ABHR Mar/Apr 2021

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VOLUME 26, ISSUE 2 | MARCH/APRIL 2021

In this issue: Choosing the right belt Asset write-offs for automation Designing belt feeders

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CONTENTS MARCH/APRIL 2021

16

22

36

44

6 Industry News

26 Picking the right industrial vibrator

58 Life cycle costing - A case study

11 Women in Industry column

28 Measuring up to the Internet of Things

61 Using jackets for offshore berth construction

12 No Stopping Progress

30 Not wasting a drop

68 Member Profile: Geoff Liddle

14 Asset write-offs accelerates automation

32 New deal stacks up for Astec Australia and OPS

BELTS

34 Lifting Australian manufacturing

42 Uncovering the benefits of belt covers

36 Realising safer, faster, and more accurate tank scale calibration

44 Choosing the right belt type

16 Ploughing through plant commissioning delays 18 Bulk bag discharger ups efficiency of cocoa powder line 20 Tradition drives Sumitomo

38 Conveyor solution for infrastructure spoil

22 Nelson Silos goes for gold 24 Supporting vertical integration for Manildra

55 Approaches to the calibration and application of DEM models for cohesive bulk materials

40 New belts for Lucky Bay

48 Designing the right belt feeder 52 Conveyor belts built for almost any application

www.bulkhandlingreview.com

VOLUME 25, ISSUE 8 | MARCH/APRIL 2021

In this issue: Choosing the right belt Asset write-offs for automation Designing belt feeders

INTELLIGENT BRAKING TO SECURE OPERATIONAL EFFICIENCY

NO STOPPING PROGRESS Stromag, one of Altra Motion’s brands and a global supplier of braking systems, has installed a new, Internet of Things enabled braking system onto a container crane at one of the largest inland ports in the world.

ABHR speaks to to Altra Motion’s Christian Klein and Rex Sinclair to find out how the bulk handling sector can benefit from implementing similar technologies.

For the full story, see page 12.

4 І Australian Bulk Handling Review: March/April 2021

AUSTRALIA

EDITORIAL

AUSTRALIA

REVIEW

Published by:

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 Editor William Arnott E: william.arnott@primecreative.com.au Business Development Manager Rob O’Bryan E: rob.obryan@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 Art Director Blake Storey Design Kerry Pert, Madeline McCarty Subscriptions T: 03 9690 8766 E: subscriptions@primecreative.com.au

www.bulkhandlingreview.com 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.

Domo arigato REVIEW

As part of the 2020 Federal Budget, the Australian Government introduced a $1.5 billion Modern Manufacturing Strategy.

In a release at the time, Federal Industry, Science and Technology Minister Karen Andrews said a resilient and competitive manufacturing sector should be at the heart of a modern Australian economy.

The centrepiece of the strategy was the $1.3 billion Modern Manufacturing Initiative, which aims to help the Federal Government strategically invest into projects that help manufacturers scale up and create jobs.

Identified within the initiative were six priority areas: resources technology and critical minerals processing, food and beverage, medical products, recycling and clean energy, defence, and space.

One critical piece of technology has the potential to tick all of the boxes, helping industries scale up, improve their competitiveness and build more resilient supply chains – automation.

According to the Australian Department of Industry, Innovation and Science, around 44 per cent of jobs are highly susceptible to automation.

These jobs are often the ones humans arguably shouldn’t be doing in the first place. They’re dull, they’re dirty and can put human lives at serious risk.

This technology is no longer just a science fiction pipe dream – in fact it has been in use for years at this point. Large mining company such as Rio Tinto, BHP and Fortescue Metals Group have been automating their trucks, trains and plants to stay competitive. It’s not just mining either, the agricultural, logistics, and construction industries have started embracing the technology.

However, while the technology brings with it new opportunities for productivity and safety, there’s a somewhat prickly topic that will continue to come up – jobs.

The Australian Centre for Robotic Vision released a Robotics Roadmap in 2018, almost three years ago, that said to properly harness the benefits of automation, concentrated programs that re-skill and support workers that lose their jobs will require development.

It further found that there is a lack of national focus on robotic technologies in areas where Australia can excel.

More needs to be done to encourage workers to re-skill into roles that add more value to a process that can’t be automated. Humans are capable of incredible feats of engineering and innovation. They must not be forgotten as technology drives forward.

William Arnott Editor - ABHR

Australian Bulk Handling Review: March/April 2021 І 5

NEWS

Ahrens builds $50 million grain export facility CONSTRUCTION, ENGINEERING, mining and rural infrastructure company, Ahrens, designed and built a $50 million grain storage facility for Bunge in Western Australia.

Works for the complex, located at the Bunbury port, included six 7300 tonne flat bottom silos, four 700 tonne hopper bottom silos, office and road intake buildings, as well as material handling infrastructure.

The project combined Ahrens’ inhouse capabilities including design, complete project management, manufacturing, site erection, and material handling equipment. Using in-house steel fabrication facilities, Ahrens also manufactured all of the structural steel and bases for the hopper bottom silos.

Being involved early in the design phase meant Ahrens were able to finalise more details up front and coordinate works more efficiently. This enabled Ahrens to incorporate all components of the project in the initial design and

Ahrens built six flat bottom silos, four hopper bottom silos, office and road intake buildings, and material handling infrastructure.

planning stage, minimising variations later in the project.

The provision of dual truck receival hoppers saw Bunge able to transfer grain at 1000 tonnes per hour via belt conveyors and bucket elevators to the bulk storage silos. The advantage of the custom designed and engineered conveying systems was that grain could be delivered to any of the 10 silos before being conveyed to the existing ship loader at the port.

Using a vertically integrated business model, Ahrens was able to provide a

cost-effective option for the client that provided them with 50,000 tonnes of storage capacity. The investment was the first step towards ensuring Bunge could supply its customer base all year round.

Ahrens delivered the project on time and on budget within a ten-month period.

Since the delivery of this project, Ahrens can now offer a full range of silo storage solutions, tailored to client’s specific requirements, designed and fabricated in its advanced South Australian facility and assembled on site by their skilled teams.

Concetti reveals new LAMPO automatic palletiser ITALIAN MANUFACTURER Concetti has released a new automatic palletiser for bags capable of handling up to 1800 bags per hour.

Called LAMPO, which means quick movement of a short duration in Italian, the machine excels when handling unstable products and partially filled bags.

Concetti has designed the machine with a focus for accuracy. Precise control of the bag overlap and the ability to compact the layers helps to provide stability while stacking and improves warehouse operations and load security during subsequent supply chain logistics.

The machine confirms each layer and

6 І Australian Bulk Handling Review: March/April 2021

uses full-height side compactors with a flexible, shell-type gripper head to stack pallets precisely.

The new PL-AA LAMPO can handle any type of bag ranging from one to 50 kilograms. Format changes are undertaken completely automatically in just over a minute, meaning there is no need for manual intervention. If necessary, the system can mount a multi-head gripper for use with bundles and cases.

A touch-screen operator interface provides the operator with a clear, easy to use panel for program selection a display of machine status.

LAMPO’s control system has been

designed to make programming complex pallet patterns quick and easy. With just a few strokes on the touchscreen, operators can compose layer patterns using a simple graphic interface.

The palletiser can be particularly efficient for the feed, pet food, seeds, fertilisers, chemicals industries, minerals etc. LAMPO is specially designed for rugged, heavy-duty palletising operations.

Concetti more than 45 years of experience in manufacturing packaging and palletising systems for bulk products. It provides customised solutions to satisfy every customer need, even the most demanding.

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NEWS

Queensland approves $300M alumina plant

Gladstone’s infrastructure and port facilities helped attract Alpha HPA to the region.

THE QUEENSLAND GOVERNMENT has granted planning approval to a $300 million high purity alumina (HPA) plant set to create 120 jobs and a new state export industry.

Queensland’s CoordinatorGeneral approved the application to build the plant in the Gladstone State Development Area (SDA).

HPA is the pure form of aluminium oxide and its desired physical properties include extreme hardness, thermal conductivity and chemical stability.

Alpha HPA has used its aluminium purification technology at a Brisbane demonstration plant, operating since July 2019.

Deputy Premier and State Development Steven Miles says this will see 120 jobs created locally.

“A material change of use application has been granted allowing advanced manufacturer Alpha HPA to build its plant within the Gladstone SDA,” Miles says.

“This means Gladstone is now one

8 І Australian Bulk Handling Review: March/April 2021

step closer to becoming the home of an exciting new industry, with the production and export of high purity alumina used around the world in neweconomy manufacturing.

“The high purity alumina will provide the raw materials used by lowcarbon growth industries including LED lighting and lithium-ion batteries for electric vehicles.”

Regional Development, Manufacturing and Water Minister Glenn Butcher says the government assisted in bringing Alpha HPA to Gladstone by conditionally making a large, 9.2-hectare site available.

“The extensive infrastructure and port facilities in the Gladstone region, an established industrial sector and skilled workforce all helped attract Alpha HPA to the Gladstone,” Butcher says.

“SDA, securing the plant over two potential interstate sites in Newcastle, New South Wales and Kwinana, Western Australia.

“Alpha HPA plans to produce 10,000

tonnes of HPA equivalent annually at Gladstone using their proprietary licenced solvent extraction and refining technology.”

Alpha HPA Managing Director Rimas Kairaitis says the company is looking forward to starting large-scale HPA production in Gladstone, currently set for early 2023.

“Alpha HPA looked at interstate locations in New South Wales and Western Australia but chose Queensland and the Gladstone SDA because of the facilities and access to key industry partners and infrastructure,” Kairaitis says.

“We have already signed a memorandum of understanding with Orica, who are also located in the Gladstone SDA, for the supply and offtake of the chemical reagents we use to produce HPA. “We are also progressing agreements in place with Gladstone SDA businesses for the supply of feed product and utilities.”

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EVENTS - WOMEN IN INDUSTRY

Women in Industry

Rachael Ashfield

WELCOME TO MY FIRST COLUMN as Ambassador for the Women in Industry Awards.

I am currently the Marketing Manager at an advanced automation company, and my career has been challenging yet rewarding so far.

I started out as the Executive Assistant to the Managing Director. My training and experience had provided me with a career in administration, but I felt I had more to be achieved.

Then five years ago, I was appointed

as Marketing Assistant. As I grew within the role I was seeking newer and more exciting challenges, and as a result invested a lot of time learning many aspects of the company’s product offering.

This proved to be quite complex and challenging, but extremely rewarding.

I am now in my fourth year as Marketing Manager and firmly believe that the more you strive, the more you will be fulfilled within your career.

In 2020 I was nominated by my peers for the Women in Industry Awards. This was a surprise to me, and I was honoured that my colleagues felt so highly about my efforts. The nomination itself was extraordinary, and then to reach the list of finalists and subsequently win the award was a personal and career defining highlight.

The Women in Industry Awards recognise outstanding success in industries traditionally dominated by men, including manufacturing, mining, engineering, transport and logistics and waste management.

My aim as Ambassador is to encourage you to nominate for these fantastic Awards, so that you receive recognition for your efforts in building a strong, well-

defined and lasting business.

Women bring alternative viewpoints and experiences to a business which often fosters creativity and change. Yet the career pathway for women can be quite challenging, especially in an industry that is not highly represented by women. The Women in Industry Awards give you an opportunity to highlight key aspects and career defining moments of your many years of success and dedication.

The journey is extraordinarily rewarding, and when you have been with a company as long as I have, you can dig deep into the knowledge base that you have built and realise you can contribute exponentially to your company, and industry more broadly.

I look forward to celebrating all of your success at the 2021 Women in Industry Awards.

Rachael Ashfield 2021 Women in Industry Ambassador

Nominations for the 2021 Women in Industry Awards are now open.

Visit www.womeninindustry.com.au to submit a nomination.

The awards recognise success in the manufacturing, mining, engineering, transport and logistics industries.

Australian Bulk Handling Review: March/April 2021 І 11

COVER STORY

No stopping progress Industrial Internet of Things technology is helping turn crane braking systems into smart devices. ABHR speaks to Altra Motion’s Christian Klein and Rex Sinclair to find out how the bulk handling sector can benefit from the cloud.

THE PORT OF DUISBURG, LOCATED on the Rhine River in Germany, is one of the largest inland ports in the world, accommodating 20,000 ships and 25,000 trains each year.

With the high volume of arrivals on a daily basis, a single delay can cause a knock-on effect across the entire supply chain, forcing the port operators to play

Altra Industrial Motion owns a wide range of brands across the motion control and power transmission sectors.

12 І Australian Bulk Handling Review: March/April 2021

an expensive game of catch up.

As a result, port operators began looking into ways to reduce any unscheduled downtime.

Christian Klein, the Global Product Manager for Altra Motion, says that port gantry cranes in particular have a need for the highest availability possible.

“If you imagine that a vessel needs to be unloaded with a crane, downtime can cause huge chaos and extremely high monetary losses,” he says.

“Braking systems on port cranes have a high duty cycle as they are always opening and closing when a container is getting lifted and positioned.

“As the brakes are safety components, they are the last device in the safety chain and protecting the load from falling down, even if the drive train is collapsing. Any downtime or malfunctions on the brake leads to a complete shutdown, as the safety system is affected.”

The port operators selected Stromag, one of Altra Motion’s brands and global supplier of braking systems, to install a new, internet of things (IoT) enabled braking system that could allow a predictive maintenance solution to be established on an older container crane.

The company had already been developing new ways to combine its products with IoT technology to produce ‘smart’ machinery.

Working closely with the Port of Duisburg, the company installed specialised sensors on a TDXB thruster service disc brake and a SHC18 spring-applied, hydraulically released emergency disc brake. The service brake acts on a disc installed on the high-speed shaft of the crane’s winch drive. The emergency brake acts on a disc mounted to the gearbox low speed shaft. An SHPU hydraulic power unit and disc/hub assemblies were also supplied.

A Series 51 geared cam limit switch, with a multi-turn absolute encoder, was also included. It provides feedback about the hook’s actual positioning, speed and turning direction of the elevated movement. These brake sensors and a limit switch encoder exchange data through a programmable logic controller (PLC), via a cloud connection.

Klein says the system goes beyond simply monitoring for faults.

“The problem with traditional monitoring is that it only gives data on downtime, which for a port, is far too late. Once we have a sizable sample of data uploaded to the cloud, we can start rationalising it intelligently to proactively influence maintenance. We will utilise a modular-based modelling program to achieve this,” he says.

“When complete, we can rely on artificial intelligence (AI) to identify parameters that affect the performance of key systems on the crane, which

allows for highly targeted predictive maintenance scheduling. This will eventually promote uptime and logistical efficiency for Duisport.”

One of the main priorities for Stromag when developing this system was security. All of the data is protected and encrypted before being analysed by the company’s own data specialists to analyse critical events and to be able to use the artificial intelligence for selflearning and analysing the incoming information.

The collected data can also be used to create augmented reality (AR) models of the crane and its systems. Stromag aims to provide remote maintenance support to Duisport further down the line using the data models in combination with an e-commerce platform to streamline the procurement of replacement parts.

brakes, you can see exactly what parts may need replacing and when. Traditionally, to obtain that information would require shutdowns for manual inspections, which takes time and can miss hard-to-see problems,” he says.

“Data not only helps operators improve their process but can also improve the products available through enhanced research and development.”

Cloud-based systems also allows users to access information remotely.

In a large country like Australia, this can mean significant reductions in travel times. For example, a mining company with operations in the Pilbara can have an operator in Perth – 2000 kilometres away – access the system to monitor the equipment.

Altra Industrial Motion, the parent company of both Svendborg and Stromag, owns a wide range of brands

“When complete, we can rely on artificial intelligence (AI) to identify parameters that affect the performance of key systems on the crane, which allows for highly targeted predictive maintenance scheduling. This will eventually promote uptime and logistical efficiency for Duisport.”

Bringing bulk brakes to the 21st Century IoT-enabled technology, similar to the systems installed at the Port of Duisburg, can also be included in traditional bulk handling systems.

Conveyor systems that transport coal, iron ore and grain at ports around Australia face similar issues to the German port. The ability to detect small problems before they escalate can save a business from eye-watering downtime costs.

Svendborg, another of Altra Motion’s brands, has developed a preventative maintenance system that allows bulk handlers to access realtime data about their operations.

Rex Sinclair, National Sales Manager at Altra Motion Australia, says this advanced warning system is much more cost effective than the traditional method.

“With Svendborg’s IoT-enabled

across the motion control and power transmission sectors. It employs more than 10,000 people at sites around the world, with an extensive authorised reseller and service centre network in Australia.

The company’s brands focus heavily on research and development, sharing their advancements with Altra to be distributed to the market. This, along with factory trained technicians and engineers, allow Altra to provide the latest technology to bulk handling sites.

Sinclair says predictive maintenance technology is only going to keep growing, as customers realise the productivity gains it provides.

“Some companies can be a bit frightened of change – preferring to trust what already works than take a chance with something new,” he says.

“However, with automation on the horizon, the ability to remotely monitor equipment will become more vital.”

Australian Bulk Handling Review: March/April 2021 І 13

AUTOMATION

Asset write-offs accelerates automation The Federal Government’s instant asset write-off scheme is allowing bulk businesses to make massive investments into their capital infrastructure. ABHR learns more about how the scheme is also encouraging new automation.

AT THE RELEASE OF THE 2020 Federal Budget in October, the Federal Government accounted a new scheme that would make investing into new equipment much more appealing to businesses.

Businesses with a turnover of up to $5 billion, around 99 per cent of Australian businesses, could immediately deduct the full cost of eligible depreciable assets worth up to $150,000 and first used or installed by 30 June 2022.

The move aimed to unlock investment, expand the productive capacity of the nation and create tens of thousands of jobs. Treasurer Josh Frydenberg at the time said small businesses will buy, sell, deliver, install, and service these purchases.

“This will provide a targeted cash flow boost that businesses across the country desperately need,” he said. “Normally, businesses would have to return to profit

Aurora focuses on automating the grain, seed, flour, cement, fertiliser and stockfeed industries.

14 І Australian Bulk Handling Review: March/April 2021

Robots excel in jobs that are usually dull, dirty or dangerous, and can improve safety by removing humans from the equation.

before they can use their losses, however, these are not normal times.”

The scheme has been updated and remains on going, scaled back slightly to affect businesses with an aggregated turnover of less than $500 million.

Several bulk handling equipment businesses have been quick to take advantage of the scheme.

Braden Goddin, Sales and Marketing Manager for Aurora Process Solutions says many of its customers have been able to invest in automation, thanks to the funding.

“The schemes have been set up to get businesses up and running – to encourage growth. Say, for example, you’re a grain or seed processor and struggling to find seasonal labour due to COVID-19 workplace restrictions.

“As the owner of a small to medium sized business, you may not have the time to apply for grants or your cash flow faces competing requirements. Investing into capital equipment can be a bit like putting the cart before the horse if you are focusing on the week-to-week operations.

“Grants like this offer the potential to upgrade with less risk and get past that barrier for investing – and it can be as easy as asking your accountant if you’re eligible.”

Aurora Process Solutions provides semi- and fully- automated machinery for packaging, conveying, conditioning and palletising of commodities. Based in New Zealand with operations in Newcastle, New South Wales, and distribution centres in Melbourne and Sydney, the company provides on-site consultation, project management, installation and servicing across the Oceanic region.

The company focuses on the grain, seed, flour, cement, fertiliser and stockfeed industries, which Goddin says are facing a labour crisis.

“Viability of manual labour jobs in these industries is under significant pressure from a variety of directions, including changing societal norms and automation – a phenomenon that has repeated itself since the industrial revolution,” he says.

“The workforce is ageing, and recent

graduates are much less likely to go for local manual labour positions, instead they’re looking to upskill themselves through university and other higher education.

“A lot of these jobs are also not wellsuited for humans to be doing. They can be risky, repetitive and relatively lowskilled.”

In the research paper Mechanical Boon: will automation Advance Australia?, The Australian Department of Industry, Innovation and Science estimates that 44 per cent of Australian jobs are highly susceptible to automation.

Robots excel in jobs that are usually dull, dirty or dangerous, and can improve safety by removing humans from the equation. One of the benefits of automation is that robots don’t get tired, bored, or distracted, meaning there is less rework required and often significant safety benefits.

The researchers also found new opportunities and jobs begin to flourish as industries moved to automate processes,

freeing up resources to employ workers in high value, high skilled and high paid roles.

Goddin says COVID-19 restrictions revealed how important the role of automation was for risk mitigation “Many businesses have seen the economic shock that COVID-19 had. Now we know the market can be turned upside down at a moment’s notice, and it will most likely happen again. Whether it’s geopolitical tensions, a pandemic or the climate, economic shocks can happen at any time and they don’t discriminate,” he says.

“The biggest thing we saw our customers having to deal with was managing their manual labour workforce.

Simply getting labour into a factory safely required significant time and expenditure.

To make matters worse, it was also during a time of peak demand, but manufacturers often simply could not meet it.”

With the new instant asset write-off scheme in effect, Goddin says small- and medium-sized businesses have even less

Aurora provides semi- and fully- automated machinery for packaging, conveying, conditioning and palletising.

barriers to modernising their processes and gain a competitive edge.

“The scheme allows businesses to leap years ahead in their capital investment plans without endangering their cash flow positions or exposing themselves to unwise risk,” he says.”

“It’s a valuable opportunity to grow your business and prepare for the future.”

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DIVERTER PLOUGHS

Ploughing through plant commissioning delays A diverter plough has been installed on one of the Pilbara’s newest mine sites, helping the operators commission a processing plant further upstream in the operation quicker than expected.

DYNA ENGINEERING HAS INSTALLED a new way of diverting material off a conveyor belt before it reaches the head pulley at one of the newest and largest iron ore sites in Western Australia’s Pilbara region.

Designed, engineered and manufactured in WA in just 12 weeks, the Diversion Plough can be fitted onto a typical conveyor system to redirects or discharges material off the belt at a selected point.

Thomas Greaves, General Manager for DYNA Engineering says that while the discharging of material may seem like a common occurrence, doing so at a point which is not the end of the conveyor can be problematic due to its size and scale and the forces involved.

One of the key issues is how to divert material from a troughed belt.

Early stages of fabrication, a view from the front showing the extended wear life treated blade being fitted.

16 І Australian Bulk Handling Review: March/April 2021

An overhead rear view of the Diverter Plough under construction. Over 15 tonnes of locally sourced steel work were used in its fabrication.

“This is one of the largest Diverter Ploughs installed in the Pilbara region,” he says. “At maximum operating capacity, the double-sided V blade can push 4500 tonnes per hour of iron ore

fines from the 1800-milimetre width belt into purpose designed chutes.

“This has given the operators the ability to commission the processing plant further upstream in the operation

The chutes are over four metres in height with an assembled weight of six tonnes each.

more quickly than expected and create a stockpile while the train loader is still under construction.”

The Diverter Plough assembly The assembly consists of several major parts including the blade, belt support mechanism, discharge chutes, structural frame and guarding to protect against hazards created by the diversion process.

For this project, the V blade and chutes were designed using Discrete Element Method (DEM) software. This optimises material flow, wear plate life and energy consumption. The V blade has a customdesigned nose. It utilises the best available wear materials to ensure long life between maintenance intervals. The chutes are over four metres in height with an assembled weight of six tonnes each.

HDPE used in safety guards As part of the overall Diverter Plough assembly, DYNA Engineering also incorporated latest technology highdensity polyethylene (HDPE) conveyor guards. These are made from recyclable material that is a robust and corrosion free alternative to conventional steel guards.

Greaves says the ‘X’ design in the mesh delivers more strength and better deflection properties than other HDPE guards on the market.

“Dyna’s patented X shape design increases the guard’s strength substantially (up to 60 per cent) in

comparison to standard HDPE square mesh panels,” Greaves says.

“As well as delivering reduced deflection, it is well above the minimum Australian Standard, which will help keep site personnel safer. Each panel, 2.2 metres in height and 1.1 metres in width, weighs less than 15 kilograms and was designed to comply with AS4024.3610 and AS4024.3611.

“Our engineers worked very closely with the client’s engineering team, designing and producing a detailed and customised solution that met all the customer’s needs, specifications and requirements.”

How it works A custom-designed belt support system lifts the belt from the normal troughed position into a flat diversion position underneath the V blade. The belt lift process takes less than one minute to actuate and complete the transition. When material diversion is no longer needed, the belt can be lowered at the push of a button, permitting the conveyor to carry material underneath the V blade and allowing normal operation.

Approximately 300 kilograms of recycled HDPE material was used to manufacture the guards locally in the company’s Bayswater workshop and headquarters.

Australian Bulk Handling Review: March/April 2021 І 17

BAGGING

Bulk bag discharger ups efficiency of cocoa powder line A Southeast Asian cocoa manufacturer has improved productivity and hygiene with a Flexicon bulk bag discharger.

SINGAPORE-LISTED JB COCOA initially began as a processor of wet cocoa beans in the 1980s. It has since grown into a major cocoa producer in Southeast Asia, with a total processing capacity of 180,000 tonnes of cocoa beans per year.

JB Cocoa’s core business is the production and sale of cocoa ingredients, such as cocoa butter, cocoa powder and cocoa mass.

Around 50,000 tonnes of cocoa beans are processed each year at its East Java, Indonesia facility, around 30 kilometres from the port of Surabaya. The beans are processed through a system of cleaning, roasting and winnowing to separate the cocoa nibs. These are then ground into cocoa liquor by a butter press to yield cocoa butter used to make chocolate and crumbled cocoa presscake that is pulverised into cocoa powder.

An electric hoist and trolley on a cantilevered I-beam enable an operator to raise and position the bag using a pendant, eliminating the need for a forklift.

18 І Australian Bulk Handling Review: March/April 2021

A portion of this is shipped directly to customers in one-tonne bulk bags, but most of it is processed into cocoa powder and packaged in handheld sacks.

To increase efficiency of its cocoa powder line, the plant installed a Flexicon Bulk-Out BFC-C-X bulk bag discharger.

This handles loose cocoa presscake being put in storage before it is reduced to powder and packaged for customers.

The discharger is configured with an electric hoist and trolley that ride on a cantilevered I-beam, allowing bulk bags to be loaded into the frame without the need for a forklift.

To connect a bag, the operator slips the bag straps into four Z-Clip strap holders of a bag lifting frame, and uses a pendant to hoist the bag into the discharger frame. A Tele-Tube telescoping tube pneumatically raises a Spout-Lock clamp ring, allowing an operator to

make a high-integrity sealed connection between the clean side of the bag spout and the clean side of the equipment.

With the bag spout secured, the operator pulls its drawstring, allowing the presscake to discharge into the surge hopper.

Releasing the telescoping tube’s air pressure allows the clamp ring to maintain constant downward tension by gravity as the bag empties and elongates to promote material flow. Additional flow promotion is provided by Flow-Flexer bag activators that raise and lower opposite sides of the bag bottom to promote complete discharge through the bag spout.

The 226 l capacity surge hopper with top-mounted enclosure is vented to a side-mounted Bag-Vac dust collector that creates negative pressure within the sealed system to prevent displaced air and dust from escaping into the plant environment.

The enclosure also serves to contain spillage that might otherwise escape through seams in the bag and folds in the spout, and is equipped with a hinged access door and folding bag shelf, allowing manual dumping of under-filled sacks.

A rotary valve at the hopper outlet meters the presscake into a pneumatic conveying line that moves it to a storage silo. From there, it is mixed and milled into six different recipes of cocoa powder and packed into 25-kilogram bags.

Constructed of stainless steel finished to sanitary standards, the discharger is certified for operation in food-grade environments.

“The use of the Flexicon bulk bag discharger provides a safe and hygienic way to unload cocoa cake from bulk bags,” says JB Cocoa’s Redi Koerniawan.

“It ensures efficient unloading with little to no dust released into the processing environment.”

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DRIVES

Sumitomo Hansen drives can be found in Australian timber mills, food manufacturing facilities and robotic technology.

Tradition drives Sumitomo The Sumitomo Corporation was founded on the principles of prudence, and sound management. ABHR speaks to Robert Proietti and Wayne Dunstan to learn how these values affect its bulk handling offering.

Fast Fact Sumitomo Hansen is able to offer this fast turnaround thanks to its Australian assembly facility.

The company decided to build a presence in the Australian market in 1996, starting with a small office in Parramatta.

Since then, the company has moved to an industrial assembly facility to improve availability and stock holding. With service facilities in Sydney and Mackay, it continues to expand to meet the increasing requirements of its customers.

The company’s product range also expanded in 2011, following the acquisition of Belgian-based gearbox manufacturer Hansen Transmissions.

The deal aimed to boost Sumitomo’s industrial gearbox sales in Australia, Europe and South Africa.

Dunstan, who started with Hansen originally, says the acquisition expanded Sumitomo’s product portfolio to include a more comprehensive range of products including multi megawatt gearboxes and drive solutions. This has allowed Sumitomo Hansen to position itself in the market as a respected and supportive mechanical drives business.

20 І Australian Bulk Handling Review: March/April 2021

THE SUMITOMO CORPORATION CAN trace its lineage back more than 400 years ago, when Masatomo Sumitomo opened a book and medicine shop in Kyoto.

During his time, Masatomo wrote a document called ‘Monjuin Shiigaki (Founder’s Precepts),’ which described how a merchant should conduct business.

In his writings, Masatomo emphasises the importance of honesty, prudence, and sound management to develop a trustworthy character rather than just pursuing money making endeavours.

The company soon grew, and entered into the copper mining business, opening the Besshi Copper Mine after obtaining permission from the Tokugawa Shogunate in 1691. The Besshi Copper Mine continued operations for 283 years, forming the backbone of Sumitomo’s business.

Robert Proietti, Managing Director of Sumitomo Hansen, says the company still follows the founder’s principles of honour and respect, working to provide reliable and long-lasting mechanical equipment to its customers.

“We provide quality products and innovative solutions to help our customers solve their complex challenges,” Proietti says.

“Australian heavy industry needed a rugged, gear box solution for its heavyduty applications. The Cyclo Drive is designed specifically for the bulk handling

industry, capable of withstanding shock loads of up to 500 per cent, the highest in the industry.”

Cyclo drives don’t use a traditional gear design, instead they use cycloidal discs that operate in compression rather than shear, creating a smooth, rolling movement to eliminate tooth breakage.

Proietti says the design also spreads the load across two thirds of the reduction components, enabling the units to absorb and dissipate shock better than a typical concentric drive.

Wayne Dunstan, National Product Manager at Sumitomo Hansen, says another benefit of the Cyclo is its extreme longevity.

“In high-impact applications, the Cyclo outlasts the traditional gear type boxes,” he says. “Its durability reduces replacement intervals, reducing the amount of money and time spent during scheduled downtime. Often we have found the Cyclo Drive exceeds lifespan expectations.”

Over time, the Cyclo design has been modified and updated, to provide greater power from a smaller footprint. While popular in the bulk handling industry, the drives can be found in Australian timber mills, food manufacturing facilities and robotic technology.

Included in the Cyclo range is the Buddybox family of mid-size gear reducers and gear motors. The Buddybox

input uses a cycloidal design to provide increased durability and reliability when compared to traditional bevel-helical gearboxes, enduring shock loads of up to 350 per cent.

Sumitomo Hansen also manufactures Paramax industrial gearboxes. These come in medium to large-sized bevel and helical combinations and use a compact design with a high dedendum strength.

The helical shaft mounted (HSM) speed reducer is one of the most popular products in the company’s portfolio, with more than one million units sold globally.

The HSM can be used in conjunction with a motor mount, backstop, torque arm, belt guard, belts, breathers, sheaves and harsh duty seals, locally engineered to suit every application.

The company’s drives are available in a wide range of sizes. Its wide torque range can provide for forces from 24Nm to 736 KNm, while its wide ratio coverage includes 6:1 to 658,503:1.

“On any bulk site, we’ve got a gearbox

for any application,” Proietti said. “From the smallest of the small for a weigh station, to a multi megawatt conveyor applications and everything in between.”

“We’re driven by the market and carry a significant amount of stock to react to customer demands. We can have a geared motor ready in one to two days and can deliver gearboxes within weeks,” he says.

For larger projects, Sumitomo Hansen provides in-house engineering consulting to determine the best product for the

Cyclo drives use cycloidal discs that operate in compression rather than shear, creating a smooth, rolling movement that eliminates tooth breakage.

drive application. The company takes advantage of its global network, utilising engineering expertise from Singapore, Japan and Belgium.

This engineering has seen the company invest into designing and creating smarter, more connected Industry 4.0 technology to improve its material handling offering. It is part of Sumitomo’s guiding philosophy, penned centuries ago, to pursue the best interest of its customers through reliable equipment.

SILOS

Nelson Silos goes for gold Nelson Silos delivered a lime silo to the Karlawinda Gold Project at Newman in Western Australia. ABHR speaks to Eric Nelson, the company’s Managing Director, to learn more about the 8000-kilometre round trip.

A GOLD MINE, 30 KILOMETRES south of Newman, Western Australia, needed new infrastructure as part of a site expansion.

The site’s ball mill, which uses a The silo stands at about 25 metres tall, measuring in at about 4.6 metres in diameter.

22 І Australian Bulk Handling Review: March/April 2021

mixture of lime and water to separate the gold from the other material, required a new silo to feed the lime.

Lime, part of the cement range of materials, is a high-density product.

Where grain can reach 750 kilograms per cubic metre, lime can reach one tonne per cubic metre.

Eric Nelson, director of silo manufacturer Nelson Silos, says the system requires a robust pressure vessel to handle the dense, heavy material.

“Material is added to the silo through a pneumatic conveyor, which uses a heavy blower pipe and special, wear-resistant bends. Lime is a very abrasive material, so everything handling must be able to handle it,” he says.

“Aeration pads at the cone of the silo introduce compressed air at various time intervals to dislodge the lime and make it act like a fluid. Without this, the lime won’t flow on its own.

“It then reaches a rotary valve which measures the quantity required then drops it onto a conveyor.”

Nelson Silos was chosen to deliver the new silos along with all of its associated fittings, including the rotary valve. As part of its offering, the company also provided the civil foundation design.

Ease of maintenance was also a critical component of the silo’s design. The silo stands at about 25 metres tall, measuring in at about 4.6 metres in diameter and features mezzanine level access platforms to allow site staff easy access to service the rotary valves and vibropad equipment.

Ladders and platforms to the roof deck are also included to provide access to the dust collection and extraction unit, and an over/under pressure valve was installed.

To help change out the bends of the blower pipes that will wear with time, the roof deck has walk around access.

As the mine is located thousands of kilometres from Perth, the site was provided with a suite of spare parts for most of the mechanical items and wearheavy components.

Nelson Silo’s engineers also took the location’s environmental conditions into account, ensuring the temperature

variations between the Pilbara’s sweltering days and chilly nights wouldn’t affect the silo.

Nelson says the installation only took a couple of people three days to complete, thanks to the prefabricated nature of the company’s silos.

“The silo was transported in two, large pieces – about 18 metres long. Each section is manufactured, tested and fitted together in the factory environment, meaning we know the end product will be installed as intended,” he says.

“This significantly reduces the amount of site work required. That means less time working at heights around heavy equipment, making the work much safer.

“Traditionally, when buying a silo, it could take weeks or even months to be installed, costing an enormous amount in disrupted productions and labour.

This method keeps it all simple, safe and effective.”

Nelson Silos supply pre-manufactured silos for a number of different industries,

Nelson Silos has delivered silos to places thousands of kilometres away, like Darwin, Port Headland and Kalgoorlie.

from agricultural, to food, cement, plastics and mining.

With modern courier dispatch times, Nelson Silos can provide delivery of any spare parts required within a week. The company has made the conscious effort to source its components from Australian manufacturers and suppliers to support local business and reduce turnarounds.

Transport is a major part of the business, which is why the company has a number of full-time employees dedicated to logistics. Based in Rochester, Victoria, the company has delivered multiple

silos to places thousands of kilometres away, like Darwin, Port Headland and Kalgoorlie.

“We don’t use contractors because it gives us more control over the customer experience,” Nelson says. “Our delivery team can also do the installation side of things, with staff in the pilot cars for heavy transport vehicles able to get out and build them.”

“That’s one of our secrets for reducing time spent on site. The people handling the installation have done it literally 50 to 60 times before.”

STACKERS

Supporting vertical integration for Manildra Kilic Engineering’s Super Roo stackers are being put to use on the Manildra Group’s operations. ABHR finds out how the equipment stacks up.

THE MANILDRA GROUP, AN Australian agribusiness, isn’t afraid of going against the grain. While there has been an industry trend to focus on Sydney, the company has expanded its base in the town it is named after, in New South Wales.

This regional strategy has allowed the group to operate one of the largest milling facilities in the country and continue to find expansion into other regional centres.

To support this growth, Manildra has purchased two Super Roos from Kilic Engineering (KE), one of the fastest drive over hopper fed grain stackers on the market.

KE delivered the first Super Roo to the Manildra-owned Bellata grain handling facility in time for the 2020 harvest, where it was immediately put into service unloading triple semi-trailers to bunkers.

The machine is a prototype product

based on the field performance of the KE BunkerStacker range and delivered bunker load rates of 750 tonnes per hour.

The second machine was delivered to the Stockinbingal site as harvest activity moved south and was in service and ready as grain began to arrive at the site.

Jason Kilic, KE Managing Director said both of the machines were tested thoroughly, as part of the company’s rigorous factory testing regime.

“We were very confident the machines would perform and form an integral part of the Manildra operations,” Kilic says.

“Delivering, assembling, wet commissioning and supporting the machines in New South Wales amid travel restrictions triggered by the COVID-19 pandemic proved challenging for both the KE and Manildra teams at times.

Hats off to our Adelaide based team, to the Manildra site staff and to our NSW based sub-contractors for meeting these challenges so the machines could do their job and support Manildra’s grain handling strategy.”

KE is a mechanical engineering company based in Adelaide, South Australia. Owned and operated by the Kilic family since 1973, the company has a history of designing, manufacturing and installing a wide range of conveyors, material handling systems, structures and associated equipment.

It’s local suppliers, including Tristar Electrical, BL Shipway, CavPower and SEW Eurodrive, helped the company deliver its products, including the Super Roo Peter Sloan, Manildra grain buyer, says the investment into grain storage asset is the backbone of the company’s Australian-grown wheat.

“Customers can have absolute confidence in our supply chain from the paddocks to storage and then to our flour mills,” he says.

Kilic says he is proud to be part of the Manildra success story and shares common values with both companies, each being established last century and being 100 per cent Australian familyowned operations.

KE delivered the first Super Roo to the Bellata grain handling facility in time for the 2020 harvest.

24 І Australian Bulk Handling Review: March/April 2021

Dust and buildup on the antenna? No problem!

The future is 80 GHz: a new generation of radar level sensors

VEGAPULS 69 is designed specifically for level measurement of bulk solids.

Even in dusty conditions, it always provides precise readings. Dust in the silo or buildup on the antenna have no effect.

This radar sensor also features unrivalled focusing at a frequency of 80 GHz. Simply world-class! www.vega.com/radar

Wireless adjustment via Bluetooth with smartphone, tablet or PC. Compatible retrofit to all plics® sensors manufactured since 2002.

VIBRATORS

Picking the right industrial vibrator Mark Thompson, General Manager of Oli Vibrators, shares some of the tips and tricks he has learned when it comes to choosing the right industrial vibrator.

CEMENT DUST TENDS TO COMPACT under its own weight when stored.

This poses a problem for bulk handlers, as compacted cement does not flow easily, slowing production to a halt.

Industrial vibrators are a helpful tool in this situation, working to reduce friction between the material and the container wall, shaking it off and encouraging it to flow.

Mark Thompson, General Manager of Oli Vibrators, says vibration is an effective method of improving flow, efficiency and safety.

“Vibrators are used on hoppers, bins, feeders, chutes, and conveyors for all sorts of reasons. Some people want to improve the flow rate of material, while others use them to compact flour into bags or compact boxes,” he says.

“One of the things we focus on is increasing productivity with vibration.

When things get hung up, either from ratholing or bridging, it can be dangerous to just bang the container with a hammer.

Oli Vibrators works with customers across the bulk handling sector.

26 І Australian Bulk Handling Review: March/April 2021

Each vibrator with a two-year warranty.

“This is dangerous, to both the worker and the asset. Not only is it bad for your bones to be swinging around a large hammer constantly, but it’s also not good for your hearing. Some hoppers are also elevated, meaning you’ll have people working at heights with heavy objects – a recipe for disaster.”

Oli Vibrators works with customers across the bulk handling sector. Thompson says one day they might be installing a vibrator to help move jellybeans and the next day set up equipment to handle 300 tonnes of rock after it has gone through a crusher.

To do this, the company works closely

with the customer to understand the application the vibrators will be used in.

Factors like the type of material, its bulk density, moisture content, the volume required of the application, and what it is being installed onto. Oli Vibrators encourages the customer to provide drawings and specifications to help its engineers find the right solution to the flow problem.

Different materials will often have different requirements. Sugar, for example, is hydroscopic and sucks in moisture from the air causing bridging and hang-ups where plastics aren’t. For wet products, vibrators are available with a higher frequency and lower amplitude.

Another example is ammonium nitrate, which is used in fertilisers and explosives. It compacts under its own weight and is made up of small spheres.

Vibration is used to move the product out of vessels and into hoppers. Trucks in particular face issues transporting the product, as the material is compacts in transit.

Thompson says for this material, a number of additional factors need to be taken into consideration – namely the explosion risk.

“Oli Vibrators have three ranges of safety – standard, increased safety and explosion-proof. The latter uses heavy duty seals and built-in explosion chambers to ensure that if there is an ignition, it is confined to the motor itself

Using a hammer to improve flow can damage your hearing and bones.

and does not escape,” he says.

The company’s product range is rated at a T4 Temperature Rating and are manufactured in Italy. All of its products conform to international standards and are IECEx and IP66 rated. Oli It can supply vibrators the offer three kilograms of force to 26,000.

Each comes with a two-year warranty and are made from highquality materials to ensure they can handle heavy duty applications. As part of the warranty, Oli Vibrators provides full replacement or repair of the product, including internal and electrical componentry.

Thompson says the manufacturing process for the vibrators uses state-ofthe-art technology and testing.

“We claim to have a price to performance ratio that is second to none,” he says. “It’s part of our goal to remain affordable and available.”

“We keep a lot of stock on the shelf.

Our customers have a limited timeframe

to work in, and the equipment as soon as possible. If a business has a hang up and isn’t able to get its product out of a silo or hopper, we can be there straight away.”

This availability is driven, in part, by Oli Vibrator’s 22 different subsidiaries around the world. Stock can be shared across the company’s different branches to provide any items in needed that are

sold out locally.

“The vibrator market is competitive, so we rely on our high-quality products, technical expertise and the ability to provide all the specifications an engineer could possibly want,” Thompson says.

“We’ve got all that along with a global network to back us up and specialisation in vibratory equipment.”

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MEASUREMENT & MONITORING

Measuring up to the Internet of Things What happens when critical measurements are combined with the Internet of Things? VEGA Australia provides the answer.

INSTRUMENTATION SPECIALIST VEGA Australia prides itself on its ability to extract information from level, pressure and density measurement. Now, the company has ventured into the business of making sure that information reaches the right decision makers.

It has done so by joining the Open Industry 4.0 Alliance a network of Industry 4.0 organisations committed to using existing standards and fostering interoperability.

VEGA Australia’s Managing Director John Leadbetter says there are a number of mining companies that don’t have access to all of the on-site information that they’re monitoring.

“A number of industries have this sort of inventory system available, keeping client operations and production going by ensuring their product supply are up to date and useable,” Leadbetter says.

“These days, everything is done through the Internet. So we came up with an interfacing system that allows them to get information from a remote site.”

Through joining the alliance, VEGA has gained access to a platform that can deliver measuring results to decision makers via the cloud. Decision makers can monitor the condition of a plant, a site or an inventory right on their mobile phone or desktop computer.

A major mining company in Australia, for example, is looking at having information around its inventory and throughput right at its head office to monitor site performance.

Through Industry 4.0 communications technology, decision makers in the head office can now see what is happening at the remote plants

28 І Australian Bulk Handling Review: March/April 2021

IoT connects instruments, plants and devices.

“Two parts that make up IIoT’s effectiveness are the central communication hub, and secondly, and perhaps more importantly, the reliability of the unit that is producing the information.” and have insight on what’s happening in that operation in real time.

This remote monitoring becomes ever more vital given the travel restrictions imposed by the coronavirus pandemic.

But Leadbetter says it is not enough to only have and make use of the information. Companies also need to have instruments that are reliable in taking these measurements.

“The advantage of having Industrial Internet of Things (IIoT) communication, of course, goes back to the instrument that is doing the measurement and providing the information,” Leadbetter says.

“Two parts that make up

IIoT’s effectiveness are the central communication hub, and secondly, and perhaps more importantly, the reliability of the unit that is producing the information.

“Ultimately, the primary role of our business is to make instrumentations for companies. But moving into the 21st century, it’s no longer just about the information but how users get the information.”

Despite advancing technologies, the IIoT platform retains a user-friendly quality. Users can easily draw all the information that has been uploaded from the instrumentations from the cloud.

They can also choose to use either a hosted or non-hosted system. The first option gives VEGA the responsibility to host and maintain the IIoT system and to keep communication running smoothly.

This ability depends on VEGA’s dedicated IT business units in Australia and around the world.

These teams deal with companies and

address their specific needs.

“It’s something that you grow into.

The world changes so you have to come up with different ideas. We’re now using the world’s advanced technology to achieve company objectives,” Leadbetter says.

“We listen to customers, find out what their needs are and customise our solutions to those needs. Not every site wants it, but others do. You’re working in partnership with a customer to improve their business.

“Companies have to work hand in hand to improve their bottom line and throughput. They have commitments and tonnage amounts to fulfil to their customers. By helping their operation run efficiently, you’re helping companies meet their obligations to customers as well.”

VEGA backs its communication offering with a 24/7 support, a global hotline that can give technical assistance whenever a problem arises.

They can gain access to a company’s system remotely with their permission,

1800 689 433

find the issue and fix it. This support will be delivered in the English language despite VEGA being a German company.

“We don’t just sell the components.

We sell the whole solution,” Leadbetter concludes.

VEGA provides information relating to level, pressure and density measurement.

Your Storage & Conveying Specialists

DUST CONTROL

A helicopter applies Rainstorm’s dust suppression product.

Not wasting a drop Rainstorm, a Perth-based dust control company, has a simple mission – keeping dust emissions down without wasting water.

ONE OF THE OLDEST METHODS OF suppressing dust is by applying water.

Adding water to a fine material, while in the ground or as they are agitated, increases the weight of each dust particle, making it much less likely they will become airborne.

However, using large amounts of water to suppress dust can be detrimental environmentally and economically, especially in periods of drought and water restrictions.

Mason Trouchet, Group Technical Sales and Marketing Manager at Rainstorm Dust Control argues that every drop of water spent on dust control is a drop of water lost.

“I am a firm believer in effective dust control treatments to conserve water and improve health and safety measures, especially for large-scale mining

applications,” he says.

Trouchet is part of the product development team for Rainstorm and is involved in establishing dust control services and procurement technology transfer in international markets.

One such system is the Point of Dust Extinction or PDX. PDX is the result of more than 25 years of research into non-standard ore and soil stabilising agents, developed by combining surfactant wetting agent formulations with novel, biological-based (rather than chemical), active ingredients. This highly-concentrated liquid biochemical is biodegradeable and non-toxic.

It aids wettability and friability, helping lower ultra-fine ore dust extinction moisture (DEM) and improving material handling of ore movements.

When added into the mining ore stream,

Rainstorm believes that every drop of water spent on dust control is a drop of water lost.

30 І Australian Bulk Handling Review: March/April 2021

PDX significantly reduces dust, lowers the water levels required for DEM and minimises the environmental impact in comparison with petroleum-based water extenders.

The system is made up of three components: Dispersants, trace elements and organic compounds. Dispersants in PDX help reduce the surface tension of water and promotes the uniform transmission of moisture throughout the ore. Water adhered to the fine particles is released, which can result in a significant reduction in the volume of water required for DEM. Trace elements in PDX assist ionic exchange reactions between fine particles in the ore. Ionic bonds are formed as a result of the attraction between oppositely-charged ions and ionic exchange is the capacity of ions to exchange with other ions which have a smaller charge net. In addition, much of the adsorbed water at the interface of the clay particles is altered to improve moisture-to-surface-area wetting ability for the long term.

Organic compounds in PDX serve primarily to modify excess ion exchange points in the ore lattice and alter the behaviour of adsorbed water.

PDX is more effective when added to an ore body early in the materials handling process, with immediate chemical changes to fine particles becoming apparent. Mechanical mixing

through the material handling process creates a uniform moisture content within the ore, minimising the amount of additional water required in the process stream.

PDX is only effective on the fines components of the ore, with application rates capable of being finetuned to suit fines and lump ratios. An application rate of one litre of PDX for 10 to 25 tonnes of ore fines is recommended, depending on the site conditions.

Rainstorm’s Karratha facility where DustMag and PDX are made.

The company has operation bases the Pilbara and Perth Western Australia, to provide bulk supply of the product to local mines.

Trouchet says data has driven the development of new innovations in dust control, along with strategic partnerships.

An example of this can be seen in Rainstorm’s partnership with Shockwave Gel Technologies which has developed a way of tackling the difficult problem of

dust being generated by blasting.

The solution was to replace raggregate stem with a specialised Stemgel LR2, which provides major containment that impacts on blasting efficiency. Pressure waves contained in the rock help bring about greater fragmentation and a number of downstream benefits.

“The subsequent benefit of that powerful containment is a sizeable reduction in noise and dust,” Trouchet says.

“As the gel is expressed from the blast and becomes airborne, dust particles flocculate in mid-air and fall to the ground.

“In the past, drill and blast technologies have focused on explosives, detonation timing hole stability and moisture. Very little attention has been given to containment. It’s that unique characteristic of Stem Gel to measurably reduce noise and dust output from blasting that makes it such a massive game-changer.”

BRAKES, THRUSTERS, COUPLINGS, SHEAVES, OPERATOR CHAIRS & CONSOLES

MOBILE CONVEYING

New deal stacks up for Astec Australia and OPS Astec Australia has signed an exclusive deal with its Australian dealer for Astec Telestack products.

ABHR explains.

MOBILE CONVEYING EQUIPMENT can offer significant operating cost savings for certain applications compared to traditional methods of material handling.

They can also reduce planning requirements thanks to their increased flexibility, and the ability to move from site to site.

The Astec range of equipment has made its mark around the world, operating successfully in some of the most challenging environments. Telestack, located in Omagh, Northern Ireland, was acquired by Astec Industries and specialises in the complete in-house design, manufacture, installation and commissioning of mobile conveying equipment. A complete line of material handling systems is used extensively in the port, aggregate and mining industries.

Astec Telestack continues to invest heavily in it’s facilities, as part of a long-term strategy to future proof its capacity to support the development of an Mobile conveying equipment is used extensively in the port, aggregate and mining industries.

32 І Australian Bulk Handling Review: March/April 2021

extensive range of world-class, innovative and quality products.

Astec anticipates synergies between Telestack and its aggregate product lines to be beneficial while incorporating OPS as Astec Australia’s newly appointed Dealer, which the company believes to be an important collaboration in very active and demanding markets.

Shane Czerkasow, Managing Director of the OPS Group, the Australian dealer of Astec Telestack’s products, says the market is embracing solutions which can reduce reliance on manual labour, fuel usage, manpower and ultimately improve efficiencies.

“We at OPS are delighted to formally announce the extension to our long-standing partnership with Astec Telestack through Astec Australia, which is already in effect with OPS & MPS stocking and servicing Astec Telestack Australia wide.”

The OPS Group has been the exclusive dealer for Astec Telestack Bulk Materials Handling Equipment in Western Australia, South Australia and the Northern Territory, but with the signing of the new agreement with Astec Australia, the company’s subsidiary

Mineral Processing Solutions (MPS) will distribute in Queensland, New South Wales, Victoria & Tasmania.

In addition, MPS will distribute Astec Breaker Technology International (BTI) equipment. BTI manufactures a wide range of mining, quarry, construction and demolition equipment designed to improve productivity and profitability.

Czerkasow says the timing is perfect for OPS to expand its Astec Telestack offering across Australia.

“The OPS business has grown on the core values of delivering world class products with industry leading service and support, all of which provides our customers reliability, productivity and efficiency. Astec Australia is an obvious fit and perfect partnership for our business, as these are commonly shared values,” he says.

“Great equipment requires great back up and support and we believe this is a well-matched partnership that will deliver quality outcomes for customers of these industries.

David Smale, Astec Australia’s Regional Managing Director, says MPS’s local market knowledge and mineral processing experience, backed by Astec

The Astec Telestack range covers all facets of moving material from one point to another and is capable of up to 3000 tonnes per hour capacities.

This range includes: • Track mounted stackers • Wheeled stackers and link conveyors • Radial telescopic stackers • Ship loaders and unloaders • Tracked and wheeled hopper feeders • Reclaim hoppers • Tracked and wheeled truck unloaders • Bulk reception feeders • Static and project conveyors • Tracked blending plants (Pugmill)

Telestack’s innovation prowess and manufacturing capabilities, will allow the two companies to develop into a dominant player in these markets.

“MPS’s demonstrated ability to offer innovative, quality products and services makes them the perfect partner to support customers with applications, support and service,” Smale says.

MPS will deliver the expanded Astec Telestack product offering through new and existing Australian support infrastructure. The company already has facilities in Perth, Darwin, Adelaide and Central Coast NSW which each hold new and used equipment stocks, hire fleets, spare part warehouses and local service and support teams.

To strengthen its presence on the east coast, the company has invested in local teams in Brisbane and Melbourne, along with additional inventory of equipment and parts. Additional work is underway on new facilities in these cities, expected to be completed in quarter one of 2021.

Astec’s range of equipment operates in some of the most challenging environments.

Trevor Raman, OPS Group Operations & Engineering Manager, says the company’s investment in its facilities is aimed at improving its service and support capabilities for its current and future customers.

“With the expansion and continued diversification of our range of equipment offering, it is critical that we constantly develop and improve our overall customer support,” he says.

“Our first-class facilities will enable our businesses to stock unprecedented

levels of capital equipment, readily available for sales, hire and demonstration, as well as ensure we stock industry leading levels of spare parts.

“OPS have always strived to deliver class leading service and support. These new facilities will allow us to take this to a whole new level. We now have tremendous capabilities in large scale plant refurbishment, fixed plant services, fabrication and component manufacturing and refurbishment, including screen media and conveyor products.”

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WINCHES

Lifting Australian manufacturing ABHR speaks to Rick Kelly, Sales Engineer at SAM Technology Engineers to learn how the company’s bespoke winches are used in the bulk handling sector.

DESIGNING WINCHES WAS A natural step forward for SAM Technology Engineers. Originally established in 1934 as a crane designer and manufacturer, the company had extensive experience with winches, a key component in materials handling and lifting.

SAM Technology is an Australian manufacturer based in Smithfield, NSW.

SAM Technology Engineers winches can be found on shiploaders, stackers, reclaimers, tensioning devices on conveyor belts, and winders.

34 І Australian Bulk Handling Review: March/April 2021

The company has a wide range of special purposes winches and capstan winches available for various applications, with the majority of them bespoke designed for heavy industrial use.

Rick Kelly, Sales Engineer at SAM Technology Engineers, says the winches can be found on shiploaders, stackers,

reclaimers, tensioning devices on conveyor belts, and winders across the country.

“For most heavy-industry applications, there’s not an off the shelf type of product available,” he says. “These aren’t the same as the winches you might have on your four-wheel drive, these are designed to handle some of the toughest jobs out there and handle extreme environments,” Kelly says.

“That’s why we take into consideration the capacity required and the specific application the winches will be used for.”

SAM Technology works closely with its customers to collaborate on the design of its winches before beginning the manufacturing process. The company’s engineers will learn what the winch will be required to move, what the safety margin is, what kind of use it will see, and how often it will be used.

If a winch is to be installed on a shiploader, the company will take into consideration the corrosive environment the winches will be placed into. Sea water can cause the premature wearing or failure of components, so the company will often design the winch to use stainless or galvanised steel include marine-grade painting systems to provide the necessary rust protection.

In the case of a dirty environment, the winch will also likely include heavyduty seals on mechanical components to protect the internal bearings and moving parts. As winches are often heavy, rotating pieces of machinery, safety measures are taken to protect nearby workers, such as guarding around the equipment.

Kelly says SAM Technology’s design team works within the space limitations available, using software including Microsoft Inventor, AutoCAD and Strand 7 for modelling and stress analysis.

“A lot of the time the weight and space are critical considerations as to whether a winch will fit and work effectively in the

space provided,” he says.

“Another consideration we take is whether the drum requires a single layer of rope or multiple. The winch feed is an important part of the overall design – you want to be able to control a descent to avoid introducing other loads.”

Standards and local industry.

“We design all of our winches under the crane standard, AS1418, using locally sourced steel and equipment such as gearboxes and motors from other local agencies. We also design and supply sheaves and reeving systems,” he says.

“We design all of our winches under the crane standard, AS1418, using locally sourced steel and equipment such as gearboxes and motors from other local agencies. We also design and supply sheaves and reeving systems” SAM Technology is an Australian manufacturer, with its own production facility and factory in Smithfield, New South Wales. Here, the company can fabricate, assemble and test its designs in a large machine shop. Electrical engineers can provide complex programmable logic controller programming, along with sensors and other equipment as required.

Kelly says that because the business is an Australian manufacturer, it is acutely aware of the Australian

“Customers can even get involved in the design and manufacturing process.

We regularly invite them to come in and inspect it at multiple points during the fabrication process at different milestones.

“There is also the added benefit of supporting local jobs and passing on important skills to apprentices, which has a big impact on the industry as a whole.”

The company can manufacture and design other components to its customer’s specifications if required.

Following the manufacturing stage, SAM Technology can provide installation, commissioning and ongoing maintenance services throughout the winch’s lifecycle.

It holds a number of spare parts at its Smithfield facility and can provide additional components where necessary, thanks to relationships with coupling and brake manufacturers.

Kelly says the company is gearing up for an interesting time in the mineral industry.

“There have been a lot of developments happening in the mineral sands industries and other mining sectors,” he says.

“We’ve also seen a lot of new opportunities arise out of the large infrastructure projects that have been taking place over the past 10 years. Rail metro tunnelling projects are within the scope for winches, as they require specialised support.

“It’s likely that we’ll continue to see significant growth over the next few years as we branch out into new sectors.”

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CALIBRATION

RapidCal applies downward force using hydraulics attached to the outside of the tank and the load cell.

Realising safer, faster, and more accurate tank scale calibration Manually calibrating large tanks is often difficult and has the potential to put workers at risk. That’s why Mettler-Toledo Ltd has developed a cost-effective, fast and reliable calibration method.

TANKS, HOPPERS AND RELATED vessels are likely critical tools in a bulk handling operation. Turning these workhorses into active scales can significantly improve inventory management, filling, batching and mixing. These weight-based process solutions can be particularly attractive for operations that require higher dispensing accuracy.

But according to Jim Lambros, Standard Industrial Product Manager (Australia and New Zealand) at MettlerToledo Ltd, historically the effort to calibrate a large tank scale has been nothing short of Herculean.

“From gathering a series of heavy test-weights to substituting vessel contents, the process can risk both worker safety and tank contamination,” Lambros says.

36 І Australian Bulk Handling Review: March/April 2021

“To add insult to injury, the purified water used in the process must be disposed of properly, resulting in wastehandling fees. Plus, a tank can be out of commission for days.

“Factors such as these have historically caused plant managers to put off calibration for tank scales as long as possible – sometimes to the detriment of product quality or even worker safety. But not anymore.”

A new method of tank-scale calibration, known as RapidCal, is replacing traditional calibration methods around the world.

Created by Mettler-Toledo Ltd, RapidCal offers an economical tank-scale calibration method that uses no test weights and eliminates the expensive and risky process of material substitution.

The process has provided stability to

a producer of bulk materials used in agribusiness and chemicals, which formerly used hectic calibration exercises.

Based on a consultation with MettlerToledo Ltd specialists, the company installed the anchor points required to perform the innovative calibration on 25 pre-selected tanks. Today, the complete calibration service for all these tank scales is performed using RapidCal, reducing a process that used to take more than 30 hours per tank to just two.

Lambros says that even without doing the detailed math, it’s clear this development has significantly reduced the amount of time each scale is offline, resulting in productivity improvements that cover the costs of calibration activities – and then some.

“The company has also been able to fully outsource the calibration procedure

while ensuring traceability. Plant management no longer contemplates skipping calibration activities,” Lambros says.

“The result is higher product quality and more accurate shipments.

And, because the RapidCal process is standardised, the company is looking to expand use of this highly effective technology to its other major processing centres.”

RapidCal works by applying downward force using hydraulics attached to the outside of the tank and the load cell, eliminating the need to transport heavy test weights or go through the expensive process of draining and cleaning tanks for material substitution. It has been developed through years of applied experience in metrology and weighing that Mettler-Toledo Ltd gained through serving the bulk materials market.

Calibrations are accurate to 0.1 per cent for vessels ranging from one to 32 tonnes. Process traceability to both

Calibrations are accurate to 0.1 per cent for vessels ranging from one to 32 tonnes.

internal and external quality standards is assured by Mettler-Toledo Ltd technology and service technicians. Piping effects are automatically compensated for as well.

Regular recalibrations are included as part of the quality system established for the producer.

Lambros says that because of the sheer volumes most bulk material handlers deal with, management may delay improvements because current system limitations are known, understood, and compensated for.

“However, in cases such as RapidCal when relatively straightforward activities can yield significant improvements in accuracy, uptime and productivity, any risk is almost certainly outweighed by the potential benefits,” Lambros said.

“Overall, the partnership between internal personnel, the company’s thirdparty engineering firm, and MettlerToledo Ltd’s metrology experts has added up to much more than the sum of each individual part.

“The end result? A calibration process that has improved worker safety, reduced downtime, and enhanced process quality far beyond what management originally thought possible in an almost textbook definition of true process improvement.”

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MOBILE CONVEYORS

Conveyor solution for infrastructure spoil Mobile Conveying Services was commissioned to remove spoil from the Northconnex tunnel and deliver it to a NSW quarry. ABHR learns how the company used an innovative approach to move the material.

NORTHCONNEX, A NINE-KILOMETRE tunnel linking the Hills M2 Motorway at West Pennant Hills (Sydney) to the M1 Pacific Motorway at Wahroonga, opened on 31 October 2020.

The Australian and NSW governments contributed equally to the project, which was delivered in partnership with private sector sponsors Transurban and the Westlink M7 Shareholders. The Lendlease Bouygues Joint Venture (LBJV) won the contract to design and build the tunnel.

Around 2.5 million tonnes of spoil was generated, of which around 40 per cent was used to backfill a disused quarry in Hornsby. This allows the Hornsby Shire to transform it into a 50-hectare recreational space, set to open in 2023.

Delivery of spoil to the quarry commenced in early 2017 and the last truckload was tipped in late January 2019.

Mobile Conveying Services (MCS) first commenced discussions with LBJV on how conveyor systems could be used to deliver the spoil into the quarry in mid-2015 and it was started mobilising on site at the start of 2017.

Complete unload to place system The system supplied was a mix of off the shelf conveyors and conveyors and related equipment either designed and built by MCS or substantially modified by them.

Key elements of the solution offered

by MCS included: • tri-bay truck unloader with elevated control cab and interlocked light system for controlling truck movement and tipping • purpose-built downhill conveyor (its electric motor effectively became a generator), transferring spoil from the

Assembly of the downhill conveyor transferring backfill material from the surface into the pit.

truck unloader to the pit a telescopic radial stacker (58-metre reach), transferring spoil from the downhill conveyor into the pit • vibratory pan feeder for transferring material from the stockpile in the pit to the conveyors that distribute it around the pit • two telescopic radial stackers (46-metre reach) and two folding radial stackers (46-metre reach), all fitted with tracks for radial movement • an MCS crawler ‘tugger’ prime mover for moving the mobile conveyors around the site • a site maintenance and support facility with tools, parts storage and a 16-tonne telescopic handler for maintenance support • a rented house at Hornsby to accommodate site workers, who generally rotated on two-week rosters While the energy generated by the downhill conveyor could have been used to supplement power on site, there was no suitable application and the energy was burned off by large resistors. In different circumstances, energy generated by a downhill conveyor could be harnessed for use on site. Graeme Cooney, MCS Director, said the size of resistor used at NorthConnex showed that this power, in a similar application, is significant.

•

Pioneering a mobile tri-bay truck unloader

An excavator loads a hopper at the rear from a stockpile of material placed from the surface. A string of conveyors then transfers this material into the pit.

38 І Australian Bulk Handling Review: March/April 2021

MCS has been a long-term user of mobile truck unloaders in Australia, having bought both Ashross and Superior single bay unloaders (being significantly different in design, they have strengths in different applications and site lay-outs).

It has modified the Superior unloaders – initially developing hydraulic folding

ramps so that the unloader does not require an assist machine to set up. It then converted a single bay unloader to a dual bay unloader to ensure continuity of flow for ship unloading.

While a dual bay truck unloader would have been theoretically capable of handling the required peak throughput of the NorthConnex project, there was potential for oversize material to be present in some loads, making it necessary to install grizzly screens in the tip bays to avoid damage to the belt. With some spoil having high moisture content, there was potential for the spoil to bridge over the grid and block the feed.

Due to these factors, MCS elected to develop a tri-bay unloader so that, in the event of a blockage, one bay could be closed while the blockage was cleared while the remaining bays stayed open.

An excavator or loader was located at the unloader to assist with speedy clearing of blockages.

Other innovations in this machine

were an enclosed operator control cabin in an elevated position and an interlocking light system to control truck movements and tipping as they passed through the unloader. Concrete barriers were used to delineate the bays and prevent trucks from damaging the equipment.

Given the need to maintain placement schedules to clear tunnel spoil, a dual bay truck unloader was parked on site to cover any extended downtime of the main unloader.

Options for pit transfers MCS offered a gravity-fed stockpile reclaimer as an option for loading the transfer conveyor in the pit with spoil dropped from the surface. The contractor opted to use a vibratory pan feeder fed by an excavator to load spoil onto the conveyor.

Cooney says the workability of the stockpile reclaimer was proven subsequently on a WA mining project where it was part of a conveyor system

supplied by MCS to replace short haul with a dump truck and excavator. The conveyor solution cut the per-tonne haulage cost to a third of its previous level.

The combination of a folding conveyor and a telescopic conveyor meant that the opposite side of the pit to where material was transferred from the surface could be reached.

Because of the problems with oversize material and high moisture material, trucks coming from sites with known problems were directed to a stockpile on the surface to minimise disruption to the truck unloader. The stockpiled material was transferred into the pit by truck.

MCS Director Graeme Cooney believes that, if these are known in advance, an alternative of dumping all material on the surface and running it through a sizer and then into the downhill conveyor should be considered as an alternative to the tri-bay truck unloader (with an overbelt magnet if steel contamination is also an issue).

BELTS

A conveyor will be installed along a 500-metre-long causeway as part of the project.

New belts for Wallaroo ABHR speaks to John White, Managing Director of Allied Grain Systems, to learn more about the belts being installed at T-Port’s latest facility.

BUILDING A NEW DEEP-WATER port is expensive, ecologically damaging and often requires a high capital expenditure.

This poses a challenge for bulk exporters looking to increase the amount of product shipped. Larger shipping vessels often have decreased maritime transport costs and can handle significantly more material.

T-Ports, a specialist exporter of bulk commodities, found a solution that allowed it to ship more grain without any expensive, extensive infrastructure upgrade.

The Lucky Bay grain storage and export facility, located on the shores of the Spencer Gulf, on South Australia’s Eyre Peninsula, features 24,000 tonnes of grain storage in steel silos in addition to a nearby bunker storage site that provides 360,000 tonnes of grain storage The nearby marine environment was taken into account for the conveyor design.

40 І Australian Bulk Handling Review: March/April 2021

across 10 bunkers.

A transhipment vessel, named the Lucky Eyre, loads grain from the port to move it onto deep water vessels five nautical miles from the port. The 87-metre self-propelled and selfdischarging vessel has the capacity to load up to 13,800 tonnes per day.

Mark Antushka, General Manager Construction for T-Ports, says this method of transhipment has not previously been used for Australian grain exports and eliminates the need for major jetty structures and other port infrastructure.

“Fully laden, the vessel can operate in relatively shallow conditions,” he says.

“Due to the port being located close to the product, these facilities substantially reduce the road haulage distances, reducing the cost to government for road repairs and maintenance and reducing

carbon dioxide emissions considerably.”

The initial project proved immensely successful, to the point where T-Ports awarded Allied Grain Systems a contract to build a second port in the network at Wallaroo on South Australia’s Yorke Peninsula.

Part of this development will see a conveyor installed along a 500-metre-long causeway, from the storage leading to a shiploader for the transhipment vessel.

John White, Managing Director Allied Grain Systems, says the company has designed and is beginning to fabricate the conveyors required for the project.

“We have a design team full of mechanical engineers that take on board the specific requirements of each belt conveyor,” he says.

“The main conveyor needs to be able to start fully loaded and handle up to 1500 tonnes per hour of wheat.

“It’s an overland conveyor, meaning it needs to start from a fully stopped position to allow for the proper cleaning and maintenance procedures.”

The design of the belt has also taken into account the corrosivity of the nearby marine environment. A weather cover made of urethane protects the top of the

conveyor, while the belt has been coated with anti-corrosion agents to enhance its longevity.

Allied Grain Systems will provide all of the structural work and has independently tested the belt to ensure it complies with Australian Standards. With proper preventative maintenance, the conveyor is expected to last for around 20 years.

White says collaboration has been key to this project, as multiple contractors are involved.

“Everyone’s got the client’s best interest at heart, and people were quick to adopt video conferencing to keep safe during the COVID-19 pandemic,” he says.

Allied Grain Systems will also deliver two new silos, providing 20,500 tonnes of storage at the port itself. The silos will be fully sealed to allow for fumigation and will be connected to two hoppers with an intake of 500 tonnes per hour each. The belt conveyor across the top of the silos is an enclosed Hi Roller belt conveyor, with dust filters equipped at each transfer point to minimise dust emissions.

The belt conveyor across the top of the silos is an enclosed Hi Roller belt conveyor.

The facility is expected to be highly automated, managed through one of Allied Grain Systems’ contractors, Bitwise.

White says Allied Grain Systems provides a total solution for major projects like this, providing pricing, concepts, detailed design, final fabrication and site installation.

“Engineering is the most important thing to us. We wouldn’t be able to do projects like this without our highly skilled team of experts,” he says.

“They’ve coordinated with the designers and other contractors to ensure the shiploading belt conveyor has the correct overhang to load the vessel.

They have also coordinated with other companies to ensure the way we’ve designed the trestle supports work well with the causeway foundation.”

Construction of the facility is expected to take between 12 and 18 months, with around 200 jobs expected to be created during this time.

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BELTS K-AllShelter Capotex Conveyor Covers

Uncovering the benefits of belt covers Neil Kinder, Managing Director of Kinder Australia, explains how installing the right conveyor belt cover can provide vital protection for one of the most expensive parts of a bulk handling operation.

MOTHER NATURE CAN BE VERY harsh, unpredictable and unforgiving, with her extremes of weather from the scorching sun, belting rain, wind gusts and varying degrees of temperature and humidity.

Conveyor belts are used to convey a vast array of bulk materials and are exposed to constant and unrelentless environmental conditions. On the exterior there is the real and visible damage the sun, wind and water can have on the conveyor belt.

The harsh conditions conveyor belts are exposed to can lead to the issues of material run back and damaging material spillage, which can have negative impacts to productivity targets and operational bottom lines.

Prolonged exposure to UV radiation can cause irreversible damage to the conveyor belt’s top rubber surface. This process is called oxidation of the rubber, which can contribute to surface cracks

42 І Australian Bulk Handling Review: March/April 2021

and worst-case belt tear. The adhesive properties and mechanical strength of the belt can also become compromised making once easy repairs on the belt more difficult and thereby reducing the belt’s overall useful life. In the event moisture finds its way into cracks and grooves, it can make isolating potential belt mistracking problems harder to detect and resolve.

Selecting and installing the correct conveyor belt cover for specific applications and environmental exposure is critical. For applications where a consistent and high-quality finished product is imperative, conveyor belt covers can act as highly protective barriers for consistent moisture control.

In environments where there is heavy reliance on a dry conveyed bulk product throughout the crushing and screening process, conveyor belt covers can protect the conveyed material from the wet weather. Humidity and excess moisture

can potentially cause productivity shutdowns due to screen blinding, clogging and maintenance issues in the production process. Rain can also cause the belt to slip particularly on the drum leading to significant belt tracking issues.

Keeping conveyor belts completely covered with the use of conveyor covers can also result in less wear on critical high-performance conveyor components and the conveyor belt itself. Due to the overall reduced weight of installed conveyor components, protection provided from the conveyor belt covers can yield longer service life for conveyor hardware and the backbone of all bulk materials operations, the conveyor belt.

Operating within a highly exposed and harsh Western Australian regional area, one of Kinder’s major international grain exporter client sought a reliable and cost-effective solution to protect their grain assets from loss due to the areas renowned windy conditions.

Protecting and extending the service life of the conveyor belt was also a key consideration for the grain operator. Capotex Conveyor Covers were successfully installed protecting the operations most important capital asset, the conveyor belt from the extremes of weather. The conveyor covers have also proven to be very beneficial in minimising product loss and maintaining a high standard of final product to fulfil the local and international grain export industry.

Protecting the environment and neighbours Dust emissions and their damaging effects on human health and the environment present a serious occupational health and safety issue for bulk handling operators. Using conveyor belts to transport bulk materials effectively leads to dust, and lots of it.

It’s unavoidable.

Dust becomes a concern when it becomes fugitive and airborne. It can cause havoc and cost blow outs within every step in the production process.

There is also the ongoing costs and additional maintenance resources allocated to cleaning up dust and personal protective equipment required by workers when dust is not contained effectively.

Many operators have turned to conveyor belt covers as an economical, effective and safe solution for dust containment and airborne dust reduction.

By covering up conveyor belts, the chance of dust emissions going outside the boundaries and negatively impacting nearby residents, communities and eco-systems can be greatly minimised and the health and longevity of these communities remain intact for future generations.

Dust is also highly visible when viewed from outside a plant, causing raised concerns of its impacts to workers, communities and regulatory compliance adherence by the operator.

Currently, as outlined in Safe Work Australia, Workplace Exposure Standard for Airborne Contaminants, for crystalline silica the standard is set at 0.05 TWA/mg/m3. In Australia, bulk materials handling operators must

ensure that all workers are not exposed to airborne contaminants such as respirable dust that exceeds levels set by regulatory health and safety bodies.

Non-compliance would normally result in community backlash, noncompliance fines and complete shutdowns to the production process.

Stricter environmental regulations, particularly in European countries mean that all conveyor belts are covered, this is a mandated legislation and the norm for all operators in this region. Installations of conveyor belt covers can help operators meet their environmental and OHS obligations in those countries where belt covers are not compulsory.

Neil Kinder

Protecting workers Covering conveyor belts can also be a logical solution for preventing against work-related trawling accidents and other accidents that arise due to the volatile characteristics of the conveyed material.

Without shielding provided by belt covers, heavy, sharp and abrasive conveyed materials have a higher chance of flying off the conveyor belt and inflicting potential harm to site operators and workers while conducting routine maintenance repairs.

Conveyor belt covers can suppress dust emissions, uncontained, excessive dust in the air leaves operators exposed to potential health hazards, they have failed in their duty of care to their workers when this dust is inhaled by

staff working in close proximity. Long term can lead to potentially irreversible lung damage and diseases such as silicosis.

Not all covers are created equally Durability, lightweight, aero-dynamic materials and ease of maintenance access are important aspects to look for when considering which conveyor belt cover is the best to select and install.

With the evolution of engineering designs and high-quality materials currently available, conveyor belt covers can be designed and manufactured using a wide range of high-performance materials such as galvanised steel, pre-lacquered steel, stainless steel and aluminium and fibre reinforced polyester.

From these engineered materials, conveyor belt covers can be designed for any size, shape, and application, as well as to suit the varying extremes of weather the conveyor belt is exposed to and the level of protection required.

Traditional conveyor belt covers are high strength and versatile, shielding the entire conveyor belt from all weather conditions and suppressing dust emissions. Some also feature a patented lock/hinge system, which can effectively withstand the extremities of heat, wind, humidity and rain over long periods. Conveyor covers that are hinged on both sides ensures ongoing access and maintenance from both sides of the conveyor is simple and hassle free.

Like conveyor covers, service props and struts also come in varying designs, shapes and sizes. These handy tools allow operators to gain access inside the cover to conduct routine maintenance.

Most service props are fully adjustable systems that hold up the conveyor belt cover safely and securely so that any maintenance inside the covers can be easily performed.

Currently, conveyor belt covers can be designed and manufactured using the latest, high-grade and highperformance materials. Like procuring other important conveyor components, selecting the best belt cover option will entail due diligence process and review of the belt covers cost-effectiveness, material strength and accessibility for future maintenance.

Australian Bulk Handling Review: March/April 2021 І 43

BELTS

talk Choosing the right belt type Steve Davis, Senior Bulk Handling Expert at Advisian, explores the ins and outs of different conveyance types and how they can be deployed for different applications.

STEVE DAVIS In his regular BULKtalk column, Steve Davis considers the basics of bulk handling that sites often struggle with.

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.

CONVENTIONAL TROUGHING belt conveyors are the most common conveyances for bulk materials with good reason. They are cost effective with multiple component suppliers and well understood by our design,

operations and maintenance teams. These conveyors have high carry capacity and reasonable terrain capabilities. They have horizontal curve capability.

Speeds in excess of 10 metres per second are proven as are high

Agudio’s FlyingBelt system also uses a wire rope structural support and support towers.

44 | Australian Bulk Handling Review: March/April 2021

tension belts. Overland conveyors exceed 20 kilometres for a single flight.

There are alternative conveyance types that are suitable when conventional troughing conveying is either unsuitable or the layout and cost is compromised through designing around the limitations.

Typical reasons for considering alternate system include steep angle conveying, enclosed conveying, cross country rough terrain, routes where multiple transfer stations can be avoided, high temperatures, long distances, low footprint, poor ground conditions and others.

The temptation is to use conventional and conservative conveying to define a solution rather than finding a different conveyance that provides a better or alternate solution. Here are some of the larger options, and there are many more in use and in development.

Metso ‘Cable Belt’, the longest of which single flight installed is in WA and is a 31-kilometre single flight overland, has better incline capacity than troughing belts and can manage horizontal curves. This potentially results in single flights across country that is too rough for troughing conveyors. Most components are specific to the conveyor. Carry capacity appears to be limited by available belt width and lower trough angle than conventional

belts.

Doppelmayr’s RopeCon system uses a wire rope structural support which carries a flat belt with convoluted sidewalls. The conveyance is strung between steel towers that can be more than one kilometre apart. The footprint is low. Access for maintenance is via a specialised trolley that also runs along the ropes. These conveyances do not have curve capability but are often able to run a straight line between points that is not possible for other systems.

In between elevated rough terrain sections, the belt can be carried on rails at ground level. Capacities are high and conveying distance relatively high.

Most components are specific to this type of conveyor. There is a long span across the Nile in Sudan, for which other conveyances would have required an expensive bridge and would have interfered with local agriculture. Every year sees more of these conveyances being installed.

Agudio’s FlyingBelt system also uses a wire rope structural support and support towers. This system supports a conventional belt on catenary idlers and uses a maintenance trolley. The conventional belt gives an opportunity to run elevated in rough terrain and then as a convention troughing conveyor when practical, and this does give horizontal curve capability. This conveyance is relatively new but there are already a few installations. This system has capacity up to 10,000 tonnes per hour and spans to one kilometre.

Chevron belts and cleated conveyors use all conventional components except for the belt and belt cleaners.

These are used where an increase in conveyor angle by 10° or more can reduce plant footprint or avoid using a two-stage conventional conveyor and transfer system. These are generally used for lower capacities and in plant.

Specific types of belt cleaner now allow conveying of sticky materials.

Sandwich belts also use many conventional components. Two belts are used to sandwich the bulk materials.

These machines can convey vertically and even beyond vertical, as in self unloading ship loop belts, to feed above and back toward the load point.

Conveying capacity so far is 3500 tonnes per hour.

Flexwall uses a flat belt with a convoluted sidewall arrangement and cleats. Many different arrangements for these machines are possible from steep to vertical incline through ‘S’ shapes, ‘L’ shapes and others. Idlers and pulleys are like conventional components but there are some special parts. These are best for dry materials and are mostly smaller capacity units.

Pipe conveyors load and discharge bulk in a conventional manner in a troughing section of a special flat belt.

Between loading and unloading the belt is rolled into a circular shape and resembles a pipe. Pipe conveyors have

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BELTS

Doppelmayr’s RopeCon system uses a wire rope structural support which carries a flat belt with convoluted sidewalls.

excellent curve and incline capability and can wind through complex multicurved routes. Many components are like conventional conveyors. There are many examples in use. Capacity is limited by the diameter of the pipe and is about 4000 tonnes per hour depending on density and other factors.

The footprint is generally narrower than a troughing conveyor. The longest single flight is 15 kilometres.

Pipe conveyors are also excellent for containment and dust and do not need a gallery enclosure. Pipe conveyors can be installed in tunnels where there is a requirement to conceal, such as through a suburban area to a port.

Thyssenkrupp and Contitech have developed the Megapipe. This is a larger diameter version of the pipe

46 | Australian Bulk Handling Review: March/April 2021

conveyor with a special belt having moulded cleats. The belt can travel multiple curves and steep or vertical slopes. Capacity is high and particle size greater than found in most pipe conveyors, leading to potential use for haul truck replacement in the mine pit environment.

Beumer have a ‘U’ conveyor. This is like a pipe conveyor except that the belt is rolled into a vertical walled U section rather than a full pipe. This promises many of the benefits of a pipe conveyor for multi-curves and a higher capacity.

Pouch conveyors also fully enclose the carried material, and are more route flexible than any other conveyance, being able to wind through multiple tight curves and inclines in almost any path. Capacity is relatively small

at perhaps 1000 tonnes per hour maximum and depends on density.

Multiple distributed drives keep the belt tension low. The small cross sections, ability to run carry and return in separate paths allows these machines to be installed in small spaces and follow existing walkways making them useful in brown fields installations.

Bucket elevators are mainly used for vertical conveying and allow loading conveying and discharge in a small footprint. Buckets are attached to chains or to belts (steel cord or fabric) and can haul up to approximately 3000 tonnes per hour depending on material and height. The tallest single flights are 175 metres. Bucket elevators are generally enclosed and are good for controlling dust.

Air support conveyors are similar to conventional conveyors, however the carry idlers and sometimes return idlers are replaced by a perforated trough which provides a film of air to support the belt. Loading and discharge is the same as conventional. These conveyors are relatively short and cannot have horizontal or vertical curves. They are useful for dusty and friable materials where the lack of idlers does not disturb material. There is a potential energy saving in the reduced friction carry, but this must be offset against the air supply energy.

Air slides are generally rectangular trough sections where air is introduced through a membrane. The air reduces friction in the carried material between material and the trough and the material flows down a slight gradient under gravity. Direction changes can be above 90° angle and need little space.

They are useful for powdery materials such as alumina. Length is limited

by the required slope from load to discharge.

There are many other conveyances in the materials handling arsenal, and new possibilities are being developed at all times.

Light rail systems offer possibilities for low cost contained high-capacity transport over unrestricted length.

Systems such as Railveyor, MRL BOSS, ARC and Cont-e-bahn are all in various stages of development. The last three systems are Australian developments.

A study example assessed transfer of 5000 tonnes per hour primary crushed ore between points that were 14 kilometres apart. Because the terrain on the direct route was not conducive to conventional conveyors, a route was selected to allow their use. This resulted in some 32 kilometres of conveyors with three interim transfers and drives.

The alternative options included Metso’s cable belt, Dopplemayr RopeCon and Agudio FlyingBelt. All

three conveyances have capacity and can cross rough terrain. RopeCon and FlyingBelt both had the capacity to transfer almost in a straight line in a single flight, and when assessed on a total installed cost basis appear attractive propositions. However, as is often the case with studies, conveyances were compared solely on the mechanical cost and ranked on incorrect perceptions of risk.

I have recently been involved in a project where the design parameters were different in the extreme to my normal materials handling problems. Many conveyance types were considered in two stages. The first stage excluded any conveyance that could not carry the high temperature being handled and would not be able to fit on the limited footprint.

This left roughly twenty different potential conveyances, and only one which eventually met all requirements.

Of course, the first pass was how can we convey using troughing conveyors!

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BELTS

Designing the right belt feeder Historically, belt feeder design has been based on a variety of empirical or ‘speculative’ procedures, which, in many cases, equipment manufacturers have kept confidential. Corin Holmes, Operations Manager for Jenike & Johanson, shares some design considerations that may help improve an operation.

A BELT FEEDER IS A CRITICALLY important element in many bulk material handling systems, since it controls the solids flow rate from a storage vessel (bin, silo, bunker, hopper) or stockpile and can affect live capacity. When the belt feeder stops, solids flow should cease. When it is running, there should be a close correlation between its speed of operation and the discharge rate of the bulk solid.

Belt feeders differ from belt conveyors in that the latter are only capable of transporting material, not modulating the volumetric or mass flow rate. The maximum throughput of a belt conveyor is limited by the rate of solids flow onto it from the hopper above, so changing belt speed may only change the

Figure 1: Funnel flow and Mass flow patterns

48 І Australian Bulk Handling Review: March/April 2021

depth of material, not the belt’s capacity.

When a belt feeder is flood loaded by the hopper located above it, changing belt speed changes the amount of material discharged per unit time.

Volumetric or gravimetric?

Two basic types of feeders are volumetric or gravimetric ones. A volumetric feeder modulates and controls the volumetric rate of discharge from a bin. A gravimetric feeder modulates the mass flow rate. This can be done on either a continuous basis or on a batch basis where a certain mass of material is discharged and then the feeder shuts off.

Criteria for feeder selection Regardless of whether a volumetric or gravimetric feeder is selected, it should

provide the following: 1. Reliable and uninterrupted flow of material from the upstream device.

2. The desired degree of control of discharge rate over the necessary range.

3. Uniform withdrawal of material over the outlet of the upstream device.

This is particularly important if a mass flow pattern is desired, so as to control segregation, provide uniform residence time, minimise caking or spoilage in stagnant regions, etc.

4. Minimal loads acting on it from the upstream device. This minimises the power required to operate the feeder as well as particle attrition and abrasive wear of the feeder components.

The feeder should be selected based

If the interface between the hopper and belt feeder is not properly designed to discharge material uniformly over the entire cross section, a funnel flow pattern (see Figure 1) will develop with the additional potential problem of ratholing.

Figure 2: Example of improper interface that allows feed from front.

on the application and matched to the material that is being handled.

Belt feeder design considerations Belt feeders are often an excellent choice when feeding material from an elongated hopper outlet but can also be used with square or round outlets. They are preferable when handling friable, coarse, fibrous, elastic, sticky, or very cohesive materials. Since belting is commonly available in large widths and unrestricted lengths, belt feeders can be designed for much larger outlets than most any other type of feeder.

If the gap between the bin interface and belt is constant along the length of the outlet with capacity set by the opening of a front gate, material will be withdrawn preferentially from one end of the outlet. If the outlet through which the bulk solid is expected to flow is too narrow, arching due to interlocking of large particles or cohesive strength of smaller particles can prevent material from discharging. If the interface between the hopper and belt feeder is not properly designed to discharge material uniformly over the entire cross section, a funnel flow pattern (see Figure 1) will develop with the additional potential problem of ratholing.

These issues can result in flow at either the back or front end depending on the front gate opening (see Figure 2).

With fine powders, the discharge rate may be limited if the belt feeder is operating at a speed greater than the bulk solid’s critical steady state rate of discharge. Similarly, flooding of fine

powders is a common problem if the interface is not designed for uniform withdrawal or if the bin is not designed for mass flow. A proven design that eliminates most of the problems just described is shown in Figure 3.

Since the idlers of a belt feeder can be mounted on load cells, can be used in either a volumetric or gravimetric application. Belt feeders have many moving parts and are prone to spilling material from return idlers. They therefore generally require more attention and maintenance than a well-designed screw or vibrating pan feeder. It is important to ensure that the maximum feed rate from the upstream device is always greater than the maximum required operating rate of the feeder. Otherwise, the feeder will become starved, and rate control will be lost. This problem is particularly pronounced when handling fine powders, since their maximum rate of flow through an opening is significantly less than that of coarser bulk solids whenever a mass flow pattern is used.

If the gap between the bin interface and belt is constant along the length of the outlet with the capacity set by the opening size of a front gate, as example, material may be withdrawn preferentially from one end of the outlet. The key to proper belt feeder design is to ensure increasing capacity along the length of the bin outlet by providing expansion in both plan and elevation. It is also important that the clearance between the belt and frond end of the outlet be at least 1.5 to two times the largest particle size to

prevent blockage.

Mechanical arching due to interlocking of large particles or cohesive arching due to a material’s cohesive strength can prevent material from discharging through an undersized outlet. Therefore, the minimum outlet width at the rear end of the interface must be greater than or equal to the critical dimension to prevent a stable arch from forming. The sloping side walls must be at least as steep as the hopper wall slope required for mass flow. The slot length should be at least three times the width in order to realise the benefits of a rectangular outlet.

Often it is advantageous to use a much longer slot with large silos or with wedge or chisel-shaped hoppers containing vertical end walls.

Both the minimum outlet width and required hopper angle can be calculated from measured flow properties of the material.

One design approach is to start with standard 20° picking idlers with the centre roll being wider than the width of the interface at the front to set the initial belt width. A reasonable gap between the interface and belt is then chosen and use of a shallow angle of surcharge, allows for quick determination of whether a wider belt is required to prevent spillage or if a slower belt speed is appropriate.

There are trade-offs to be considered, such as capital and operating costs between a wide belt operating at low speed and a smaller belt operating at higher speed. Another consideration is the power consumption of different belt sizes. Wider belts require more belt tension but may require less power if speed is reduced.

However, low speed belts require high

Figure 3: Properly designed mass flow feeder interface.

Australian Bulk Handling Review: March/April 2021 І 49

BELTS

Electrical/mechanical drives can deliver up to 300 per cent of their rated torque during start-up, which helps to overcome feeder start-up loads. ratio gear reducers, which will result in more drive loss than standard units.

Taper of the slot in elevation must be sufficient for particles to freely form an angle of surcharge on the belt. The gap between the interface and the belt at the front end must be at least three times the normal maximum particle size and must be greater than the maximum possible particle size. Once a front-end gap has been selected for the desired slot length, the belt’s size and speed can be determined. This process can then be repeated with a different belt size, type of belt, type of idler, or slot length to obtain an optimal configuration.

At the tail end, troughing of the belt, if necessary, can be accomplished with transition idlers beneath the hopper interface. This allows the centreline of the tail pulley to be located closely behind the rear of the interface. The belt line work point should be the top of the idlers and pulleys, so as to avoid belt lift when starting the feeder. If required, detroughing of the belt can start a short distance downstream of the interface however, the centreline of the head pulley must be located beyond the material’s angle of surcharge in order to prevent spillage from the belt.

Other important aspects of belt design include: • A slanted ‘nose’ with an arch-shaped cut-out to provide stress relief and prevent stagnation at the front or discharge end.

• Capacity should be set by belt speed and not by an adjustable front gate.

• A flexible rubber or plastic buffer at the rear end to allow a gap for uniform material withdrawal without belt or interface damage.

• Spillage skirts that expand slightly in the direction of belt travel and that are remote from the feeder interface.

This prevents the skirts from interfering with uniform withdrawal.

• Replacing side rolls with slider bars within the hopper/feeder interface region to eliminate uneven skirt wear, spillage due to belt sag, and high loads on idlers.

50 І Australian Bulk Handling Review: March/April 2021

•

Properly designed and wellmaintained belt scrapers, which are critical to minimising the amount of spillage due to carry-back.

•

Drive types Two main drive types are available: electrical/mechanical and hydraulic.

Electrical/mechanical drives are capable of operating over a 10:1 speed range by varying the motor frequency. However, the drive’s output torque, efficiency and temperature will change with frequency, which must be considered in the selection of the drive. Electrical/ mechanical drives can deliver up to 300 per cent of their rated torque during start-up, which helps to overcome feeder start-up loads. Hydraulic drives have constant output torque from 0 to 100 to per cent of design speed, providing a larger operating range.

Hydraulic drives are compact, shaftmounted units, and usually smaller than an equivalent electrical/mechanical drive. This is particularly beneficial with slow speed drives since they require large gearboxes to provide the desired output speed.

below a hopper outlet is an essential component in determining drive details.

The first factor is the vertical material load acting on the belt, which is used for determining belt support requirements and the required tension in the belt to overcome drag of the supports. The second factor is the force (belt tension) required to shear the material from beneath the interface. Both of these loads are sensitive to interface geometry and loading conditions; consequently, the approach developed by CEMA [2] for belt conveyors does not apply to belt feeders.

Using an approach based on the work of Jenike [3] and assuming that the bin and belt feeder interface provide mass flow, the vertical load can be expressed as: AxF+B Where: A = integrated vertical material force at the shear plane (generally assumed to be at the bottom of the interface) F = dimensionless multiplier used to correct for different loading conditions B = weight of material between shear plane and belt The shear load can be expressed as: CxF Where: C = Value of A multiplied by the effective coefficient of internal friction, usually taken as (sin δ).

The value of dimensionless multiplier

Sometimes the power required to shear material and operate a belt feeder exceeds the available drive power. This problem is usually the result of an improperly designed interface that does not allow uniform withdrawal over the entire cross section of the outlet.

Power considerations Sometimes the power required to shear material and operate a belt feeder exceeds the available drive power. This problem is usually the result of an improperly designed interface that does not allow uniform withdrawal over the entire cross section of the outlet. If the feeder interface is not structurally designed to withstand the pressures exerted by the bulk solid, it will deform in such a way that significantly higher forces are needed to shear the material [1].

Knowledge of the material loads acting on the portion of a belt feeder

F is close to 1 during steady state running conditions but can easily exceed a value of 3 during start-up, particularly if there is significant relative deflection between the hopper interface and feeder. Other factors that influence F include outward deflection of the interface walls [1], belt sag between idlers, and filling of the bin from empty.

It is common to find that the value of F dominates the material loads acting on a belt feeder; consequently, design details and experience are critical. One approach to minimising material loads is to maintain a sufficient heel (i.e., minimum

material level) above the belt. This will help to isolate the belt from overpressures developed during refilling of the bin and prevent excessive belt wear due to impact of hard particles. Another approach, which can be used in conjunction with a material heel, consists of mounting the belt interface rigidly to the feeder frame and using a connection that allows vertical slip between the hopper and interface in order to isolate the belt from any relative deflection. The location of this connection must be approximately one outlet width or more above the bottom of the interface in order to be fully effective. A similar effect can be achieved by operating the belt whenever material is added to the bin or by mounting the belt on flexible supports.

Conditions at and below the hopper

outlet are just as important as the overall container geometry. Understanding the flow properties for your bulk material

Corin Holmes is the operations manager for Jenike & Johanson in Perth.

and how equipment design affects flow patterns and possible development of flow obstructions in storage containers and feeders will ensure that you are protected against baked in design flaws.

By following well-proven design rules, belt feeders can perform reliably and with minimum power, but a mass flow interface is critical.

Do you have a bulk solids handling question? Jenike & Johanson has developed the science of bulk solids flow and specialises in applying it to solving the most challenging bulk solids handling problems. So why not put them 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.

References 1 Jenike & Johanson. 1983. Beware of hopper wall deflections. Flow-of-Solids Newsletter. III(2).

2 Conveyor Equipment Manufacturers Association (CEMA). 2002. Belt Conveyors for Bulk Material. 5th ed. July.

3 Jenike, A.W.: Storage and Flow of Solids, University of Utah Engineering Experiment Station, Bulletin No. 123, Nov. 1964 4 H olmes. C.P.M., Bradley. M.S.A., Reed, Alan R., and R.J Berry: Startup And Running Forces On Bulk Solids Feeders: Experimental Findings Versus Available Models.

Proc. 4th Int. Symp. Reliable Flow of Particulate Solids (RELPOWFLO IV). Tromsø, Norway, 10 – 12 June 2008 5 Strydom, E. 2006. The challenges and advances in belt feeder and hopper design. Bulk Solids Handling. 26(2):106-115.

6 Roberts, A.W. 2001. An overview of feeder design focusing on belt and apron feeders. Bulk Solids Handling. 21(1): 13-25.

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BELTS

ProEdge is specialised, high-strength belt which uses a pre-supplied hot vulcanised edge strip.

Conveyor belts built for almost any application With more than 30 years of experience servicing clients such as Rio Tinto, BHP and FMG, Australian bulk handling equipment manufacturer Transmin, produces and supplies belts under its ConveyorPro brand to suit almost any application.

IN MOST SITUATIONS, DROPPING A large boulder onto an expensive piece of equipment is a quick way to break it.

However, in the mining industry, this is a daily occurrence.

Mining companies need durable machinery to withstand the daily barrage of materials.

Following continuous research and development into its hybrid feeder, the Low Profile Feeder (LPF), Transmin identified an opportunity to further build on its unique offering.

“We needed a way to assist in the prevention of punctures and tearing, which is why ProTough was developed,” Adam Dodson, Head of Aftermarket at Transmin says.

ProTough was designed from the ground up to be one of the toughest belts on the market, ideal for hard rock mining, quarrying and the recycling industries.

It is made up of a hybrid kevlar and steel mesh composite with special grade antiabrasive, cut and gouge resistant cover, allowing it to withstand high impact rock falls of three metres.

The belt’s tensile strength exceeds Australian and International Standards.

Thanks to its increased durability, the belt is significantly less likely to malfunction and requires less

52 І Australian Bulk Handling Review: March/April 2021

maintenance, reducing operating costs.

ProTough is just one type of belt in Transmin’s toolbox. Dodson says the company’s ConveryorPro brand specialises in providing everything an operator needs for a conveyor, including belts, idlers, rollers, pulleys, impact tables and scrapers.

“ConveyorPro supplies to all industries with an extensive product range all under one roof. If you’re looking for anything conveyors, then ConveyorPro is really your one-stopshop,” he says.

“We can provide belts with widths that range from 300 millimetres to four metres, with each laboratory tested and independent inspection verification by global leading inspection service providers to ensure the belt will exceed both lifecycle and budget expectations.”

The ConveyorPro team, comprised of a dedicated Business Development Manager, a Product Specialist and an Engineer who work closely with clients in a range of sectors to find the right solution for a specific problem.

Spillage is one of these common problems that ConveyorPro encountered from its customers. Traditionally, the company used a bonded or glued edge, but this depended on the correct

alignment of the belt. Glued edges also can detach themselves, making it more inefficient than normal.

The answer to this problem was the ProEdge specialised belt, a high strength belt which uses a presupplied hot vulcanised edge strip.

The edge keeps material away from the track and componentry while also minimising spillage. It also features vastly more strength when compared with a conventional edge strip, capable of withstanding up to 800 newtons before signs of fatigue.

ConveyorPro’s offering also includes steel cord, multiple fabric, bucket elevator, corrugated side wall, fire resistant, chevron, rip stop, heat resistant and chemical resistant belts.

“ConveyorPro’s team can do all the calculations and design work for a specific application, then provide a quote,” Dodson says.

“As a local West Australian company, we can provide fast, efficient turn around on quotes and we also carry a range of widely used, fast moving items both here and in our Brisbane warehouse, to greatly reduce leadtimes.”

“Depending on client requirements, we can even service equipment and handle field calls.”

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DEM

Approaches to the calibration and application of DEM models for cohesive bulk materials Shaun Reid, Consulting Engineer with TUNRA Bulk Solids, shares TUNRAs take on the current state of DEM application to industrial bulk materials handling problems. He discusses both the advantages and limitations of the method and shares key tips to ensure that DEM users are getting the most out of their analysis.

THE UPTAKE OF DISCRETE Element Modelling (DEM) as a method for analysing bulk material handling systems has occurred at an extraordinary rate. This is largely thanks to the ever-increasing accessibility of high-performance computing hardware and advances in the functionality of simulation packages. Many advanced simulations are now possible, encompassing several million particles of complex shapes, consideration of adhesive/ cohesive influences, and the ability to couple with complementary simulation techniques that enable the detailed study of fluid-particle interactions, multibody dynamics and breakage, among others.

While these advances enable the consideration of complex physical behaviour, the reality is that unless properly applied, these analyses may tend towards animation rather than simulation. In order to develop DEM simulations that yield robust physical predictions of an intended application, both sound engineering judgements and rigorous calibration are required.

DEM as an analysis tool Any model, DEM or otherwise, is by definition an approximation of a more complex interaction. Accordingly, the development of an effective DEM approach requires appraisal of the situation to which the analysis tool is being applied and identification of potential limitations of the model in that case. The more complex the situation, the further removed the

model becomes from the physics that it was designed to predict, and the more specialised calibration efforts must become. It is here that the experience of the user, not only in application of the method but also in their broader understanding of the engineering discipline, becomes key in developing practical outcomes from the modelling tool.

When appraising the suitability of DEM as a potential analysis method and setting out to develop a suitable model, several questions can be asked up front with respect to the application at hand.

- What are the flow characteristics?

Is flow occurring at high speed or low speed and is failure occurring internally or at a boundary? What pressure is acting in the regions of interest? Is cohesion or adhesion present? Are suitable flow property characterisation test results available for these conditions?

- Is the bulk material uniform?

Can the flow characteristics be adequately represented with one set of material conditions, or do several components need to be developed (representing coarse and fine components for example).

Does flow tend

to generate segregation or mixing?

Could settling or aeration occur during handling?

- Is the flow behaviour time dependant?

Can steady state operation be achieved practically within a shortened window of simulation time?

- What is the scale of the problem?

What is the throughput and total system volume? What particle size is required to appropriately resolve the flow volumetrically? Are shaped particles necessary to develop suitable packing characteristics? Can symmetry be utilised to reduce the scale of the problem?

In considering the above, it becomes apparent that these aspects interplay in governing the most suitable approach to a simulation. Take for example the selection of particle size, this governs the number of particles required in a simulation to represent a given

DEM simulations can encompass complex applications, but diligence is required to ensure that the method results in simulation rather than animation.

Australian Bulk Handling Review: March/April 2021 І 55

DEM

Considerations for calibration

It is best practice to validate DEM predictions (right) with those from fundamental methods, such as continuum-based analysis (left).

While DEM is often applied for the prediction of macro material behaviour (characteristic of the stream), its implementation requires the input of micro parameters (characteristic of an individual, simplified particle). Some of these parameters, for example a rolling resistance factor, are non-physical (cannot be measured in a laboratory). volume of bulk material. An instance that involves high throughputs, a long transient period and complex particle shapes, cannot be efficiently represented by the same size particle utilised for a smaller system, that reaches steady state quickly and requires only simple particle shapes.

It is also important to consider the focus of your application. Take for example a case in which extremely cohesive parameters are implemented so that chute build-up occurring over hours in practice, can be reproduced in a minute or less of DEM time. In doing so, it may be found that adverse outcomes are observed in more general flow characteristics, so that the form of the build-up could be artificially accelerated

56 І Australian Bulk Handling Review: March/April 2021

in the simulation. By instead calibrating DEM models within well understood limitations, treating the method as a tool rather than an answer, and then applying this with fundamental experience and understanding of the application, it is often the case that a more useful outcome will arise from a more simple but robust approach.

Further to this, it may be necessary to partition the system of interest into sub-systems, so that appropriate calibration can be applied to each component. Where it is deemed that a physical behaviour cannot be suitably represented within the limitations of the modelling method, it is necessary to consider complementary approaches, such as physical scale modelling.

The rise in the application of DEM has occurred alongside widespread research into calibration methods. This has resulted in some acceptance of standardised calibration approaches in less complex applications, such as the collaboratively developed white paper for the calibration of cohesionless bulk materials under rapid flow and low consolidation conditions [1]. However, once the influence of inter-particle moisture is considered, as is the case for troublesome bulk materials that exhibit adhesion and cohesion, the complex and multivariable nature of the model has seen many different calibration approaches proposed for such materials.

While various approaches for the calibration of cohesive bulk materials exist, any successful approach must replicate the handling conditions that are present in the application that is being modelled. Particular attention is required to be afforded to the dynamic interactions (at what velocity are particle interactions occurring) and the consolidation pressure acting throughout an application, so that calibration conditions can be chosen accordingly. Due to interdependencies of these aspects, it is usually the case that a model cannot be calibrated adequately for generalised conditions - the simplifications (in size/shape and mechanics) at play mean that a model calibrated correctly for a low consolidation/fast-flow application such as a transfer chute is unlikely to adequately predict the behaviour of a high-consolidation/quasi-static application such as drawdown from a hopper.

While DEM is often applied for the prediction of macro material behaviour (characteristic of the stream), its implementation requires the input of micro parameters (characteristic of an individual, simplified particle). Some of these parameters, for example a rolling resistance factor, are non-physical (cannot be measured in a laboratory).

Therefore, it is generally the case that a calibration test is required to produce a macro characteristic that is dependent on the nature of the bulk material, an

example being the angle of repose for material of a given moisture content.

The test would then be repeated within the simulation domain, with necessary particle simplifications, and the microparameters optimised to yield the desired macro result/behaviour.

In consideration of the above, the selection of tests upon which numerical calibration is based will vary with application. In most applications, tests will be required to govern the calibration of interparticle, particleboundary and bulk density/packing parameters. The nature of these interactions, for example whether they involve sliding or impact, must be considered as appropriate to each case.

A common set of testing performed for the calibration of DEM parameters in low consolidation conditions (as required for a typical transfer chute analysis) may involve: - Shear-box/slump angle and repose angle testing for the calibration of interparticle parameters.

- Adhesion or sliding versus inclination angle testing for the calibration of particle-boundary interactions.

- Bulk density test, given that the

packing of simplified DEM particles is typically less volumetrically efficient than occurs in practice and the particle density likely needs to be increased to compensate.

The above tests could be performed in either a static condition or a dynamic condition, depending on the nature of the final application. In calibration testing scopes undertaken with TUNRA, it is also commonplace to supplement calibration specific testing with a basic flow properties test regime, for the identification of worst-case moisture characteristics, compressibility, and wall friction data.

In addition to a dedicated testing and calibration procedure, it is advised that the resulting DEM material model is validated and refined as necessary, by implementation in a full-scale system that may be benchmarked to behaviour observed on site. This may involve analysis of an as-built piece of equipment, ensuring that flow characteristics and handling difficulties reported on site can be replicated in DEM, before applying the same model to assess changes in design that are aimed to improve operating performance.

GP4849

[1] Katterfeld, André & Coetzee, C.J. & Donohue, Tim & Fottner, Johannes & Grima, Andrew & RamírezGómez, Álvaro & Ilic, Dusan & Kačianauskas, Rimantas & Necas, Jan & Schott, Dingena & Williams, Kenneth & Zegzulka, Jiri. (2019). Calibration of DEM Parameters for Cohesionless Bulk Materials under Rapid Flow Conditions and Low Consolidation. 10.13140/RG.2.2.26318.31048/1.

In summary It is paramount that when developing analysis scopes within which DEM is to be utilised, that the user is able to appraise the suitability of the method for the given application.

By familiarising oneself with the advantages and limitations of the modelling tool, the engineer utilising DEM simulations is able to make informed design and operating decisions. It is recognised that research into calibration methods and underlying DEM models must continue, so that a more rigorous framework for material model development can be realised. However, it is critical that this development occurs in such a way that it contributes to solving industrial problems pragmatically, rather than creating additional complexity in the translation from the simulation realm to the real world.

Would you like to know more? TUNRA Bulk Solids runs regular training courses for the bulk materials handling industry. These courses extensively address the application of DEM, with a particular focus on transfer chute troubleshooting and design.

ASBSH TECHNICAL PAPER

Life cycle costing - A case study Life cycle costing helps organisations estimate the costs incurred over the projected lifespan of a project. Eric Lau, a committee member of the Australian Society for Bulk Solids Handling, aims to demystify the process.

LIFE CYCLE COSTING OR TOTAL cost of ownership includes the whole of life implications of planning, design, construction, operating, maintaining and disposing of an asset. The ‘operate and maintain’ phase is usually the longest part of the life cycle and typically accounts for more than 70 per cent of the total cost of ownership [1, 2].

However, many projects focus on the capital expenditure (CAPEX) and the operational expenditure (OPEX) is overlooked. The total cost of ownership of an asset can be more effectively reduced in the early planning and design stages compared to when it is operating.

Life cycle costing is an important process that should be carried out to estimate the costs incurred over the projected lifespan of the asset. The life cycle costing is used to examine the aggregate costs to design, install, operate, maintain and dispose of an asset in order to provide a more complete comparison for selecting the most appropriate option [3].

If the lowest immediate cost option has high servicing costs or reduced availability which decrease the profits over the long term, it may not be favoured. The level of detail in life cycle costing calculations can make the process tedious, extremely complicated and impractical. The life cycle costing process for a rail mounted bridge reclaimer is presented below.

Methodology Several standards and guidelines describe the process of life cycle costing. ISO 15686-5 establishes a methodology for life cycle costing of building and constructed assets.

AS/NZS 4536 is an application guide to life cycle costing and was published prior to ISO 15686-5. AS/NZS 4536 took into consideration SAE ARP 4293, ASTM E917 and IEC 60300-3-3. Both AS/NZS 4536 and ISO 15686-5 exclude income which is part of the broader whole life costing. When assets being compared have different potential incomes, these must be assessed

58 І Australian Bulk Handling Review: March/April 2021

as part of the overall evaluation. Life cycle costing is an input to the evaluation and a component of the whole life costing.

Definitions The following definitions are reproduced from AS/NZS 4536 and ISO 15686-5: Discount rate: rate reflecting the time value of money that is used to convert cash flows occurring at different times to a common time.

A discount factor, q, is calculated from the real discount rate per annum, d, and the number of years, y, between the base date and the occurrence of the cost.

q =

1 (1 + d)y

Nominal cost: the expected price that will be paid when a cost is due to be paid, including estimated changes in price due to forecast changes in efficiency, inflation/ deflation, technology and the like. The nominal cost is calculated by multiplying the real cost by the inflation/deflation factor, f.

f = (1 + a)y where a is the expected increase in general prices per annum and y is the number of years between the base date and the occurrence of the cost.

Discounted cost: the resulting value when real cost is discounted by the real discount rate, or when nominal cost is discounted by the nominal discount rate.

Nominal discount rate: the rate to use when converting nominal costs to discounted costs. The rate, Q, includes a component for general price inflation.

Q =

1 (1 + a) (1 + a)y y

Real cost: the cost expressed in values of the base date, including estimated changes in price due to forecast changes in efficiency and technology, excluding general price inflation or deflation.

Real discount rate: the rate to use when converting real costs to discounted costs. The rate does not include a component for general price inflation.

Net Present Value (NPV): sum of the discounted future cash flows.

NPV = Σ (Cyq + a) = Σ np =1

cy (1 + d)y

where Cy is the cost in year y and p is the period of analysis.

Net Present Cost (NPC): sum of the discounted future costs. Where costs only are taken into account, the NPV may be called the Net Present Cost.

Purpose and scope The purpose of this analysis is to quantify the costs that have been and will be incurred over the lifespan of a bridge reclaimer. It can be used as an input for evaluating the options for replacement of the machine. Tax, depreciation and income have been excluded from the analysis. The energy costs were not included as part of the operational costs.

The following assumptions were used for this case study: •T he costs have been expressed as real costs without inflation/deflation.

•A discount rate of 8 per cent was used.

•A n exchange rate of AUD$1 to US$ 0.70 was used.

•O perational and capital costs have been estimated where data is not available.

•F orecasts have been used for future costs.

The bridge reclaimer was acquired in Year 0 for $7.5M. The original design calculation based the fatigue life on 20 years.

Operation Two machines reclaim and blend secondary crushed ore from the chevron stacked stockpiles by travelling along the stockyard rails as shown in Figure 1. The ore is then conveyed to bins feeding the grinding mill circuit. Due to the limited

bin storage capacity and the mill demand, high availability is expected from the reclaimers to avoid production loss. More reclaim capacity was required to maintain the feed bin levels compared to the design calculations.

Maintenance Maintenance plans aligned with the original equipment manufacturer (OEM) recommendations were created in the Computerised Maintenance Management System (CMMS) for critical mechanical and electrical components of the reclaimers.

These plans included preventive and foreseeable corrective work.

Condition monitoring and regular inspection of wear components were necessary due to the ore variability.

Structural and mechanical integrity inspections were also scheduled in accordance with the machine risk management plan.

Upgrades Both reclaimers were upgraded in year 11 to increase the peak capacity from 2000 tonnes per hour to 3200 tonnes per hour. This included modifying volumetric capacity of the buckets and the harrows, optimizing the bucket wheel fixed ring openings, increasing the bridge conveyor belt speed from 3.7 to 5.1 metres per second and installing new coolers on the bucket wheel and traverse drive gearboxes. The design fatigue life after the upgrade was extended to Year 24.

Following the upgrade, the reclaimers experienced electrical, mechanical, structural and operability issues which

reduced the reliability. Improvements and repairs to fix fabrication and design defects were made to increase the reliability.

Life cycle costing In developing the life cycle costing for the reclaimer shown in Table 1. The acquisition, operation, maintenance and disposal phases were taken into account.

The maintenance costs were spread over operational and capital expenditure.

The total operational and capital expenditure over the 24 years is AUD$28.8M. When applying the discount factor, the net present cost in Year 0 is $15.9M and is double the acquisition cost of $7.5M. Therefore, when performing an evaluation, the operational and capital expenditure over the life of the asset should be considered. The access to actual data or lack of relevant costs linked to the asset is often an issue. Due to the costs reporting practices, not all operational and capital expenditure were linked to the reclaimer. Some of the expenditures were allocated to other functional locations and cost centres.

A life extension strategy to Year 24 was implemented for the reclaimer in order to defer capital investment in Year 20 for a replacement machine which was estimated at $15M. To reduce breakdowns and the risk of failures, an ongoing inspection and repair plan was required. The asset management and capital plans were updated with the reclaimer’s end of life so that a replacement study and project are initiated prior.

Following the major upgrade in Year 11, the reclaimer experienced production losses and additional operational and capital funds were spent for remediation. Some of the issues could have been identified and addressed in the engineering and construction phases resulting in reduced life cycle costs for the machine.

Life cycle costing is used as an asset management tool by several organisations to realise value from their assets through coordinated activities as defined by ISO 55000.

Several methods detailing life cycle costing have been published in literature.

Additional work is required to refine the simple life cycle model presented in this paper. Using the energy costs and the data for the second reclaimer will provide a more complete model. However, there are many challenges to achieving an accurate model such as availability of reliable data, inconsistent practices, sensitivity of the model to the factors used and validation of the life cycle costing method.

References [1] Y. Asiedu & P. Gu, 1998. Product life cycle cost analysis: State of the art review, International Journal of Production Research, 36:4, 883-908, DOI: 10.1080/002075498193444.

[2] Navarro-Galera, A., Ortúzar-Maturana, R.I. & Muñoz-Leiva, F., 2011. The Application of Life Cycle Costing in Evaluating Military Investments: An Empirical Study at an International Scale. Defence and Peace Economics, 22(5), pp.509–543.

[3] A. Dimache, L. Dimache, E. Zoldi, T. Roche, 2007. Life Cycle Cost Estimation Tool for DecisionMaking in the Early Phases of the Design Process, Advances in Life Cycle Engineering for Sustainable Manufacturing Businesses: Proceedings of the 14th CIRP Conference on Life Cycle Engineering, Waseda University, Tokyo, Japan, pp 455-459.

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OFFSHORE CONSTRUCTION

Jacket structures can be used as an alternative to freestanding piles for the wharf and jetty substructure for offshore berths.

Using jackets for offshore berth construction Richard Morgan, Director of Aspec Engineering, and Daniel Squires, Director of Rendel Limited, examine design considerations for offshore marine bulk loading terminals, including techniques used previously for open sea tanker terminals.

THE EXPANSION OF AUSTRALIA’S minerals exports has created the need for suitable export facilities. Sizes of dry bulk material carriers are increasing with the largest class up to 400,000 dead weight tonnes (DWT) potentially placing further demands on export facilities.

Suitable sites in natural protected deep-water harbours are the ideal locations for export facilities but are scarce and are not always politically acceptable. With vessels of such deep drafts as modern bulk carriers, the cost of creating artificial harbours by conventional means involving dredging and breakwater construction can be prohibitively expensive. Because of this, a feasible option can be to load large vessels

in the open sea. Suitable design of the terminal and lower berth occupancies to compensate for loss of time due to bad weather are usually necessary for open sea conditions.

Design of terminals for open sea conditions is a challenging exercise due to factors such as: a) L arge height of structure above the seabed required to accommodate vessel draft, tidal range, movement of vessel in waves, vessel keel clearance and requirements for clearance of deck above extreme waves including allowance for climate change b) Large berthing and mooring forces c) L arge environmental loads due to waves, wind and earthquake d) P ossibility of difficult and uncertain

foundation conditions e) D ifficulty of construction over water Jacket structures can be used as an alternative to freestanding piles for the wharf and jetty substructure for offshore berths. An advantage of this form of construction is that the jacket modules are fabricated off site and the amount of site work can be dramatically reduced.

Piles are typically driven through the legs of the jacket framework. This form of construction is particularly suitable for construction in deeper water.

Design considerations Ship size One of the first criteria which needs to be established is the maximum size of ship likely to use the terminal. There is a

Australian Bulk Handling Review: March/April 2021 І 61

OFFSHORE CONSTRUCTION

trend that larger vessels result in a more economic freight rate. This trend is more pronounced on longer voyages. However, to produce an efficient bulk transport operation, the selection of the ship size must be considered as part of the total system, which includes the materials handling and marine facilities at both the loading and discharge ports, and the availability of other cargoes that may be handled as part loads or backloads.

The maximum size of ship will allow design draft, berth pocket size and outreach of loading equipment to be determined. Sizes of smaller ships also need to be considered in the design of berthing, mooring and loading facilities.

Figure 1 shows the distribution of ship sizes over 65,000 DWT in the world fleet as of 2017. There are a significant number of large ships over 200,000 DWT which require deep water berths. In terms of maximum size, typical design values for length, beam and draft for a very large 400,000 DWT Chinamax bulk carrier are 360 metres, 65 metres and 24 metres respectively.

The depth of water required below low tide is determined by the maximum vessel draft and the required under keel clearance. Allowance also needs to be made for movements of the ship due to waves while moored and while approaching and leaving the berth.

Prediction of these movements is a complex subject which is preferably handling by dynamic computer simulation.

in the siting, orientation and layout of a terminal as well as in consideration of the resultant loadings in the detailed structural design. The tidal range and operational wave heights will determine the level at which such items as shiploaders, mooring hooks, walkways etc must be placed and hence the deck level. It is desirable that the deck level be above the highest water level due to high tide, surge and wave conditions occurring in combination. Allowance also needs to be made for sea level rise due to climate change.

Wave loadings on offshore structures can be very high. Effects due to drag and inertia must be considered. For jackets this is generally done by determining water particle velocities using a suitable wave theory and applying the Morrison equation to determine induced forces.

Wave uplift factors on a submerged deck can be of very high magnitude. These forces should be considered in design for structures where the deck level cannot be placed above a combination of extreme wave, surge and tide level, particularly in cyclonic areas. This is usually the case for dolphin decks which are usually at a lower level than the main wharf.

Wind effects are important, particularly regarding the forces acting on a ship at berth during operational conditions and extreme wind loads on superstructure elements such as shiploaders, and berth superstructure.

In certain areas in Australia and overseas, earthquake loadings on the structure can be significant and must be considered in the design.

Environmental effects

Berthing and mooring forces

Wind, waves, tide, current and earthquakes are important considerations

Berthing and mooring forces are generally the critical loads for design

Depth of water required

Figure 1: Ship Sizes >65,000 DWT

62 І Australian Bulk Handling Review: March/April 2021

of berthing and mooring dolphins. In offshore terminals dolphins have different functional requirements to the deck and supporting elements for shiploaders, conveyors and roadways and are often configured as separate structures.

Mooring dolphins are usually isolated structures supporting quick release mooring hooks with access provided by catwalks. Ships of the sizes considered require four mooring dolphins for each berth. Each dolphin must be designed for line pulls of up to 4000 kilonewtons from several lines.

Berthing dolphins have rubber fendering systems on their faces but must be designed to take overloads in the event of an abnormal or extreme berthing situation. This is normally done by allowing plastic deformation in the structure to occur for extreme overloads.

Integration of the berthing dolphin function with the jackets supporting the wharf deck by mounting marine fenders and mooring hooks on the jackets can be carried out. In this case an overload mechanism should be incorporated into the design so that plastic deformation can occur in the upper part of the jacket structure so underwater repairs are not required.

Berth configuration The type of shiploader and overall combination of shiploader and berth structure greatly influences the berth configuration.

The length of the berth is determined by the largest ship expected and to a lesser extent by the type of shiploader selected.

In the case of a long travelling shiploader shown in Figure 2, the travel length (and berth length) should be at least equal to the distance between extreme hatches on the largest ship using the berth to avoid the need to move the ship along the berth (termed warping).

A variation of the long travelling shiploader is the long travelling slewing shiploader as shown in Figure 3. This has the advantage that it requires a shorter wharf rail length as the shiploaders can slew to cover the end bow and stern hatches. The slewing shiploader also allows for efficient use of wharf space as the conveyor is positioned between the rails. This type of shiploader can also allow ships to be loaded on each side of the, allowing for layout

Figure 2: Long travelling shiploader

efficiencies. There are other types of shiploaders. However, the long travelling type is most suitable for offshore berths using jacket construction.

Where there are a range of ship sizes from small to large, a long travelling slewing shiploader may be fitted with a telescoping boom to give a greater range of coverage than with a fixed boom. This is shown on Figure 3.

Jacket structures A jacket is a braced framework which can sit directly on the seabed or be suspended above the seabed on temporary piles (spuds). Piles are typically driven through the leg of the jacket and the annulus between the pile and the jacket leg grouted, welded or swaged to provide the

connection.

In some cases, the berthing dolphin can be made integral with the wharf jacket to reduce the amount of piling required on site. A rubber diaphragm closure is often used to prevent water entering the jacket leg and improve buoyancy during jacket placement. The rubber seal is broken when the pile is installed. Above the diaphragm closure is a grout seal which also acts as a wiper to prevent soil entering the annulus between the pile and jacket leg. In some cases, additional inflatable seals are used.

There are primary grout inlets at the base of the jacket leg. Depending upon the height of the jacket, additional inlets may be placed up the pile to allow grouting in stages. The grout inlets are connected by pipes to the surface.

An advantage of the jacket structure is that the jacket modules are fabricated off site, reducing the amount of site work required. Jacket structures generally have a smaller number of heavily loaded piles than freestanding pile structures.

However, in order to achieve the high axial capacities required, it is often necessary to construct drilled sockets or bells at

the base of the piles or to use groups of skirt piles. The jackets also provide lateral restraint to the piles against buckling.

Analysis and design Several software systems are available for structural analysis, wave loading, code checking, and fatigue analysis for efficient jacket structure design. The software typically has wave modules, structural analysis modules, member and joint code check module, and fatigue modules Jackets are fabricated from steel tubes.

The start of the jacket fabrication process is the cutting of square and profiled tube ends including the weld preparation.

This is preferably done with a computercontrolled flame cutting machine. The process is reliable and reduces errors in fabrication.

After individual elements are cut and end elements profiled, members are assembled, and tack welded. Following inspection for straightness, circumferential joints are welded. Semi-automatic methods such as submerged arc are often used. Where possible seamless pipe should be used for jacket bracing members up to

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Fatigue critical joints should be fabricated separately as a joint can with attached stubs to allow welding of profiled brace-chord connections from both sides. Following fabrication of individual leg and bracing members, side panels to the jackets are assembled and welded in the yard.

These panels are then transported to the assembly area and lifted upright into saddles supporting the legs on the ground and secured by guy ropes at the top.

Horizontal and diagonal bracing members are welded into position, scaffolding being required for access to the top level.

After fabrication jackets are lifted or skidded onto a barge or heavy lift ship and secured for shipment. Analysis and design of loading configuration, sea fastenings and transportation loads are also carried out.

Jacket installation Jacket construction on site requires heavy floating cranes or a heavy lift ship for unloading and positioning jackets.

Jackets can be placed on the seabed in a storage area and the legs flooded to provide stability. In some cases, anchoring is also necessary for stability in rough weather. At the appropriate time, jackets are positioned in their final position on the line of the berth. Flooded legs may be de-ballasted with compressed air to reduce the effective to assist in lifting to the required position.

Once the jacket position is set, top closure plates on the jacket legs are removed ready for piling. Guide frames may be required to support the piles

64 І Australian Bulk Handling Review: March/April 2021

during driving. The ability to move the pile inside the jacket leg during the placing of superstructures to tops of piles allows for some dimensional inaccuracies. It also allows the jacket to be levelled to the correct elevation if required.

Guides are positioned in the jacket legs to provide a gap between the pile and inside of the jacket leg for grouting and to prevent fouling with the seals at the base of the jacket leg. The top of the guide is tapered to allow the pile to slide over the protrusion.

Jacket piles are usually heavily loaded.

Different pile types can be considered depending upon foundation conditions, such as driven piles, grouted insert piles or belled piles.

In the case of grouted inert piles and belled piled, rock drilling will be required.

Drilling to the required depth is carried out first then the belling operation is carried out with a special belling tool.

Spoil is carried to the surface in the drilling mud (bentonite) which is filtered and recirculated.

Shear connectors are welded inside the pile during fabrication to allow for force transfer between the pile and the drilled foundation. The base of the pile may also have a thickened pile shoe for hard driving into rock.

Following construction of the drilled socket at the base of the pile, the gap between the inside of the jacket leg and the pile is grouted to provide a structural connection. Grout is injected at the base of the jacket leg displacing water within the leg towards the surface. Pumping of grout is continued until the grout escaping from the top of the jacket legs is of the

correct consistency.

Grout commonly used is a mixture of cement and sea water with additives. It has a colloidal consistency before setting and expands on setting. To increase workability a plasticiser may be added.

Grout should have the following properties: • Adequate fluidity for at least 1 hour from time of mixing at ambient temperature • Minimum water/cement ratio compatible with workability • Unrestrained expansion not more than 10 per cent and not less than one per cent • Settlement of sediment from the grout not exceeding two per cent at three hours by volume • Strength of set grout not less than 10 megapascals at 24 hours, and 30 megapascals at seven days

Superstructure Different superstructure components are constructed for different functions. The philosophy is to prefabricate as much as possible of the superstructure and deck off site including both steel and concrete items. The rail girders for supporting the superstructure are integrated with cross girders supporting the wharf deck so that large modules can be lifted into position with offshore cranes or a heavy lift ship, minimising offshore work.

Pile stubs are welded to the soffit of the superstructures and decks at the fabrication works. In some cases, this is done on site as actual dimensions are required to be confirmed. Stubs are welded to the piles in the field with complete penetration welds.

NO

Conclusion Installations providing for mooring of large vessels in deep water produce conditions which can be beyond the practical capacity of conventional freestanding pile construction. A system using prefabricated steel jackets provides an alternative, developed and proven for offshore oil drilling platforms.

Jackets can be used on dry bulk terminals for export of mineral ores as the trend towards larger ship sizes continues.

This type of construction requires heavy and specialist plant. The method is well suited to projects some distance offshore where economy of scale can be realised.

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MEMBER PROFILE:

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

We speak to Geoff Liddle, Principal Mechanical Engineer at BHP Billiton.

To join the ASBSH, visit bit.ly/3aibXNf

I have been a member of ASBSH for... many years at this point.

I am a member of ASBSH because... my first job as a graduate was with Mt Newman Mining Co (now BHP Iron Ore) at Port Hedland, WA. I developed an interest in materials handling when working as a maintenance engineer at the crushing operations and this has continued for the remainder of my career.

I got into bulk handling because... the range of issues associated with it is enormous. Bulk handling is always throwing up surprises where it should not, based on past experience with different ores. This provides an ongoing challenge which helps make life interesting.

I love my current work because...

I get to work on some very interesting small and large projects, the latest being BHP Iron Ore’s South Flank Project. It was great being able to get past lessons incorporated into the plant to improve operability, maintainability and safety. I also learned a lot more about overland conveyors.

In my role it’s important to... share my knowledge around others that are newer to the game and bring them along on the journey. I am also always picking up new information from these people that I engage with.

I have enjoyed learning about... different aspects to materials handling and being able to translate solutions from one ore to another. One thing I found pleasing was when Engineers Australia made me a Fellow of EA, something that I had not planned on doing.

66 І Australian Bulk Handling Review: March/April 2021

I am inspired by... the younger engineers in our profession who are always asking questions and challenging more traditional solutions.

Although I’m sure they roll their eyeballs when I note that what they think is new was done 30 years ago and didn’t work then.

The most valuable lesson I have learned... is to recognise that if you are working too hard, then you are doing something wrong.

My plans for the future are to... retire in the next few years and then join the retired engineers group in EA.

When I am not working you will probably find me... volunteering as a bush firefighter, sailing, cabinet making, restoring old cars and houses.

The Australian Society for Bulk Solids Handling (ASBSH) aims to enhance the discipline of bulk solids handling through research, education and sound engineering practice. It aims to do this by • Promoting cooperation between universities, research establishments, consultants, equipment manufacturers, suppliers and industrial users.

• Encouraging research and development, technology transfer and training.

• Promoting education at the undergraduate level and continuing education at the postgraduate level.

• Holding national and international conferences at regular intervals.

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If you are unable to attend the event a substitute delegate is welcomed at no extra charge. If notification of withdrawal is received no less than 14 days prior to the event, 80% of the fee will be refunded. No refunds will be made if notification of cancellation is received less than 13 days prior to the date of the event. The organisers reserve the right to alter or cancel the program due to unforeseen circumstances. In the event of cancellation, a full refund of fees will be made.

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OVERVIEW BULK MATERIALS HANDLING

The storage, handling and transportation of bulk solid materials are major activities for a vast number and variety of industries throughout the world. These range from the gentle handling of very small quantities of material in the pharmaceutical and chemical industries to the vast quantities handled and processed by the mining and mineral companies. This diversity is particularly evident in Australia where the wide-ranging nature and scale of operations is somewhat unique.

Considerable advances continue to be made in research, development, application and implementation of the technologies associated with various aspects of bulk solids handling. This course will be of particular interest to a wide range of industries including: • Mining and mineral production and processing • Power generation • Energy and environment • Chemical and petrochemical process industries • Agriculture processing and production • Manufacturing • Pharmaceuticals • Food industry

ABOUT TUNRA BULK SOLIDS

TUNRA Bulk Solids are world leaders in applied and fundamental bulk solids handling research and have been in business for more than 40 years. TUNRA has built a strong reputation in industry for its professional services and world class research in materials handling and flow properties.

TUNRA have completed more than 4,000 projects for over 1,000 companies across Australia and more than 40 countries internationally.

Comprehensive laboratory test facilities are available at TUNRA to aid research and consulting activities at the University of Newcastle. TUNRA is committed to forming long term partnerships with business to help them overcome existing handling problems and assist with planning projects to ensure trouble-free plant operation

WHY ATTEND THIS COURSE

• Diversify your expertise and further knowledge of materials handling concepts • Professional Development (CPD hours) • Increase awareness of material phenomena occurring on site • Learn methods for troubleshooting, optimisation and best practice design • Develop skills in fundamental and numerical analysis approaches • Learn how to apply flow properties test results to benefit your operation or designs • Stay up to date with the latest developments in industry and bulk solids research

TUNRA Course Brochure_May 2021.indd 2

3 DAY COURSE OUTLINE FLOW PROPERTIES TESTING

• Description of test equipment and procedures • Influence of storage time and environmental factors such as temperature and moisture • Evaluation of hopper and chute lining materials for friction and wear • Application specific testing (inc. Dust and TML) • Analysis and application

MASS FLOW & FUNNEL FLOW

• Mass-flow and funnel-flow design procedures • Basic and hopper geometry • Interpretation of flow property reports in relation to bin design • Case studies • Dynamic modelling of bulk solids systems

STOCKPILE DESIGN

• Influence of flow properties and geometry on draw-down and live capacity • Selection and positioning of hoppers and feeders for optimising gravity reclaim • Stockpile base pressures and loads on reclaim tunnels, hoppers and feeders

D.E.M ANALYSIS

WALL LOADS

• Introduction to the Discrete Element Method • Modelling approaches and limitations • Overview of critical model parameters including particle size and shape • Considerations and best practices for industrial application • Application of AS3774 for static and flow load cases • Gate Loads • Symmetric versus Eccentric Discharge • Silo Quaking and Shock Loads • Loads on Buried Structural Elements

3 DAY COURSE INFORMATION COURSE LEARNING OUTCOMES

• Basic principles of handling plant design • Bulk solid flow properties and application to design • Loads on bin walls – symmetric, eccentric discharge – shock loads and silo quaking • Stockpile design incorporating draw-down, live capacity, base loads and locations of reclaim hoppers, feeders and tunnels • Loads on buried structures in bins and stockpiles • Discrete Element Modelling (DEM) fundamentals and application • Chute design for feeding and transfer • Belt conveying – overview of various types of conveyors – bulk solids and conveyor belt interactions – review of basic design procedures and future developments

COURSE PRESENTERS

Emeritus Professor Alan Roberts founded TUNRA Bulk Solids in 1975 to facilitate research and consulting services in bulk materials handling. Following Alan’s long standing committment to the bulk handling industry, he developed, guided and led a team of experts at TUNRA Bulk Solid who continue to be at the forefront of the materials handling industry.

Following in Alan’s footsteps, TUNRA continues to offer professional training courses to industry as a part of our commitment to continuous improvement of the materials handling field. These training courses are run by a minimum of 3 experts from our engineering group who are specialists in their fields.

FURTHER INFORMATION Should you require any further information regarding

• Importance of hopper and feeder interfacing • Review of basic feeder types • Determination of optimum hopper and feeder interfacing for uniform draw-down • Determination of feeder loads, torque and power initial and running conditions • Controlling feeder loads and start-up torque

the course, please contact:

TRANSFER CHUTES

• Basic principles of chute design • Application of flow properties in the design process • Chute flow problems due to adhesion and wear • Dynamic modelling of hood and spoon for optimum accelerated flow • Optimising chute profiles for feeding and transfer • Optimising chute geometry for controlled wear in the flow zone and at the belt feed point • Dust control in transfer chutes • Application of DEM and CFD in chute design and performance evaluation

Email: danielle.harris@newcastle.edu.au

BELT CONVEYING

• Overview of open and closed systems. Special belt conveyors and conveyor selection recommendations • Review of basic design procedures • Economic and technical considerations in optimising conveyor design • Analysis of main resistances – idler indentation, idler spacing, bearings and seals, stress states in bulk solids and contribution to drag.

• Specialised testing

FEEDERS

TUNRA Bulk Solids The University of Newcastle Callaghan NSW 2308, Australia Tel: +61 2 4033 9055 www.bulksolids.com.au

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