply of conveyor equipment and related services which can be tailored to an extensive range of applications, operations and operating conditions.

These designs incorporate common components and assemblies which allow easy modification from one design to another on short notice.

As an example, their DYNAFastFit range of belt cleaners and adjusters can be converted from polyurethane to carbide blades without major modifications or replacement. Products are of robust construction which allows them to withstand extremely harsh operating environments and deliver a long, trouble-free service life.

DYNA Engineering thoroughly test their products in both workshop and onsite situations to ensure they work as intended and to industry safety standards.

1:11 pm

BAGGING SYSTEMS

The advantages of flexibility in the bagging of bulk products Incorporating real flexibility into an automatic bag-filling operation can allow a wide range of formats to be handled, while avoiding the high labour costs and low productivity associated with multiple manual systems.

AS BAG FILLING COMPANIES GROW AND develop, it usually means moving from manual operations to fully automatic lines, often trading higher outputs for a more limited product range.

But productivity gains don’t need to be compromised, even when it comes to very short job runs, provided the new line has flexibility at its core.

The ability to handle the widest possible product range isn’t just a desirable feature, it can be key in justifying the initial investment.

By applying experience and innovation, replacing manual adjustments by servomotors, linking individual elements into a single integrated network and harnessing programmable logic controller (PLC) power to aid line management, it is possible to provide a highly versatile automatic system that makes switching between formats both quick and trouble free.

Dosing In circumstances where several products or an extended weight range up to 10 to 1 are involved, feed system design becomes vital. Using brushless motors to control aperture size, servomotors to adjust bed depth along with variable speed drives, it becomes possible for changes to the dosing rates for different products to be programmable. This reconciles speed and accuracy across the entire product and weight range. Even separate feed devices for free and non-free flowing materials can be provided.

Cleaning down to avoid cross-contamination can be done by quick access panels or automatic cycles

34 І Australian Bulk Handling Review: March/April 2019

using either hot water or air jets for hard to reach places, minimising downtime between grades.

Bag types and sizes Different bag types, such as polyethylene or paper, with different closure methods can be handled on the same line. Heat sealing, sewing or hot-melt closure methods can be fitted in combination, selectable by program, and changeovers made automatically without the need for handwheel adjustments.

Hybrid systems are available where bags from a tubular film reel can be produced and filled together with pre-made PE and paper bags. This is common in dry pet food.

Changes in bag length are made by motorised adjustment to the sealing conveyor height, although width changes tend to be more problematic. The filling spout usually has to be sized for the smallest bag which can restrict the filling rate on larger sizes and create dust suppression issues when fine powders are involved, potentially limiting the range.

Automated packaging company Concetti has overcome this for granular products by using a variable-geometry spout, which adapts to a wide range of bag widths and with the opening size set by servomotor under PLC control.

Palletising and complete lines A complete line will normally include a number of discrete elements, each with an individual PLC or

ABOVE: Automatic lines do not need to compromise productivity gains if designed with real flexibility in mind.

controller. These are often systems for product dosing, filling, closing and palletising, but also could include optional items such as printing, labelling, weight checking, and pallet wrapping.

Individual machines work together easily when operating in automatic mode on a single format, but making changes is not always straightforward. Each may need programme or physical adjustments, placing an additional responsibility on the operator to set-up everything correctly, adding non-productive time and risking problems on restart.

But linking the PLCs and control devices through a local area network (LAN) can produce an integrated system where changes are made automatically from a single operator position through a keypad or directly from the user’s plant control system.

Programmes are linked through the network and whole-line changes can be made in less than two minutes.

Product type, dosing weight, bag width and length, closure method, print details, weight check target and palletiser layer pattern are all adjusted or updated automatically without tools and consistently to the correct settings.

The network also enables data to be gathered from the lines, which can be used to log and review historical performance data and trends to help reduce plant shutdowns and raise productivity.

Support Modern automatic lines are complex, and consideration must be given to maintenance and technical support. This is especially important in Australia with huge distances between urban centres.

To account for this, Concetti has a dedicated telephone and email hotline support service, which includes a teleservice facility. A recently developed application allows for real-time sharing of data and video. Local servicing has been augmented by collaboration with Melbourne based Automaint Solutions, located in Keilor Park. The companies work together to guarantee both telephone assistance managed directly by specialised Concetti technicians in Italy, and field interventions within a few hours, by Automaint engineers.

PERFECT FLIGHTS PERFECT FIT, PERFECT ALIGNMENT

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AIR CANNONS

Why ESS’s new Air Cannon systems are a real blast The latest Air Cannon system designed by ESS is now the most powerful option on the Australian market.

THE BUILD-UP OF MATERIALS IN BULK

ABOVE RIGHT: The ESS Air Cannons are available in both internal and external valve arrangements.

BELOW: Example of the different ESS valve designs.

storage systems is a common issue. When silos and bunkers accumulate material around their perimeters it can slow operations down or even stop the flow of bulk material altogether. Air Cannons are pressure vessels with attached valve mechanisms that blast air at high velocity at speeds approaching c. They are frequently used to dislodge bulk material build-up and allow for maximum storage capacity. In the bulk materials and handling sector, Air Cannons have numerous applications. They can easily solve bulk flow problems in silos, hoppers, chutes and storage piles and are often used where vibration is not practical or other methods are too expensive.

ESS Engineering Services & Supplies have developed a new Air Cannon system that is highly effective and safer than those previously available.

Engineers Mick Hutton and James Stievenard have designed a tank and valve that can be retrofitted onto any previously installed valve arrangement – an industry first. They’ve also independently tested their valves against competitors and have found their Air Cannons to be the most powerful option currently available.

“We’ve got a flexible offering. We have the ability to supply a valve that can retrofit any previous installations we’ve done. Importantly, we’ve developed a safer and more effective option for customers,” said ESS Engineering Manager, Mr Hutton. “To substantiate our claims of supplying the most powerful air cannon valve on the market, we engaged TUNRA Bulk Solids who compared our new

36 І Australian Bulk Handling Review: March/April 2019

valve designs with those of our competitors. Results showed the ESS air cannon options outperformed all others in terms of peak blast force and blast impulse.”

The newly-designed ESS Air Cannons are available in both internal and external valve arrangements with 4” (i4) and 6” (i6) valves. The direct blast design of the i4 and i6 valves allow stored air in 40L, 70L, 150L or 250L receivers to escape directly through the valve and into a discharge pipe without bends or obstructions. This is important, as the quicker the air discharges, the greater the force, velocity and impulse of the blast and therefore, a greater area of influence.

“The main advances with our new air cannon system includes more inherent safety features such as fill-on-demand, reduced hazard level rating and statutory inspection requirements for our larger pressure vessels. Our newly designed valve includes only one moving part with no metal on metal contact.

We have also engineered out the requirement for fatigue-prone components such as springs that can cause premature failure, sometimes catastrophic,” explained ESS Mechanical Engineer, Mr Stievenard.

ESS Air Cannons can be remotely activated via a Sequence Controller that controls the fire time interval and the sequence of one or more Air Cannons.

Mr Stievenard said that ESS can help customers optimise air blasting outcomes through certain design features such as tailored pipe designs or a chute mounting arrangement that will maximise the efficacy of a blast through proper design and firing sequence.

Air Cannons are most effective when they are fired at the right angle and direction, and blasts are usually directed at problem areas such as corners or the base of known areas of build-up. A custom chute mounting design will ensure an Air Cannon blast is directed to the inside wall of a vessel, shearing material away from the wall to restore material flow.

Additionally, ESS can offer customers more advanced options with automation.

“We’ve been interfacing with our customers’ SCADA systems so they can monitor blasting cycles and sequences from their control room. For example, we can provide the air cannons with transducers and

SOLVE YOUR MATERIAL FLOW PROBLEMS

pressure sensors to help optimise and measure the effectiveness of a blast,” Mr Stievenard said. “Basically, we can offer a whole host of automation that we can implement in conjunction with a customer’s requirements.”

Because of the wide range of applications for Air Cannons, it is common for ESS to provide their customers with an end-to-end service. They don’t just supply the products, but will match products and customise designs depending on a customer’s application and needs.

“Each application will be different.

It’s our preference to come out to the site, assess what the customer needs, then design a system that will work best for them. We also provide all the installation and assist with servicing down the track,” explained Mr Hutton. “We can also provide other services such as onsite safety or hazard level assessments on pressure vessels.”

ABOVE: ESS can offer customers more advanced options with automation .

BELOW: Air Cannons are regularly used to solve bulk flow problems in silos.

CALL THE EXPERTS IN VIBRATION For more information about the ESS Air Cannons, readers can visit: www.esseng.com.au/aircannons

We sell solutions, not just products Phone (03) 9800 6777 or visit enmin.com.au

GRAIN HANDLING

From Port to Pub: Upgrading Geelong’s malt exports Allied Grain Systems, along with other major suppliers and contractors, were contacted by Malteurop to supply and install grain storage silos, walkways, towers and mechanical conveyors at its Geelong based plant to transform it into one of Australia’s largest malting sites.

BELOW: Malteurop’s Geelong malthouse facility is located on a rail, road and maritime hub.

AUSTRALIA LOVES BEER. Nationally, Australians consumed around 1.7 million kilolitres of the brew in 2017, according to the most recent statistics from Kirin’s Beer University.

However, these numbers pale in comparison to Asia, which holds around 33.7 per cent of the global beer market share. For 10 years in a row, Kirin has found the region to be the world’s largest consumer of beer, with China firmly in the top position.

This multi-billion-dollar industry on Australia’s doorstep is what sparked Malteurop Australia to upgrade its Geelong malthouse facility.

Trevor Perryman, Malteurop Managing Director,

said up to 85 to 90 per cent of Victoria’s malting barley was destined for export markets, so an expansion of its facility was of strategic importance to the company.

“Asia already has a deficit in its production of cereal grains and malt, so Australia as a major producer is well place to meet that demand,” Mr Perryman explains.

“With Malteruop’s Geelong facility so well placed in terms of proximity to the highest quality and most abundant malting barley sources and its bayside location on Australia’s main export gateway, we have a fantastic opportunity here.

In fact, the Geelong facility is located on a rail, road and maritime hub, that allows Asian brewers to source their malt from the Australian market.

Positioned between the deep-water Port Phillip Bay and number of major barley suppliers, growers were able to deliver directly to the site for international shipping.

This ability for farmers to deliver directly to Malteurop was welcomed by Andrew Weidemann, Grain Producers Australia Chairman and grain farmer at Rupanyup.

“It provides more opportunity for Malteurop to deal directly with the farmer, which improves supply chain efficiency and reduced costs associated with storage and the freight that comes with that,” he says.

“I see the upgrade as a great benefit to Victorian grain growers and for the economy of Geelong. It’s an important investment and we can only see good things coming from it.”

Building better beer infrastructure Part of the major infrastructure upgrade required a partner that Malteurop could trust to provide a high-quality service for the supply of the grain storage silos and associated structural element. This is why the company partnered with Allied Grain

38 І Australian Bulk Handling Review: March/April 2019

Systems, one of Australia’s leading designers and builders of grain storage and handling solutions.

With more than 25 years of experience in the design, installation and construction of grain storage systems, Allied Grain Systems was trusted with increasing the plant’s annual capacity from 80,000 tonnes to 200,000 tonnes. This would make the site one of the largest of its kind in Australia and Malteurop’s third largest globally.

Allied Grain Systems designed and partnered with Malteurop with the construction of the civil foundations for 17 silos, which were based on a driven pile design to a depth of more than 12 metres to overcome the site’s poor soil conditions.

Over an 18-month period, Allied Grain Systems constructed six 1000 tonne clean barley storage silos, five 1000 tonne malt barley storage silos and four 500 tonne barley analysis silos.

Each silo was of a heavy-duty commercial quality and designed to comply with all relevant Australian standards, sealed to AS 2628-2010 and constructed for fumigation.

Allied Grain Systems also designed, detail drafted and fabricated all the of associated structural steelwork for the over silo walkways, support towers and access stairs, which were then shipped to Geelong for installation. It then undertook the mechanical installation of the major mechanical conveyors for

the plant, including bucket elevators, drag chain conveyors, belt conveyors and associated valves and control items supplied by food infrastructure company Ag Growth Incorporated.

Oliver Parent, Malteurop Group – France CEO, says the major upgrade of its Geelong site symbolised Malteurop’s core values in acting together and working for the long term.

“Both values were shown with true professionalism by all those who worked on the project,” he adds.

One of the challenges Malteurop’s Project Team and Allied Grain Systems faced during the construction was the expansion had to be built around the existing day to day production, which operated 24 hours per day, seven days per week.

The new malting plant and equipment was built in stages over a six-month period as each new part of the plant was completed. Safety was the highest priority during construction, which helped the company complete the project without a minute of lost time from a safety incident.

Allied Grain Systems’ commitment to safety and quality throughout build saw Senior Construction Manager, Paul Wowk, awarded with a certificate of appreciation from Malteurop’s head office in France in September for his valuable safety contributions and quick thinking at the Geelong site.

The full site was completed in September 2018.

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GRAIN HANDLING

VEGA’s radar sensor solution for bulk solids Measurement technology specialist VEGA is helping Australian companies keep track of their grain levels, even in dusty and noisy environments.

UNDERSTANDING JUST HOW MUCH GRAIN is within a silo is often vital for accounting and logistical purposes, however due to the design of grain silos this be difficult to accurately achieve.

Radar technology has been used to collect level management readings since 2004 by producing radio waves to detect the echoes. The echoes are then detected and converted into an electronic signal which is either displayed directly on site or incorporated into a process control or management system.

However, even the smallest design or functional fault in a bulk solids level management radar sensor can have astronomical consequences for lost profits over time, meaning businesses need to implement reliable and cost-effective sensors that are able to handle these conditions.

Grain silos are often quite narrow, usually measuring in at around 60 metres in height and are commonly filled pneumatically from above and emptied at the bottom. This tends to generate a significant amount of dust and noise, impacting echo detection methods.

As it is, airborne dust is difficult to detect with radar echoes, while noise can create unfavourable reflection characteristics for the material, which potentially leads to a loss in operational efficiency.

John Leadbetter, Managing Director of VEGA Australia, says while the technology has been around for more than a decade, there was always the potential to improve it.

“With this in mind, VEGA developed the 80 gigahertz series of radars which had certain advantages over the previous 26 gigahertz series,” he explains.

“The new range were able to include a narrower beam angle and a better dynamic range to read signals better and faster.”

One of the Radar sensors released as part of this range is the VEGAPULS 69, which was the culmination of three years of research and development to respond to the market’s needs, particularly for grains handling.

Its improved dynamic range has the ability to make the returned echo a significantly stronger signal, allowing it to remain locked on to it for processing, even with constantly changing grain types.

The device was designed to be easy-to-use and able to adapt to existing process fittings, using a lens antenna instead of horns or parabolic dishes. It also contains an air purge option, allowing for periodic cleaning if required. Maintenance is kept low through an encapsulated plastic antenna or lens antenna integrated in the metal flange, making it unaffected by dust and build up.

The level transmitter operates at a frequency of 79 gigahertz, providing an enhanced focusing capacity.

This helps it to reduce the influence of background noise commonly found in complex internal structures such as silos and means the beam angle is only a third of the size when compared with previous models.

Bulk solids with a poor reflective quality are also able to be measured by the system due to the addition of new microwave components, allowing it to detect even the smallest of reflected signals.

The VEGAPULS 69 has a measuring range of up to 120 metres, with an accuracy plus or minus five millimetres, giving it flexibility to be installed on almost any silo geometry. It is ideal as a replacement for mechanical measuring systems, suitable for all flange sizes and existing wiring.

Installation of the sensors is relatively simple and is usually done by supplying units with a matching flange to the exiting tank process flange, a bracket mount of open top tanks, or a threaded version.

ABOVE: The VEGAPULS 69 provides accurate measurements even with significant amounts of dust and noise.

Australian Bulk Handling Review: March/April 2019 І 41

GRAIN HANDLING

Finding needles in a haystack: Selecting the right electromagnet Separation technology specialist, Eriez Magnetics, speaks to ABHR about what to look for when purchasing and installing a suspended electromagnet.

REMOVING DAMAGING TRAMP IRON when conveying bulk materials is an important step to effectively increase plant availability, protect expensive downstream processing equipment and deliver a clean quality product to the customer.

The Suspended Electromagnet (SE) is widely used when handling bulk materials across a broad spectrum of industries. When installed and maintained correctly, an SE magnet can operate effectively and efficiently for years under the harshest of environments.

Both manual and self-cleaning SE magnets are typically mounted over a conveyor belt to remove large pieces of tramp iron such as rebar, nuts, bolts and other steel contamination that represent a hazard to downstream handling, loading and milling operations.

42 І Australian Bulk Handling Review: March/April 2019

They also remove sharp metal rods, also known as pokers that damage or tear conveyor belts, typically at transfer points.

Selecting and maintaining the right magnet for the job is key to help ensure long-term satisfaction.

Selecting and Positioning SE Magnets SE magnets can be tailored for a number of applications, from static plants to bulk terminal loading/loadout facilities, ship loaders and even mobile equipment.

Key factors to keep in mind when selecting a magnet should be the burden depth, belt width, suspension height, position and tramp iron size and shape. Other factors are belt speed and incline, material

BELOW: Selecting the right magnet for the job is key to ensure longterm satisfaction.

Complete Packaging Lines Technical Support density and maximum lump size.

SE magnets easily capture large pieces of tramp metal such as fencing wire, discarded machinery elements, or pipe fittings, and can be designed for smaller tramp like an M24 nut or bagging needles. The larger the mass, the easier to pick up even through a deep burden layer.

The required magnet strength increases as the belt width and burden depth increases. For example, a 1066-millimetre square SE magnet suspended at 330 millimetres can pull tramp iron through 280 millimetres of burden. A wider belt with an increased magnet height will require a bigger magnet to pull tramp through deeper burden depths, with magnet manufacturers such as Eriez Magnetics able to provide SE magnets for belt widths up to 2440 millimetres.

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Standard vs. Custom Components SE magnets consist of several standard components necessary to provide the magnetic force required to remove steel contaminants. These include the coil, core, back bar and steel enclosure. Collectively, they comprise the magnetic circuit designed for the duty.

Fully immersing a coil in cooling oil helps to control heat and moisture – the greatest enemies of electromagnets – by keeping the coil relatively cool, maximising the magnet’s strength. Eriez is one of the only manufacturers to incorporate an expansion tank to ensure the coils are always completely submerged.

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Applications for Hazardous Areas For hazardous applications, Eriez can supply SE oil cooled magnets to Zone 22 specification.

Some SE magnets are air-cooled which are most often used in hazardous areas. For these environments, permanent suspended magnets can be used where the strength and deep reach of an electromagnet is not required.

Manual Clean vs. Self-Clean Manual clean SE magnets work well on low frequency tramp occurrences. The magnet is moved away from the belt and the power is shut down to release the accumulated tramp into a skip.

A higher incidence of tramp typically requires a selfcleaning option to continually operate and propel accumulated tramp from the magnet face. Self-cleaners don’t require manual intervention.

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DUST CONTROL

Eye of the storm: Vortex Global’s new ship loading spout Vortex Global has designed a new ship loading chute to reduce the environmental impact of grain dusts in ports.

RELIABILITY AND ENVIRONMENTAL SAFETY

LEFT: Each Grain Ship Loading Chute is custom designed to suit the customer’s needs.

44 І Australian Bulk Handling Review: March/April 2019

are some of the most critical design features for ship loading equipment.

Mark Schaberg, Vortex’s Chief Engineer, explains how the company has designed its new loading chute to help protect a port’s nearby neighbourhoods, waterways and surrounding ecosystems from grain dust emissions.

“Nowadays, ports worldwide consider pollution prevention a primary objective – paying special mind to reducing dust emissions and preventing cargo overflow or spillage,” he says.

“To address these concerns, it is critical to incorporate sophisticated engineering controls and dust control measures.”

The Vortex Grain Ship Loading Chute has been specifically designed to capture fugitive dust and prevent material waste. It is capable of loading more than 4,000 cubic metres of grain per hour, making it one of the fastest and most efficient loading solutions in the world.

Its discharge filtration system is located at the bottom of the chute and is used for additional dust control in chutes with longer extended travel distances. The discharge filtration system displaces dust-laden air from its source and separates dusts from the air, exhausting the cleaned air back into the atmosphere and entrains the filtered dusts back into the load.

Throughout the loading process, four highvolume exhaust blowers capture grain dusts in pleated polyester filter cartridges. An automatic pulse jet system uses high pressure compressed air to purge the filters and send the captured dusts down into the bulk carrier. By continuously purging the filters, it minimises material waste.

The filter cartridges are rated at efficiencies of 99.97 per cent at one third of a micron sizes,

RIGHT: The Vortex Grain Ship Loading Chute is capable of loading more than 4,000 cubic metres of grain per hour.

99.99 per cent at half micron sizes and 100 per cent efficiency at one micron.

Each Grain Ship Loading Chute is custom designed to fulfil the specific needs of a customer’s application requirements, including modifying the overall chute size to meet certain load rates or vertical travel distance requirements.

The chute is constructed from telescoping tubes which slide into one another as it retracts, which reduces the overall height and allows bulk carriers safe entry and exit at ports. These tubes are constructed from durable metal materials to protect the chute from the surrounding environment and abrasion from the grains being handled.

The chutes use a two cable, dual-drum, two-part reeving hoist drive system, which includes redundant features to limit travel at the upper and lower limits, as well as over and under speed conditions and cable tension monitoring. Further, its winch system has been designed at a five to one service factor.

ASK AN ENGINEER

DUST CONTROL

Q. Should I be concerned about the explosive potential of my process dusts?

ABOVE: In 2017, a corn dust explosion killed five workers, injured 14 others and reduced a facility to rubble.

BELOW: Dust Explosion statistics 2017.

(Cloney, 2019)

In this regular column, experts from specialist bulk materials engineering firm Jenike & Johanson answer readers’ queries around problems at their sites. In this edition, the company’s general manager, Grant Wellwood, explains the safety risks and explosive potential of dust.

ABOVE: Grant Wellwood is the General Manager for Jenike & Johanson in Perth and is passionate about applying the science of bulk solids handling to help people and organisations succeed. As a process engineer specialising in technology development, he experienced the pain of inconsiderate design (his own) early in his career. He can be contacted at gwellwood@jenike. com

A. If the bulk solids you are handling are oxidisable, you should definitely determine the explosive potential of the dusts inevitably generated by your processes.

When we think of process risk, we are often blinded by a cognitive bias known as the salience effect, more commonly referred to as the “squeaky wheels get the most oil”. This is often the case in many process developments when it comes to addressing risk elements, with the “wheels” being risk elements in the project’s master risk register and the “squeak” proportional to the rating it is assigned.

Now, this is not intrinsically negative as it makes

Events/Impacts Fires Explosions Injuries Fatalities

46 І Australian Bulk Handling Review: March/April 2019

sure the focus is on the elements that matter the most, as opposed to the ones with a higher level of professional interest associated with them.

But what if an important risk element is not on the list to start with, or has been assigned unrealistic likelihood or consequence score? According to this common model, it might not get the attention it demands until it is too late.

Explosive dust is a typical risk element that fits into this category. Many materials which are inert when they are in lump form are still chemically oxidisable, explosively so when they are finely divided, and whenever you handle materials, you will generate dust.

Dust Related Reportable Loss Incidents Global (2017) 169 68 163 13

Therefore, the first step in an assessment of your process dusts is to determine whether they are actually combustible. Any material that will burn in air in a solid form can be explosive when in a finely divided form. Combustible dust is defined by National Fire Protection Association (NFPA) 654 as “Any finely divided solid material that is 420 microns or smaller in diameter (material passing a US No. 40 Standard Sieve) and presents a fire or explosion hazard when dispersed and ignited in air.”

Common examples include coal, sawdust, plastics and certain chemicals, and many otherwise mundane organic materials such as grain, flour, starch, sugar, powdered milk, cocoa, coffee, lime, and pollen.

Powdered metals (such as aluminium, magnesium, and titanium) can also form explosive suspensions in air if finely divided.

While this is a broad classification, how many times have you had the explosive potential of dust from your process materials quantified? If

any of the bulk solids you handle as part of your process (feeds, products, intermediates, additives, etc) are combustible, it is prudent to have them properly tested and assessed. Even products like mineral concentrates (Department of Mines Western Australia, 2019) are oxidisable and prone to combustion if and when they dry out. It’s also important to also test systems and peripherals such as dosing plants and dust controls for their risk potential.

If materials and wastes processed have an explosive potential, then there is a risk likelihood factor. This will need to be itemised on the register and an appropriate consequence score should be considered.

There is a sad history of major loss associated with dust explosions, many of which appear in the Combustible Dust Database (Cloney, 2019). Every dust related event has potential for significant loss and the number of organisations that think it could never

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DUST CONTROL

TOP: Figure 1. Breakdown of industries reporting dust related loss events-2017 MIDDLE: Figure 2. Breakdown of materials reported as being involved in dust related loss events -2017 BOTTOM: Figure 3. Equipment cited as being the root causes of dust related loss events -2017 REFERENCES: Chemical Hazard and Safety Board (CSB).

(2019). www.csb. gov/. Retrieved from Factual Investigative Update-Didion Milling: www.csb. gov/assets/1/20/ final_didion_factual_ investigative_ update.pdf?16220 Accessed February 6th, 2019 Cloney, C (2018), “2018 Mid-Year Combustible Dust Incident Report – Version #1” DustEx Research Ltd. Retrieved from dustsafetyscience. com/2018-Report

OTHER 24%

WOOD & WOOD PRODUCTS 28%

INK & PAPER 4% AUTOMOTIVE & METAL WORKING 11%

FOOD PROCESSING 13%

AGRICULTURE & GRAIN HANDLING 20%

NOT DETERMINED 10% OTHER 15%

WOOD 30%

PAPER 5% METAL 8% FOOD 32%

Cloney, C. (2019,).

Combustible Dust Incident Database. dustsafetyscience. com Accessed February 6th, 2019 Department of Mines Western Australia.

(2019). Department of Mines, Industry Regulation and Safety. Retrieved from www.dmp. wa.gov.au/ Documents/Safety/ MSH_SB_001.pdf Accessed February 6th, 2019 US Department of Labor. (2019).

Combustible Dust in Industry: Preventing and Mitigating the Effects of Fire and Explosions. Retrieved from Occupational Safety and Health Administration: www.osha.gov/dts/ shib/shib073105.html Accessed February 6th, 2019

DUST COLLECTOR 16% UNIDENTIFIED CAUSE 30% STORAGE SILO 14%

OTHER 22%

48 І Australian Bulk Handling Review: March/April 2019

OTHER STORAGE 8% ELEVATOR/ CONVEYOR 10%

happen to them seems to be increasing year on year.

In terms of the industries, materials and devices involved, the year on year trends are relatively consistent, indicating the lessons are not being learnt. Statistics from 2017 show that wood and wood processing was the industry that reported the most incidents (figure 1), with wood as found to be the most frequent material involved in a loss event (figure 2). Bagfilters topped the list of the equipment cited to be the root cause of loss events, followed by storage silos (figure 3).

One of these incidents in 2017 statistics was the Didion Milling dust explosion, which killed five people and injured thirteen more. The investigation report (Chemical Hazard and Safety Board, 2019) should be compulsory reading for anyone with a process involving oxidisable dusts.

So, if you think your project could be at risk, you should get proactive and undertake a dust hazard risk analysis (DHA). While there are many good general reference documents like the US Occupational Health and Safety Administration (OSHA) bulletin Combustible Dust in Industry, they are often not well suited to the incidental facilitator.

Conducting a comprehensive DHA is a specialised skill that ties back to bulk solids handling, system thinking and solution development. Fresh and experienced eyes can add a lot of value in this context, so to avoid distracting the core team from their mission, engaging an external resource to handle the issue is usually the best investment.

There are four main factors to look for when selecting a suitable DHA partner: •H istory of testing powders, working with bulk solids and analysing the issue of dust generation, •A ppreciation of standard test scoping, sample sizing/ receipt/processing, testing, and data interpretation/ presentation, •A bility to see your value chain as a system and provide guidance on engineering solutions for safe dust handling as opposed to a simple factual report and/or impractical solution, • Experience Do you have a bulk solids handling question? Jenike & Johanson has developed the science of bulk solids flow and specialise in applying it to solve the most challenging bulk solids handling problems. So why not put us to the test with your question? The harder, the better.

Note: The advice here is of a general nature. Specific solutions are very sensitive to their circumstances; therefore, you should consult with a specialist in the area before proceeding.

SAVE THE DATE

1ST - 3RD APRIL 2020

MELBOURNE CONVENTION & EXHIBITION CENTRE

DUST CONTROL

Transfer point optimisation key to productivity improvements Kinder Australia’s range of transfer point optimisation products have helped quarries significantly reduce dust and increase productivity.

BELOW: Transfer points are a critical component of an effective conveyor system.

A VICTORIAN QUARRY MAINTENANCE TEAM was quick to notice a decrease in production at its site.

A transfer point located under a tertiary crusher was a source of constant, excessive material spillage and dust emissions. Material turbulence was generating massive amounts of dust during the tertiary crushing process, which was ultimately escaping and causing significant emissions from the conveyor belt system.

With a 2.5 metres vertical impact drop height from the cone crusher and material lump size of minus 60 millimetres, there was evidence the conveyed material was pooling and not moving in the direction of the belt.

A combination of conveyor belt sag and inconsistent conveyor idler profiles had given way to ineffective skirting systems, which further aggravated dust emissions and ongoing spillages at the quarry.

Neil Kinder, CEO of Kinder Australia, says the core of bulk handling operations involve transporting materials from one conveyor belt to another, while avoiding spillage, damage to the material and conveyor

50 І Australian Bulk Handling Review: March/April 2019

belt, making the transfer point a critical component of an effective conveyor system.

“By closely identifying, evaluating and optimising existing belt loading, handling plants can reduce many unpleasant on-site issues and address the safety issues of dust emissions. This process also leads to improving and extending the service life of the conveyor belt,” he says.

The maintenance team reached out to Kinder Australia, which recommended they overhaul the conveyor system by fabricating a new tail section and installing a K-Impact Belt Support, K-Sure® Belt Support System and the K-Ultra Seal® Skirting System.

Kinder’s K-Sure Belt Support System has been designed to provide stable support for a troughed conveyor belt by reducing the number of rotating conveyor components. It also eliminates belt edge sag, helping increase the effectiveness of the skirting seal.

Belt sag is often caused as a result of too few idlers being installed at the loading point. K-Sure helps to correct this by using the existing conveyor idler frames and load carrying the centre conveyor roller.

Wing rollers are then placed by the support system’s universal adaptor brackets and low friction polymer support rails.

Mr Kinder highlighted the K-Impact Belt Support’s modular system’s assistance in stabilising the load at the transfer point, which in turn improved material containment while avoiding additional maintenance and labour costs.

“The key to measuring efficiency of transfer points involves maintenance teams to continually monitoring and assessing the conveyor system before and after the load transfer point and making any necessary adjustments”, says Mr Kinder.

The K-Sure Belt Support System has also been used to address ongoing belt sag issues at a quarry in Ormeau, Queensland. The quarry produces around 400,000 tonnes per year and handles greywacke with gritty characteristics.

Weight pressure of the transferred material loading was causing major conveyor belt sagging issues between the supporting rollers, which allowed

material to spill through the gaps between the skirting and conveyor belt and get caught between them, causing permanent groove lines on the belt’s top cover.

The conveyed material was also causing dust emissions requiring containment, which used up valuable labour resources to. The K-Sure Belt Support system’s low friction ultra-high-molecular-weight polyethylene slide surface bars instead of rollers and lack of moving parts helped minimise maintenance.

It also meant there was no requirements for replacing rollers in the foreseeable future.

Recent additions to Kinder Australia’s product line include the K-Dynamic Belt Support and K-Flexal® Elastic Belt Support system, which have been engineered to allow for better absorption of energy to provide an even weight dispersion of the bulk material.

Cost advantages from this include an improved wear life for the conveyor belt and its components and a reduction in maintenance.

Kinder Australia is equipped with a team of Application specialists, who have highly technical industry knowledge. They can provide in-depth evaluations and recommendations on transfer point design optimisations and help bring about measurable

  

productivity and profitability enhancements for quarries.

“Kinder Australia has over time developed an excellent reputation and established a proven history of designing transfer points and engineering solutions that resolves our customers’ most challenging bulk materials handling problems effectively,” Mr Kinder says.

“We have also created opportunities for further productivity gains, through extension of production assets, minimising shutdowns and labour resources.”

ABOVE: The K-Impact Belt Support helps stabilise the load at the transfer point.

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DUST CONTROL

Keeping dust down in concrete batch plants Enmin Vibratory Equipment has developed a solution to keep concrete flowing in batching plants while reducing dust emissions.

ENVIRONMENTAL PROTECTION AUTHORITIES (EPA) around Australia have guidelines for dust control to prevent excessive dust generation during loading and unloading.

EPA Victoria explains airborne dust reduces air quality and may have adverse effects on health, while a construction materials company was fined thousands of dollars by the NSW EPA for poor dust management.

One of the most common ways to reduce dust in concrete batching plants is to keep the material moist, though this can have negative impacts on material flow characteristics.

Moist materials on a hot day can lead to a bin or silo drawing moisture into the holding material, making it sticky and difficult to move. Additionally, natural compaction means the material may become trapped within the bin or silo, significantly impacting a plant’s ability to ensure materials such as fly ash, sand, gravel or aggregates flow in a safe and efficient manner.

This was the problem Enmin Vibratory Equipment was tasked to solve for an Australian concrete batching plant with a steel holding silo.

The solution the company would implement was the installation of an industrial turbine vibrator, which was able to meet EPA guidelines for both dust and noise control. It operates at around 10,000 vibrations per minute, transferring high frequency but low amplitude forces to break the particle bonding and promote material flow.

Turbine vibrators use centrifugal force generated by an unbalanced rotor to provide vibratory forces.

They require no lubrication which significantly reduces the amount of maintenance required and makes them ideal for hygienic environments.

Due to their design, turbine vibrators produce less noise than standard vibrators and are often significantly quieter than factory requirements.

After seeing how effectively the vibrator operated, the customer installed a further seven throughout its plants.

Positioning was key for the turbine vibrator, because if it was placed incorrectly, it could have led to further compaction of the material. For this reason,

Enmin performs full site audits and inspections to best understand where to install its equipment.

Bulk concrete transport operations also often face compaction problems, especially when t long distances or poor road conditions are involved. When a load arrives after a long or bumpy journey, the bulk of the material may discharge easily but a significant amount can be left clinging to the trailer body.

To counteract this, truck operators are often forced to raise the body of the trailer high and rock the truck to dislodge the materials, posing potential safety risks and increasing wear on the vehicle’s brakes, clutch and hydraulics.

Industrial vibrators can help provide a costeffective solution for these tip trucks, with the operator able to remain within the cabin as the device removes compacted materials from the trailer.

Industrial vibrators for the mining, quarrying and transport industries can’t take a one-size-fitsall approach due to the vast potential combinations of materials and equipment design. There are a wide variety of industrial vibrators, including electric, hydraulic and pneumatic models.

For example, aluminium components can’t be used for underground mining operations due to the risk or sparking against rusty steel, meaning the material components used for a vibrator need to be taken into consideration.

ABOVE: Industrial turbine vibrators use centrifugal force generated by an unbalanced rotor to provide vibratory forces.

BELOW: Turbine vibrators produce less noise than standard vibrators.

For more information visit www.enmin.com.au

Australian Bulk Handling Review: March/April 2019 І 53

MINING EQUIPMENT

Flat out like a lizard: thyssenkrupp’s new mobile stacking bridge thyssenkrupp Industrial Solutions has taken its next step in mobile mining with the upcoming release of a new mobile stacking bridge, the lizard.

WHAT DO YOU GET WHEN YOU COMBINE A conveyor bridge with a tripper car? The answer is a lizard. thyssenkrupp Industrial Solutions has developed a new mobile stacking bridge it calls lizard, to provide the mining industry with a flexible and mobile machine for heap leaching and dry tailings stacking.

The lizard decouples the crawler-mounted tripper car from the conveyor bridge, allowing it to be controlled independently of the bridge. By doing so, transitions between the bridge segments are now easier as there is no stress from a travelling tipper car on top of the bridge.

As the loads on the bridge sink, the overall construction of the bridge outweighs the additional chassis and structure of the tripper car, saving weight and costs accordingly while also allowing for larger dump heights and longer outreaches.

Burhan Osmani, engineer at thyssenkrupp Industrial Solutions and the inventor of the lizard, explains that since the tripper car is not travelling on the bridge, the loads for dimensioning the

54 І Australian Bulk Handling Review: March/April 2019

bridge are significantly reduced.

Operators can benefit from a slimmer, lighter bridge structure, lower bridge height, smaller bridge crawlers and lower ground pressure. The same lightweight design can also be used for the reclaiming bridge, with fatigue issues caused by cyclic loads from the tripper car eliminated, reducing maintenance and increasing availability.

“With longer conveyor bridge systems, the lizard pays off with lower investment cost and less fatigue issues on the bridge structures,” says Stefan Ebert, thyssenkrupp Global Product Lifecycle Manager.

A key advantage of the lizard is its multicrawler chassis, which does not have an override control, instead using what the company calls a “float system” attached to the tripper car. The two crawlers with no steering cylinders ensure the lizard has unrestricted manoeuvrability in all directions. The system can be attached to any crawler to avoid the large turning circles of conventional gearing systems.

BELOW: The lizard combines a conveyor bridge with a tripper car to provide flexibility.

LEFT: Operators can benefit from a lighter bridge structure, lower bridge height and lower ground pressure.

“To be able to flexibly control the mechanically independent multiple crawlers is a game changer in mobile mining equipment,” says Paulo Costa, thyssenkrupp’s Head of Mining Systems.

The float gearing system gives the lizard operational flexibility. For example, when a stacking row is completed, the tripper car is either

at the front or rear end of the bridge. Before moving to the next stacking row, the tripper car has to turn to its crawlers through 90 degrees in the direction of bridge movement without impacting the performance of the system. This means the tripper car and stacking bridge can move backwards or forwards as one.

Register Online Now for the 3-day event Papers received on the folllowing ARE YOU A DESIGNER / MANUFACTURER / topics: RESEARCHER / OPERATOR OF BULK SOLIDS HANDLING SYSTEMS / EQUIPMENT / STORAGE? Storage / Handling: characterisation; bin, hopper, chute & stockpile design; If so, you can now expand your capabilities by joining simulation & calibration; life-cycle the Australian Society for Bulk Solids Handling. costing and maintenance; mixing, The Society has a mission to enhance the discipline of bulk sampling and segregation; wear solids handling through research, education and sound engineering practice.

For further information on the Society’s activities, constitution and registration procedures, contact: Australian Society for Bulk Solids Handling The University of Newcastle University Dr, Callaghan, NSW 2308 Phone: (02) 4033 9039 Email: Danielle.Harris@newcastle.edu.au

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www.newcastle.edu.au/icbmh-2019 Australian Bulk Handling Review: March/April 2019 І 55

EQUIPMENT

Hydraulic solutions for harsh situations Hydraulic tool specialist Enerpac has introduced a range of new products to help maintain, repair and construct heavy machinery and plant.

UNDER A HOT AUSTRALIAN SUN, IT IS NOT

BELOW: The XC Cordless Torque Wrench has been designed for situations where a cord could cause a tripping hazard.

uncommon for the temperature to rise above 40 degrees Celsius in many mining operations.

The Department of Primary Industries and Regional Development reports that these temperatures have been on the rise in the last 40 to 60 years, with regions such as the Pilbara expected to get even hotter.

In addition, mining, maintenance and processing operations can result in the release of dust into the air, creating an environment requiring robust equipment.

Hydraulic tool specialist Enerpac has released two new tools into the Australian, New Zealand and Papua New Guinea markets that are able to withstand these pressures: the XC Series Cordless Torque Wrench Pump and the LG-Series Lock Grip Pullers.

The XC Cordless Torque Wrench uses 28-volt lithium ion technology to power swift and precise hydraulic bolting and fastening on remote sites where a cord could cause potential tripping hazards.

56 І Australian Bulk Handling Review: March/April 2019

Darryl Lange, Enerpac National Sales Manager, says the latest XC Torque Wrench pump complements existing cordless pumps proven in other applications such as mining, rail, construction and maintenance of heavy machinery.

“Enerpac designed this product with a highstrength, fiberglass reinforced composite housing to be able to provide superior durability in the demanding job site environments that our customers are typically working in,” Mr Lange explains.

“The XC-Series Cordless Torque Wrench pump is ideal when you need the lightweight portability of a battery pump with the precision and power supplied

by Enerpac hydraulics.”

It features an interactive pendant that can be operated in manual or auto-cycle mode and allows the operator to store a set operating pressure. The pump has an easily accessible and adjustable relief valve for precise pressure control along with a bladder reservoir that allows the pump to be used in any position.

The pendent can provide visual feedback with LED indicators and vibrates when tasks are completed. The pump itself has an integrated handle and carrying strap for portability. It is applied with two 28-volt/ 5-amp hour batteries that use lithium ion technology to ensure it has maximum battery performance and a quick one-hour charge time.

“This latest XC pump complements Enerpac’s market leading range of hexagonal and square drive professional bolting technologies, backed nationally

by Enerpac’s long-established service and supply networks to ensure optimum uptime and reliability,” Mr Lange adds.

Enerpac’s new LG-Series Lock-Grip Pullers similarly have been designed for the harshest operating conditions to help in the removal of shaft mounted parts. The pullers are available in compact, mechanical and hydraulic versions to provide an alternative to the often laborious and sometimes damaging hammer, impact and heat process.

They are designed to pull small-to-medium sized wheels, sprockets, bearings and other shaft mounted

RIGHT: The LG-Series LockGrip Pullers are suitable for harsh environments.

parts and have a locking mechanism to prevent the jaws slipping during the pulling action.

The Hydraulic Lock-Grip Pullers are able to apply up to 55 tonnes of force thanks to a 700-bar hydraulic cylinder, allowing it to remove larger objects up to 660 millimetres in diameter.

Other features of the Lock-Grip Pullers include synchronous jaw movements to enable entire pulling jobs to be performed by a single operator, new leg design to improve reach and enable use on thicker objects and a spindle protector to prevent damage to the spindle when pulling against a flat surface.

“The new Lock Grip pullers have been designed for a greater reach from the same diameter spread, allowing for the removal of thicker objects,” Mr Lange says.

“Enerpac offers a complete line of pullers with the widest range of sizes, capacities and styles.

All are made of high-strength steel alloys that are dependable, providing years of trouble-free operation, even in the harshest environments.”

Phone: 02 4928 5600 Email: sales@reliable.com.au

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CHUTE DESIGN

Roy Hill extends conveyor belt life Conveyor belt developer ContiTech helped Roy Hill improve its main belt’s wear life without a costly shutdown.

ROY HILL’S CVR030 FIXED STACKER BOOM conveyor belt had shown what the company considered an unacceptably short wear life performance, sometimes as low as one month.

The company, a 55 million tonne per year iron ore mining operation in Western Australia’s Pilbara region, aimed to maximise the return for each tonne produced from its mine and was looking for ways to optimise its operations.

A belt changeout would have been significantly expensive, as it would require a new belt, splice kits, labour and a 70-hour shutdown required for the replacement operation, leading to around 750 kilotonnes of lost production.

Unsurprisingly, Roy Hill decided to find a way of improving the belt’s wear life instead.

Following a comprehensive assessment, design changes were made to the chute to reduce the direct impact to the belt, which was also upgraded to a ContiTech Monsterhide GX ST1600 19/6 High Impact Resistance Belt, which features a breaker fabric two millimetres above the cords in the top cover.

58 І Australian Bulk Handling Review: March/April 2019

ContiTech’s new breaker fabric design was selected for its ability to handle high impact energy without cutting or gouging while the new chute design was chosen for its ability to significantly reduce the impact energy transferred into the belt.

After installation, ContiTech’s engineering team estimates showed the new belt had the potential to last through the scheduled October 2018 major shutdown, six times longer wear life than the previous belt.

This proved to be the case, with the boom belt changeout occurring during the scheduled shutdown, with wear monitoring showing there was still a fair degree of wear left, even after six months of operation.

Additionally, the belt has exhibited the most linear wear recorded at Roy Hill across all processing plant belts, with no visual signs of belt gouging when it was changed out. Since the belt’s installation, the trigger point for replacement had been eight millimetres above the breaker fabric or 10 millimetres above the cords, selected conservatively in response to the rapid

BELOW: Roy Hill’s CRV030 Fixed Stacker Boom was in need of an upgrade.

RIGHT: This graph shows the even wearing of ContiTech’s Monsterhide belt exhibited the most even wear across the width of the belt that has been seen on any conveyor at the PSA except for the Scrubber feed conveyors.

degradation of the previous belt and chute design and significantly more conservative than any other belt on site.

A major benefit from the redesign is that Roy Hill now has an accurate understanding of the belt’s performance and life expectancy, giving the maintenance team confidence in future

changeout decisions.

Jane Macey, Roy Hill’s Head of Engineering, says the company is very satisfied with the outcome.

“ContiTech’s team, using their expertise and latest product technology, have really lifted this part of our operation to a point where we now have tangible, provable production output improvements as well as significantly lower costs,” she says.

Scott Little, Business Development Manager for ContiTech Australia was also pleased with the results.

“You don’t often see a graph showing such beautiful, even wear across the breadth of the belt like this,” he explains.

“Roy Hill are definitely very happy too, because they’ve now asked us to check and assess several other conveyors at Roy Hill to see if we can help improve things even further for them.”

LEVEL MEASUREMENT

SWR’s measurement management Level measurement device manufacturer SWR has recently assisted two companies monitor the material flow of its operations.

BELOW: The MaxxFlow HTC has low maintenance costs due to its design.

TWO GERMAN COMPANIES RECENTLY required an increase in their level measurement technology.

One produced lime and manufactured a wide range of products across its cement and lime plant, including coarse limestone grains, lime sand, finely ground unburnt limes or highly reactive lime hydrates.

Lime was delivered to the grinding plant and then ground in the ball mill into fine lime, which was then carried out of the mill and transported by different screw conveyors and a bucket elevator to a silo. Between the last screw conveyor and the bucket elevator, the material quantity was measured in freefall.

The company needed the ability to measure quantity of the different lime products during fabrication processes and to get a more detailed overview of the fabricated material volumes. To do so, it reached out to Level measurement device manufacturer SWR, which installed the MaxxFlow HTC. The MaxxFlow HTC measures high mass flow rates from the exit of the pre-feeding devices, such as screw conveyors, air slides, rotary valves or bucket elevators. It has been designed to have low height and be wear free, cutting maintenance costs

down significantly. Additionally, simple calibration systems were taken into account to ensure ease of use.

The customer installed the MaxxFlow HTC in different places around the site, including on included lines to minimise installation costs.

Silo Monitoring A German refiner of kaolin and crystal quartz also needed to upgrade its capacity for level measurement.

It extracts raw materials in an opencast mine and, as part of the quartz sand recovery process, the extracted material is washed and dried, with a downstream sieve helping to achieve the required grain size. After the milling and screening process, the material is then transported by conveyor belts to feed into a silo.

The company wanted to monitor the material being conveyed, especially the feeds, and required a device that could detect the material flow at the silo entry with a flow/no flow signal transmitted to the control room to control the transport state and avoid a wrong filling of the silo SWR assisted the company by installing a FlowJam microwave detector for contactless monitoring of material flows, looking for flow or now flow signals. The system was installed on a pipe at the silo entry and generates a signal through a relay circuit, which is then sent to the control room to help initiate a material stop.

The system is able to immediately recognise misguided material flows and has led to an overall increase in quality and process reliability.

Bintech Systems are the Australian distributors of SWR products. They offer a full range of level switches and transmitters, flow metres, pressure transmitters, temperature transmitters and analytical instruments.

On-site technical support and advice is available, along with custom built products to help provide a personalised service for each customer.

For more information contact Bintech Systems at 1300 363 163 or at sales@bintech.com.au

60 І Australian Bulk Handling Review: March/April 2019

SCREW CONVEYORS

Bulknet boosts productivity by breaking bulk blockages Bulk materials handling specialist Bulknet helped a New South Wales company increase its throughput with a triple screw live bottom bin.

A NSW-BASED MULTI-NATIONAL COMPANY had encountered an issue with its product hanging up in the hopper of a dust collector.

The company’s product line was often sticky and formed clumps that went on to cause blockages in the bottom of the hopper as well as the rotary valve and the blow line returning to the product stream.

These blockages were causing productivity issues across the company, which is why it reached out to screw conveyor solution specialist Bulknet to design, manufacture and install a solution.

Discussions began with the company to find a design that would fit the company’s needs, and address their multiple criteria. By working closely with the company to understand the reasons behind the change, Bulknet created a detailed concept of what their planned system would entail.

The design that was selected removed the bottom of the hopper and replaced it with a triple screw live bottom bin. It uses a small screw with opposing flights that brings the product to the centre outlet, then through a rotary valve to a belt weigher and inline screw onto an aero mechanical conveying system.

Because of the sticky nature of the product, the system required steep angles on chutes to avoid any hang ups. Additionally, the company examined the technical aspects of redesigning the bottom of the dust collector and the use of an air lock to encourage material flow.

The winning design was selected as it achieved a specific throughput, recertified the structure and ensured safe working methods. Site meetings and measurements were then taken to ensure the system’s modular design would be quick and easy to install.

Included within the electrical installation was seven motor and gearbox combinations, with lowand high-level sensors, that were then integrated into the site’s automation system. Bulknet worked with local mechanical and electrical contractors that knew the site to ensure there was a smooth transition.

The system is now up and running, after a short commission and some minor tweaks.

Bulknet has more than 50 years of experience as a designer and manufacturer of screw conveyors. It also specialises in providing custom built screw feeders, multi bin dischargers, dewatering screws, screw classifiers and centreless screw conveyors. Factors such as extreme material heat, lumpy materials, corrosive materials, materials that require high containment and systems operating under pressure or a vacuum are taken into account by Bulknet’s engineering team.

A number of potential flight types are available for bulk handling systems, from standard screws with a pitch spacing equal to the diameter suitable for most conveyors, to notched flights to provide a gentle mixing action, through to a centreless flight for extremely sticky and fibrous materials.

“By working closely with the company to understand the reasons behind the change, Bulknet created a detailed concept of what their planned system would entail.”

LEFT: The highlighted items make up the components of the system.

Australian Bulk Handling Review: March/April 2019 І 61

CHUTE DESIGN

talk

Best practice in chute design – Part two STEVE DAVIS In his regular BULKtalk column, Steve Davis* of Rio Tinto considers the basics of bulk handling that sites often struggle with.

In Jan/Feb 19 he shared his insights gained from more than 30 years in bulk materials handling. *Steve Davis is the principal advisor – bulk materials process at Rio Tinto, based in Perth.

Steve has worked in bulk handling for 30 years, for both resource companies and professional engineering firms, in Australia, South Africa, the Middle East and Canada.

His experience encompasses such commodities as iron ore, coal, potash, phosphates, petcoke, sulphur, sands and grain.

The second in a series of articles addressing systems involving chutes. Steve Davis explores how the multiple functions of such systems can result in designs that leave safety, operation and maintenance legacies.

ACCESSORIES Chute systems include a wide range of different accessories, including pulleys, drives, doors, samplers, magnets, sprays, dust collection, lights and sensors. These components, and their design and location, all contribute significantly to how well the chute system functions. The interfaces between chute and components can make access and maintenance difficult and unsafe (Figure 1).

CONVEYOR DRIVES Drives are often part of a chute system, and usually have external features such as oil circulation and cooling, brakes, electric motor cooling and external runback devices. When designing a chute, it is important to use proper interface management to

ensure these external features to not limit access to chute flange bolts bearing lubrication, and even some integral drive components such as gearbox level and temperature sensors.

Arrange these components with space and maintenance access and avoid compromising access to other parts of the chute system, and to personnel egress routes. Give sufficient walkway access around drives for maintenance. Overhead monorails may facilitate removal of components. Consider the height of the lifting equipment and slings, the weight of components, and location and direction of travel for the components to a landing zone. Incorrectly designed monorails lead to unsafe use.

Components such as walkways, handrails and structure may hinder removal of drives for repair, or access to the chute or pulley. When removing additional parts and structures, the process can be time-consuming and complex. Consider the location of electric cables, overhead structures, dust extract, pipework and the like in design. If electrical and control components allow, consider quick-disconnect fittings instead of direct wiring.

PULLEYS RIGHT: Chute with Accessories. Flanged spray bars difficult to remove; multiple bolts on top flange, door latches vibrate open, door access is at a difficult height and there is no safety mesh, conduits mounted to the chute, conflict between bearing, cleaner and cable (inset). Chute penetrations are safe, but pulley is not guarded behind the support frame.

62 | Australian Bulk Handling Review: March/April 2019

Head chutes incorporate pulleys. Pulley bearings should be outside of the chute and supported from a separate structure with alignment provision. The bearing location and support base should ensure force transmission into the base of the bearing housing. Bearing housing bolts should not be subject to shear or tension loads. Pulley alignment is critical for many reasons and a sufficient threeplane adjustment should be provided in the design.

Pulleys wear out; lagging, bearing, shaft locking element or shell. Design the chute system to facilitate pulley removal from the chute quickly and safely at some stage in the life of project. Provide a method that does not require belt cutting and if a special pulley-lifting device is required, provide methodology.

Snub and launch pulleys on head end drives present an additional maintenance problem due to limited access, and can compromise chute design.

Design without a snub pulley is feasible in most situations. If included, the design should provide for a safe methodology for maintenance and removal of pulleys.

CHUTE PENETRATIONS Pulley shafts penetrate the chute, as do belt cleaners and other components. Any penetration must consider the chute as a complying safety guard. This usually results in bolt on covers, plates or other devices that are adjustable and removable to provide for alignment and maintenance.

Sometimes the design omits this need, and unsafe chute systems result (Figure 2).

Many chute penetration covers are light duty, easily damaged and difficult to remove and replace.

Consequently, there are safety violations on chutes from inability to refit covers. There are proprietary covers available from belt cleaner and other suppliers.

However, some rubber covers may not comply with guard standards, so be sure to ask for covers that are safe and functional.

DOORS AND HATCHES There are many examples of chute access doors that may have been acceptable 30 years ago, but do not meet minimum safety and practicality requirements today.

Chute systems incorporate doors and hatches for inspection and access. Each door is a breach in the conveyor safety system, and the design must consider the impacts of this. Tool removable internal protective mesh or bars allow opening of inspection doors while the plant is operating at minimal personnel risk (although an assessment is required). Mesh and bars are a guard and must comply with safety standards. If there is no mesh, then there must be a sign indicating machine isolation is required before opening doors.

Doors and hatches must be in a suitable location, be the appropriate size and perform the correct function. Many doors and hatches open into an area of the chute that has no viewpoint or has no maintenance function, making them less useful.

Doors and hatches without permanent personnel access are common and are occasionally located metres up in the air or on top of chutes, which is a poor ergonomic choice. Working at heights is a major safety concern, and if doors must be there for a

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CHUTE DESIGN

chute for a better design, avoiding compromises in operation and maintenance and potential health, safety and environment shortfalls. Consider different sampling systems if the reduced sample accuracy is acceptable

IN CHUTE TRAMP MAGNETS The best tramp separation is from suspended magnets over the conveyor free fall discharge.

To be effective, the magnet must be sized for the duty, located close to the trajectory and at a matching angle. Magnet support, maintenance access, electric cable support, tramp metal discharge arrangements (manual, cyclic or selfcleaning and likely a tramp discharge chute) all affect the operation and maintenance of many other chute components. Non-magnetic materials may also be required for pulley, cleaner and chute.

Magnets also need extra guarding and signage due to the magnetic field.

Over-belt suspended magnets are an option if some reduced functionality is acceptable. Consider non-magnetic materials for stringers, idler frames and idler rolls.

ABOVE: Access door, 1, with safety bars (Bendtech) note: 2, access platform to door; 3, inclined face adds gravity force to door operation; 4, good pulley shaft guard; 5, few bolts on chute flange; 6, dust extract (poor design for flow) and conduit have to be removed to split chute.

reason (such as inspections), then permanent access to them is preferable.

Many chute doors and hatches do not have usable or safe access, with pinch points often common in the door itself, and between door and adjacent chute and structure. Doors that block walkways when open, cut off egress in emergencies, or can trap personnel between the door and handrail or structure, are also common. Doors can become sails in windy conditions so may need to be latched open. Doors on inclined chute faces require more force to open than on vertical faces and go “over centre� past the half-open point. This creates a safety consideration. Figure 3 shows this.

Latches keep doors closed in operation, and release to open. Several styles of door latch are in use.

Sea container style double latching systems function well and remain closed. Rotating latches can vibrate open, or need locking so tightly it is difficult to open them manually. Wedge locks lead to unsafe use of trash as hammers, levers and similar.

IN CHUTE SAMPLE CUTTERS Falling stream sample cutting in chutes gives the most representative samples. These sampling systems add complexity in almost all aspects of chute system design. They affect ore flow design, need extra space and chute height, need maintenance access and add a sample discharge in an already congested area. Select a supplier early and integrate the sampling system into the

64 | Australian Bulk Handling Review: March/April 2019

MOVING CHUTES Diverters, splitters, shuttles, ploughs and trippers all provide means to divert a chute discharge to two or more positions. These chutes add complexity and additional height to the design. There are several more components to consider and most will need maintenance. Safety considerations are more complex, as parts of the system move from place to place, with multiple discharge points, and everything still requires safe access to operate and maintain.

Common operational shortcomings with moving chute systems, apart from lack of safe maintenance consideration, result from change of position on the run. It is relatively easy to accommodate stop-start flow changes where no chute discharge occurs in the interim locations. Where material flow is continuous during chute movements, consider ore flow paths during movement. Spills, build up on structure and rails, and damage and entrapment of components are common. Fixed and moving chute component interfaces often need added flexible seals to contain ore and dust flows.

Flop gate diverters or splitter chutes are complex, often having operational and maintenance problems such as jamming, partial bypass, accelerated wear, or unguarded actuators. It is difficult to get accurate flow splitting with a bottom-hinged gate. Consider top swung diverters or shuttling chute components to overcome these problems.

CAPACITY AND BLOCKAGE All chute systems can become bogged or blocked, meaning each should have blocked chute detection installed. The detector shuts down the upstream feed to the chute before any serious damage results, but also stops potential injury and mess resulting when the chute spills over. The detector is not expected to generate spurious upstream shut downs through incorrect operation.

Chute capacity above the blocked chute detection point should contain any run on from the upstream feed, such as run-down of the feed conveyor, without damage or uncontrolled overflow. For large rundown capacities, such as from an overland conveyor, use either a large chute, even a bin, or a chute with a controlled overflow facility to a safe collection location.

Select the block chute detection point and detector type so that normal flow through the chute, in dry dusty, wet or other conditions does not trigger shut down. A short delay between detection and shutdown may prevent spurious trips from fly rock.

Multiple blocked chute detectors may be beneficial in large chutes. Generally, the speed at which a chute fills from onset of blockage is too fast to monitor level in the chute. There are some developments that may give early warning of ore build up through change in vibration signature and allow for a controlled shut down.

Detectors should always fail to the blocked

condition. Install blocked chute detectors so that they can be maintained with the chute still operating.

CONTAINMENT In addition to containing ore flow, chute systems have to manage dust and airflow generated by ore flow. There are many types of dust extraction and suppression systems available. They are only effective if designed into the chute system where the dust is generated. A convenient stub in air duct connection into the side of the chute is unlikely to provide sufficient control of the airflow in the chute to extract much dust (Figure 3 for example). Model dust flow as an extension to discrete element modelling to confirm dust extract locations. Dust extraction and wet suppression combined will result in blocked air ducts from wet dust.

Skirt systems are installed at the inlet to the chute, and at the discharge to a receiving conveyor.

Skirt systems can cause significant belt damage.

There are many different styles of skirt available, and no universal solution to containment. Select a skirt system proven for the duty, and one that is easy and safe to maintain. Provide a method to safely access skirts for adjustment and maintenance, including removal of mandatory guarding. Consider a slider bed under the skirts to provide better wear and sealing.

These are available in many forms, with and without centre rolls, and with impact absorbing devices.

RIGHT: This chute could be better: 1.

Inaccessible heavy access door; 2. Too many bolts for top cover; 3. Trip hazard from adjuster (top adjustment inside chute); 4. Unsafe gap; 5. Cleaner cannot be inspected or removed; 6 Welded to structure prevents removal; 7.

Pulley inaccessible, dismantle structure and chute to remove.

Australian Bulk Handling Review: March/April 2019 | 65

MEMBER PROFILE

I have been a member of ASBSH since…

2007.

I am a member of ASBSH because…

MEMBER PROFILE:

Timothy Donohue In each issue, ABHR profiles a member of the Australian Society for Bulk Solids Handling (ASBSH).

We speak to Timothy Donohue, Manager of TUNRA Bulk Solids.

It’s one of the only societies with a focus on bulk materials handling.

I got into bulk handling...

Through my undergraduate degree – the University of Newcastle is one of the only universities that teaches bulk materials in their mechanical engineering degree. After my undergraduate degree I completed my PhD at Newcastle which focussed on the permeability and porosity of structures, specifically stringy and compressible materials. Following that I worked with TUNRA which is where I have been ever since.

I am currently researching …

The connection between bulk materials and numerical modelling, and how this connection can be optimised to deliver the most value to the end user. This sounds general but at times we get buried in the detail of the problem and it’s worth taking a step back to ensure the resolution of the tool we are using (e.g. Discrete Element Modelling) is in line with the expectations of the intended outcomes of the study.

I love my current work because...

The variety. In my role with TUNRA I have been involved in many different types of projects, both in Australia and internationally, and have had the chance to work with many people across many sites. Given the nature of TUNRA, where we exist as an interface between industry and academia, we also are involved in new research developments and technologies.

In my role it’s important to...

Have an appreciation for bulk materials – both their behaviour and their variety. Many general comments can be made based on experience, but it is important to note that all materials behave differently, and the

66 І Australian Bulk Handling Review: March/April 2019

best materials handling decisions are made with specific test data.

My most creative engineering solution to a problem was…

During my PhD I needed a large number of flexible uniform size cylinders for a benchtop experiment.

The solution was to cut up fishing line – lots of it. I used a Lego creation to automatically feed the fishing line to a guillotine that ran via an electric motor and used this to cut fishing line into 5-millimetre pieces over two days. The system was reliable and consistent – the standard deviation was 0.5 millimetres. In solving this task, I got to combine my love of learning with my love of Lego.

My career highlight is...

Winning the AW Roberts Society Award in 2015. Professor Alan Roberts is a pioneer in bulk materials and has a vast amount of experience and knowledge, so to be presented with this Award, by Alan himself, is a memory I will always look back on fondly.

I am inspired by ...

Those who achieve great things. I have been lucky enough to meet some inspiring people, including academic and business leaders, as well as some absolute legends of Australian sport, and I try and learn something from each of these people I meet.

The most valuable lesson I have learned is ...

Always keep an open mind, always ask questions, and never stop learning.

When I am not working you will probably find me...

At home with my family (I have 3 young boys) or out on my bike. I’m training at the moment for a half ironman in May this year, so I have to do a bit of swimming and running as well, but my main love is the bike and I try and spend to spend as much time as I can on my pushy.

My plans for the future are …

To keep learning.

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Australian Bulk Handling Review: March/April 2019 І 67

AD INDEX

SUBSCRIBE

To Australia’s only publication 100%-focussed on bulk solids handling. It covers conveyors, silos, engineering, dust control, powder handling, weighing, pneumatics and much more, in such industries as mining & metals, ports and terminals, grain, fertiliser, sugar, salt, foods, milling, resins, cement and woodchips.

ADVERTISERS INDEX Advertiser

Page

Ag Growth International ........................................... Cover Allied Grain Systems........................................................23 ASBSH - Australian Society for Bulk Solids Handling ....55 Aspec Engineering...........................................................51 Astec Australia .................................................................27 Bintech Systems ..............................................................31 BulkNet ............................................................................35 Concetti S.P.A...................................................................45 ContiTech.........................................................................12

www.bulkhandlingreview.com

VOLUME 24, ISSUE 2 | MARCH/APPRIL 2019

www.

bu

lk ME 23 handlingr , ISSUE ev 6 | NO iew.com VEMB ER/DEC EMBE R 2018

VOLU

In this issue: Grain handling feature Dust control safety Designing better chutes

Dana SAC Australia ..........................................................47 DSH Systems Ltd .............................................................59

alyse andr How to an wea uipment reduce eq ature fe g lin Grain hand ns tal solutio gi di on s Focu

w.com ngrevie GUST 2018 lkhandli LY/AU www.bu23, ISSUE 4 | JU VOLUME

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Food & Advancpowder handlin New in ed valve bag g feature: Processinovation in 3Dtechnology ng hem p for nuscanners trition

Enmin Vibratory Equipment ...........................................37 Eriez Magnetics Pty Limited ............................................39 ESS Engineering Services and Supplies ...........................6 Fenner Dunlop Conveyor Belting Australia ......................9

More Information Visit

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1 year

2 years

$99.00 (inc GST)

PWB Anchor Limited .......................................................14

6 issues of Australia Bulk Handling Review and

Reliable Conveyor Belt ....................................................57

1 copy of the Equipment and Services Guide

REMA TIP TOP ..................................................................33

$179.00 (inc GST)

Rotolok Australia .............................................................63

12 issues of Australia Bulk Handling Review and 2 copies of the Equipment and Services Guide

Stanley Engineered Fastening Australia .........................21 thyssenkrupp Industrial Solutions ...................................7 TUNRA Bulk Solids Handling Research Associates ........19

Subscribe today: www.bulkhandlingreview.com/subscribe

Vega Australia ..................................................................25

Australian Bulk Handling Review: March/April 2019 І 67

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