Page 1

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH April 2019

OIL TO DETERMINE GEAR WEAR CONTACT-FREE CONVEYORS REDUCE SPILLAGE

T O D A Y


Piecing together your success.

12415/E

We understand that you’ve been building your career piece by piece, and that all those hours, projects and plans allow you to live the lifestyle you deserve. Partner with PPS, and let us help you ensure your success is more than the sum of its parts. Proud sponsor of the SAICE Young Engineer of the Year. Visit pps.co.za to find out more about our financial solutions for graduate professionals. PPS is an authorised Financial Services Provider.


BULK

HANDLING

T O D A Y

T O D A Y

Endorsed by: CMA l LEEASA l SAIMechE l SAIMH April 2019

HAN LING April 2019

Contents

OIL TO DETERMINE GEAR WEAR CONTACT-FREE CONVEYORS REDUCE SPILLAGE

On the cover: ELB Equipment A Member of the ELwB Group Tel: (011) 306-0804

5 4

CMA News

Endorsing Bodies

Company Profile

CMA (Conveyor Manufacturers Association)

LEEASA (Lifting Equipment Engineering Association of South Africa)

Beltcon 19

SAIMechE (SA Institution of Mechanical Engineering)

Conveying

SAIMH (SA Institute of Materials Handling)

also mailed to members of the RFA (Road Freight Association)

Lifting

6 8 12 17

Cranes Come Under the Microscope Cranes Get a Facelift Official Distributor From all Angles and Directions

23 Aramid in Operating Conveyor Belts 31 At Any Speed 32 Making Its Mark with Belt Cleaners 35

Market Forum

12415/E

Copyright

All rights reserved. No editorial matter published in “Bulk Handling Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Our e-mail address is bulkhandling@promech.co.za Visit our website on www.bulkhandlingtoday.co.za

The monthly circulation is 3 673

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Advertising Sales: Louise Cresswell DTP: Sanette Badenhorst Administration: Netta Janse van Rensburg Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas. Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)

BULK HANDLING TODAY

April 2019

3


COMPANY PROFILE

thyssenkrupp “thyssenkrupp has been a trusted supplier of premium quality products and services to the SubSahara African mining industry for decades,” states Philipp Nellessen, CEO of thyssenkrupp Industrial Solutions Sub Sahara Africa. “In order to keep up with the evolving market, we have placed Industry 4.0 at the crux of operations which will in turn be to the ultimate benefit of our customers.” The company’s Minerals Processing division which concentrates on comminution also boasts one of the largest crushing and grinding technology portfolios, which are customised to customers’ plant process requirements. The division recently launched two new innovations; Eccentric Roll Crusher (ERC) and online monitoring of the High-Pressure Grinding Roll (HPGR). Equipped with state-of-the-art features, the new Eccentric Roll Crusher delivers a large throughput and application in hardrock mining as well as a small footprint that is perfectly suited for under ground crushing applications.

Based on over three decades of proven grinding technology, thyssenkrupp has enhanced the HPGR through the development of several innovative process enhancements and application. The HPGR application ensures improved process efficiency and optimised power usage. The machine’s dry grinding technology assists customers in optimising water consumption and in reducing total overall cost of ownership. With these new developments, it is now possible to monitor HPGR performance remotely including continuous wear measurement and notifications of stud breakage. “We have been intricately involved in the process design and optimisation of various mines in the region,” continues Philipp. “We utilise our process expertise and unique in-house test facilities to assist customers make their projects feasible during the planning stages, and later to ensure the process warranties when we transfer the plant.” thyssenkrupp’s Materials Handling division caters to customers from pit-to-port. “Our division is perfectly positioned to offer state-of-the-art technology and system design products for efficient bulk handling solutions,” states Jacques Steyn, General Manager of Materials Handling at thyssenkrupp Industrial Solutions South Africa. “Our all-inclusive range of bulk materials handling equipment includes bucket wheel excavators, crushers, feeders, overland and plant conveyors, stackers, reclaimers, transfer cars, as well as trains and ship loading and unloading systems.” Shifting focus to its world-class conveyor belt technology, the division’s most recent innovation, the Mega Pipe, was developed in collaboration with a key supplier and business partner. The Mega Pipe effectively enables the transportation of material out of a mine pit at 35 to 45 degree incline angles. “The ability to escape a pit at such high angles greatly minimises belt length and enables customers to use routes that are not used by other equipment,” notes Jacques. “It also supports the push of mining companies to reduce CO2 emissions by replacing the previously required mining trucks,” he adds. thyssenkrupp’s latest innovations also extend into the Energy and Sugar division, which smartly encompass digitalisation for enhanced sustainability. The biomass and cold cyclone circular fluidised bed combustion technology focuses on efficiency, while the sugar technology brings operating costs down. When it comes to chemicals, the company is focused on clean carbon to chemical that minimises carbon footprints. Currently the company has three offices in the southern region; South Africa, Mozambique and Zambia which assist in the delivery of products, technology and services to customers. thyssenkrupp’s offices in Ghana and Nigeria provide support with their strong presence in the western and northern regions of Africa. In line with thyssenkrupp’s customer-centricity, the company also offers financial engineering solutions, rounding off its turnkey equipment and technology portfolio.

4

BULK HANDLING TODAY

April 2019


CONVEYOR MANUFACTURERS ASSOCIATION

From The Chairman’s Desk

T

he CMA is a proud supporter of the IMHC and the Beltcon conferences. If you haven’t already done so, please make a note of the Beltcon 20 conference dates in your diary. The conference takes place at St George Hotel, Centurion, on 31 July and 1 August. Exhibition stands are selling fast and some eager delegates are already taking advantage of the early bird discounts! The programme contains some very interesting papers covering the latest research and case studies presented by speakers coming from round the world (America, Australia and Germany) as well as our own South African experts. Check out the website www.beltcon.org.za for more information and registration forms.

Raising skills

The CMA not only supports research projects like induced belt stress at the idler junction; and unidirectional rollers among other topics, but is also very active in presenting training courses to raise the skills level of all working in the bulk materials handling industry. The six-day Diploma course in the design and operation of belt conveyors has been running for the past 12 years and over 260 engineers have achieved Diploma status in that time. Every one of these achievers has nothing but praise for the course content and for the course presenter, Graham Shortt. Other very popular courses are the three-day conveyor certificate course, the one-day “on-site” beltsman course, both presented by Alan Exton, and the one-day refresher course for experienced belt splicing teams. Also on offer is the introductory course in the theory of splicing textile re-inforced

Jay Pillay

belting. This course is not designed to teach how to splice, rather to educate supervisors and other overseers of what to look out for as best practice and to recognise common mistakes that cause splices to fail. The very popular transfer chute design course is planned for the last quarter of the year. The course will explain the basic design principles of guided flow hood and spoon chutes, rock/dead box chutes and combinations of these two chute concepts. The course also covers the use of Discrete Element Modelling as a tool to supplement the traditional calculation methods. Please visit the website www.cmasa.co.za for more information on CMA sponsored research projects and training courses, and for registration forms. Jay Pillay Chairman

Membership at April 2019 All members subscribe to the CMA Code of Ethics Acrow Limited Actom Afripp Projects Altra Industrial Motion South Africa (Pty) Ltd Bauer Bearings International Belt Brokers Belting Supply Services BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CedoTech cc Closeal Manufacturing Collisen Engineering ContiTech South Africa (Pty) Ltd Conveyor Watch (Pty) Ltd Conveyor & Engineering Equipment CT Systems David Brown Gear Industries DRA Projects SA (Pty) Ltd Dunlop Belting Products

Dymot Engineering Company ELB Engineering Services Fenner Conveyor Belting (South Africa) Flexco SA (Pty) Ltd FLSmidth Roymec Giza Technologies (Pty) Ltd Habasit South Africa (Pty) Ltd Hägglunds Drives South Africa Hatch Africa (Pty) Ltd HMA South Africa (Pty) Ltd Hosch - Fördertechnik (SA) International Belting & Marketing (Pty) Ltd KevConBelt (Pty) Ltd Lesa Mining Equipment and Conveyor Belt Lorbrand Martin Engineering Megaroller Melco Conveyor Equipment Merlin consulting (Pty) Ltd Moret Mining Nautilus Projects (Pty) Ltd

Nepean Conveyors OE Bearings Oriental Rubber Industries SA Osborn Engineered Products Pegasus Industrial Services cc Regal Beloit South Africa Rema Tip Top South Africa Ringspann South Africa Rossi Gearmotors (Pty) Ltd Rula Bulk Materials Handling SENET SEW Eurodrive Shaft Engineering (Pty) Ltd SKF South Africa Tenova Takraf ThyssenKrupp Industrial Solutions South Africa (Pty) Ltd Timken South Africa (Pty) Ltd Transvaal Rubber Company Voith Turbo Weba South Africa (Pty) Ltd WorleyParsons RSA Zest Electric Motors

BULK HANDLING TODAY

April 2019

5


LIFTING

Cranes Come Under The Microscope The packaging industry is hungry for paper, with sales in this sector increasing by 3.4 percent last year alone. This is the area of operation for the paper machine 6 (PM6) at the Palm paper factory in Wörth am Rhein, Germany.

T

he 650 000 tons of corrugated base paper it produces each year is handled at various stages by eleven double girder overhead cranes, all playing their own role in the paper production on PM6. In order to safely transport these large paper rolls, the hoisting gears of the eleven

In order to determine whether there is already damage, Konecrane used the Crane Reliability Study (CRS)

cranes must always be in top operating condition. For this reason, Palm tasked Konecranes to look at eight of its most critical cranes. Following the results of the oil analysis and subsequent endoscopic investigation, the maintenance experts identified a significant risk to future production and replaced one of the hoisting gears.

Paper production around the clock

At the Palm paper factory, located in Aalen in Baden-Württemberg, everything revolves around recovered paper. Nine paper machines in five factories annually produce approximately 2.2 million tons of newsprint and corrugated base paper. Correspondingly high are the demands from the eleven double-girder bridge cranes that have been in use in the factory in Wörth am Rhein since the start of production in 2002. “The cranes are in use day and night,” says Sven Bohrer, electrical engineer at the Palm paper factory. “If one should break, production will stop or slow down, costing time and money.” Because you can look deep inside the oil, the wear metals and waste substances it contains make it possible to draw conclusions about the state of the entire gear.

Method

Nico Zamzow, Vice President for Industrial Service EMEA Central at Konecranes, comments on the method, “The oil analysis protects the crane. Any damage can be identified and treated early with its help. Moreover, system operators are able to optimise the maintenance and servicing of the cranes thanks to the detailed analysis report, and thus significantly increase their lifespan.” Using oil analysis, wear traces, such as rust or metal particles in the gear oil, can be identified and unplanned downtime can be prevented

For the oil analysis at Palm, Konecranes experts took samples from the hoisting gears of the eight doublegirder bridge cranes. “The samples are analysed

An important element of the Konecranes CRS is inspecting the crane systems for signs of wear

6

BULK HANDLING TODAY

April 2019


by our laboratory, which specialises in industrial drive train analysis. Here, the lab staff compares the current state of the oil with the samples taken in 2016 and against the OEM design limits,” says Nico. “In this way, we also use trend analysis to provide the best possible picture of any change within the condition of the gearbox.” The result for Palm was that seven of the eight cranes were found to be healthy, as the gear oil contained few to no foreign elements or waste substances indicating contamination or wear. However, the gear oil of a crane used in the roll warehouse had a noticeable increase in its wear partial count, triggering the lab to issue a “Caution” notification on the analysis report

The cranes in the roll warehouse of the Palm paper factory are in use at all times. For this reason, one important element of the Konecranes CRS is inspecting the crane systems for signs of wear

System operators are able to optimise the maintenance and servicing of the cranes thanks to the detailed analysis report, and thus significantly increase their lifespan “Iron particles in the oil can be an indication of increased wear and a deeper look may be required for this particular hoist,” comments Nico.

Getting to the root of the problem

If the reason for the wear is not clearly identified and removed, the gear may be permanently damaged. “If the gear is jammed while there is a roll on the hook, it becomes very difficult to recover,” he explains. In order to determine whether there was already damage, Konecrane used the Crane Reliability Study (CRS). The modular analysis allows the team to check safetyrelevant components, like the hoisting gear as well as the steel structure, the motors and the electrical equipment of the crane.

Task distribution: Experts analyze the gear oil of eight of the eleven doublegirder bridge cranes that are used in the large paper machinery hall and in the fully automated roll warehouse.

“Just as in the medical field, we use the endoscope to reach inaccessible places without having to dismantle the entire gear,” says Nico. “For the CRS, we use an oil-resistant model developed for industrial use which can be fitted with different lenses.” Following the endoscopic investigation, Konecrane can be certain that the hoisting gear must be replaced. In addition, the cable drum, the cable drum support, the slip-ring unit, the cylinder coupling and the motor coupling must be renewed. “Thanks to discovering the wear early on, there was no risk to safety and we were able to replace the old gear with a new one without affecting production,” concludes Nico. Konecranes, Nico Zamzow Tel +49 6103 7333-235 www.konecranes.com

BULK HANDLING TODAY

April 2019

7


LIFTING

Cranes Get a Facelift Liebherr's maritime customer service is carrying out a modernisation project on Sakhalin Energy’s Molikpaq offshore platform off the Russian island of Sakhalin. Two RL 1500 ram luffing offshore cranes are going to be completely renewed. In addition, a BOS 1900 will be upgraded with the same generation control system as the RL 1500.

S

ince December 2008, oil from the platform streams through the trans-Sakhalin pipeline system to the oil export terminal of the Prigorodnoye production complex. After two decades of continuous operation, the existing three offshore cranes now need to be renewed. In terms of planning, logistics, technology and craftsmanship, this is an extraordinarily demanding conversion project. Several Liebherr companies cooperated with each other to implement the project.

The main reason which triggered this modernisation was to have the same software and handling for the crane operators as the two new RL 1500 Support structure in place

The replacement of the first crane (BOS) with a brand-new RL 1500 has already been undertaken. In order to be able to move large parts on the platform, Liebherr installed a 230 HC-L 8/16 Litronic support tower crane. In addition, a sliding system was designed and built by the company´s customer service team to move particularly heavy components and modules over the platform.

8

BULK HANDLING TODAY

April 2019

The second phase, the modernisation of the existing BOS 1900, has also already been completed. The main reason which triggered this modernisation was to have the same software and handling for the crane operators as for the two new RL 1500s. A further reason was to use the same control system components to increase spare parts interchangeability and availability. Simultaneously reducing spare parts storage costs. The third phase will include the installation of the second ram luffing crane.

Characteristics

Both RL 1500 cranes are characterised by a cylinder


luffing box boom design and a dieselhydraulic driven main engine. When it comes to the project specifics, the cranes can handle loads up to 65 tons, equating to 25 more tons than the standard lifting capacity of the RL 1500.

Arctic temperatures

This customised solution has been ensured by providing a three fall reeving. Equipped with a main and an auxiliary hoist the RL cranes have a maximum reach of 42,6 metres. This makes them an ideal solution for general purpose applications such as maintenance work or lifting supply. Taking environmental conditions into account, the cranes are equipped with an arctic temperature package which allows operation down to -36°C. Another feature is the large and comfortable cabin. Upon customer request, a mid-sized cabin with 10m³ can be installed. Liebherr +49 381 6006 5023 www.liebherr.com

BULK HANDLING TODAY

April 2019

9


TRANSFORMING FREIGHT LOGISTICS

10

BULK HANDLING TODAY

April 2019


TRANSNET FREIGHT RAIL

www.transnet.net www.transnetfreightrail-tfr.net

BULK HANDLING TODAY

April 2019

11


LIFTING

Official Distributor Global tower crane leader, Potain, has appointed Gauteng-based Crane & Hoist Equipment as its official distributor in South Africa, Namibia, Botswana, Mozambique, Lesotho and Swaziland.

Telescoping a Potain MD 310B to 120 metres high

12

BULK HANDLING TODAY

April 2019


With about 80 years of combined experience in this sector, focusing on Potain equipment, we are certainly very proud of this close partnership with a world player of this stature,” says Brenden Crous, managing director of Crane & Hoist Equipment SA. “The management and staff of our business have a long relationship with Potain products, which we will leverage to the benefit of our customers.” A major producer of tower cranes and self-erecting cranes since 1928, Potain offers over 60 models in a variety of product ranges. Over 100 000 Potain cranes have been sold and installed around the world. “With at least 200 Potain cranes in active service in South Africa alone, we can see that the local market is very loyal to this strong brand,” says Brenden. The company’s direct sourcing from Potain in France will make life easier for customers and prices more competitive. “We place a priority on safety and compliance and being part of the Potain family also gives us direct access to their global expertise. We are, of course, a registered lifting machine entity (LME) with the Department of Labour, and believe in close compliance with OEM specifications in all our work.”

Expertise on tap

Crane & Hoist Equipment SA was formed in 2017 by a management team that together have amassed over 40 years in the tower crane sector. This team includes sales director, Louw Smit, and operations director, Danie Roos. Their experienced staff includes two Potain-certified master technicians, accredited lifting machine inspectors (LMIs), and qualified riggers and electricians.

We place a priority on safety and compliance and being part of the Potain family also gives us direct access to their global expertise “We even have in-house training capacity which is certified by Potain, so we are able to train our own staff and customers’ staff,” adds Brenden. Strong relationships with key customers in the local market has meant that Crane & Hoist Equipment SA has been busy since day one, mainly in rentals, servicing, anchoring and jacking but also in crane sales. The company already boasts its own fleet of seven tower cranes suitable for medium-sized and small projects, where 5 to 8 ton lifting capacity is required with 50-60 metre jib lengths.

An MCT 205 from the Potain Asian range of tower cranes

Preparing to telescope a Potain MCT 85 in Rosebank

BULK HANDLING TODAY

April 2019

13


The Local Manufacturing Expo Aims to:

21 – 23 MAY 2019

Promote local manufacturing

EXPO CENTRE, NASREC,

Demonstrate Southern Africa’s export potential

JOHANNESBURG, SOUTH AFRICA

Provide access to global markets

A Showcase of Southern Africa’s Manufacturing Capabilities Who Will Exhibit?

Networking opportunities Develop public / private partnerships Public / private sector collaborations Identify industry challenges and opportunities for growth

Manufacturers across a variety of sectors, including:

Agriprocessing

Automotive

Business Process Outsourcing

Capital Equipment

Chemicals

Construction

Engineering

Food and Beverage

Furniture

ICT and Electronics

Metals

Mining

Plastics

Textiles/ Clothing/ Footwear

Transport

www.localmanufacturingexpo.co.za In association with:

14

Endorsed by:

BULK HANDLING TODAY

Implemented by:

April 2019

Brought to you by:


LIFTING Far afield

Beyond its Gauteng base, the company has also recently been active in several KwaZulu-Natal residential developments and its experts have been called on from as far afield as Ghana, Sudan and Burkina Faso. Potain itself has also collaborated with Crane & Hoist Equipment to assist with a commissioning project in Guinea. In addition to Potain’s GME and GMA ranges, the company offers specialised cranes such as the giant MD3200; this model has a maximum capacity of 85 tons and can lift 26 tons at 85 metres, and boasts a hook height of some 104,5 metres. Crane & Hoist Equipment SA Louw Smit Tel: 083 413 7524 Email: louw@che-sa.co.za www.che-sa.co.za

or

wth

Professional planning of the tower crane position minimises the disruption to the finished facade

BULK HANDLING TODAY

April 2019

15


16

BULK HANDLING TODAY

April 2019


LIFTING

From all ANGLES and Directions A unique service whereby lifting machines and lifting tackle are examined and tested on-site, gives clients the assurance that they comply fully with all regulatory requirements, as well as ensuring the safety of all personnel.

T

he newly-established Mandirk Lifting, is part of the Mandirk Group, a specialist supplier of engineering tools and equipment for Maintenance, Repair, and Operating (MRO) applications in a range of industrial sectors.

All of our global brands are not only SANS- and SABScompliant, but subscribe to all relevant international regulations and accreditation The lifting division was established to extend the group’s service offering and total solutions approach, under GM Jaco Vorster, who points out

that management has over 30 years’ combined experience in the lifting industry. “In addition to our extensive expertise, we have a comprehensive inventory of equipment and spares stockholding, and are able to leverage off the nearly 250-branch network that the Mandirk Group has access to through its holding company, BMG,” Jaco comments. Brands represented by Mandirk Lifting are Kito (electric chain hoists, manual chain blocks, and lever hoists, with SABS permits on the manual units as well as the chain), Ingersoll Rand (lifting and materials-handling), Liftall (chain blocks and lever hoists), and below the hook (sling protection and load hugger cargo control.) Lifting tackle brands available are Myte, McKinnon Chain and Umoya. Enerpac is a leading manufacturer of hydraulics tools, equipment and bolting solutions.

Complete solutions

The combination of all these global brands means Mandirk Lifting can offer complete solutions tailored to suit specific requirements, as well as different budgets. “What gives us the leading edge in the marketplace is that we have the full support and back-up of all of the global brands we represent, which gives us a depth of technical support that is hugely beneficial to our customers. “In addition, all of our global brands are not only SANS- and SABS-compliant, but subscribe to all relevant international regulations and accreditation,” Jaco points out.

Qualified specialists Mandirk Lifting GM, Jaco Vorster

The importance of the on-site service offered by Mandirk Lifting is that testing and certification of lifting equipment is not only a legal requirement in South Africa, but must be carried out by qualified specialists with access to calibrated testing equipment. The company also issues certificates for all new equipment sold, in addition to inspecting, testing and certifying equipment that is already in the field. Here Mandirk Lifting complies fully with the requirements of the Lifting Machine and Lifting Tackle Regulations of the Occupational Health and Safety Act 85 of 1993.

Electric chain hoists, manual chain blocks, and lever hoists

BULK HANDLING TODAY

April 2019

17


WORLD-CLASS performance requires speed, agility and endurance

STRATEGY

INFRASTRUCTURE

OPERATIONS

Planning strategic direction benchmarked to world-class standards

Development of world-class infrastructure from concept to realisation

Development of operations to best practice and world-class standards

Supply Chain Strategy

Facility Design & Development

Process & Operations Design

• Supply Chain network analysis & design • National & Regional DC strategy development • Facility Sizing and OPEX estimates • On-line fullllment • Slow vs. Fast movers network set-up • A Supply Chain that supports business strategy • Site development strategies • Technology, IOT and digitilisation strategy

• Greennelds site development

• Operations assessment and benchmarking • WMS / WCS review • WMS / WCS functional requirements • Process and operations optimisation • Long term operational development strategies • Process audit • Labour standards and incentive programs

planning • Brownnelds site development planning • Functional building requirements speciication • Technical liaison to professional / development team • Facility sizing requirements (short to long term) • Design to execution • Procurement, program and vendor management

In today’s competitive business world you need to focus on every opportunity to advance your company mission

18

BULK HANDLING TODAY

April 2019

Cape Town: (021) 816 2000 | ils-ct@ils.co.za Johannesburg: (011) 656 1100 | ils-jhb@ils.co.za www.ils.co.za


One of the premium international brands on offer

Its lifting machinery inspectors are certified in terms of the Engineering Profession Act 2000 (Act No. 46 of 2000), and the company is a registered member of the Engineering Council of South Africa (ECSA). The Department of Labour has approved the company in terms of the Driven Machinery Regulations 18(5) of the Occupational and Safety Act 1993, for examining and testing lifting machines and lifting tackles.

Wide scope

The scope of approvals offered includes lever hoists, chain block and lifting tackles. An ongoing training and skills development programme ensures that the company’s personnel are up-to-date with the latest trends and developments.

The equipment range catered for includes mechanical ratchet jacks, hydraulic pumps and cylinders, chain and lever blocks, geared and plain crawls, pneumatic hoists and winches, Tirfors and ropes, mechanical grabs and clamps, and slings (chains, polyester, and steel wire rope), together with inspection and proof load testing services. Mandirk Jaclyn Bilson Tel: (011) 922-5300 Cell: 082-385-7711 Email: jbilson@mandirk.co.za www.mandirk.co.za

enquiries@greentechnical.co.za www.greentechnical.co.za BULK HANDLING TODAY

April 2019

19


TRACE Inte is a globa anti-br or leading pr party risk

TRACE due diligence solutions are based on internationally accepted best practices and our experience and familiarity with the compliance needs of multinational companies. Services range from a denied parties screening to enhanced due diligence, including TRACE Certified Due Diligence.

20

BULK HANDLING TODAY

April 2019


International, Inc. globally recognized ti-bribery business organization and g provider of third risk management solutions.

BULK HANDLING TODAY

April 2019

21


Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of fifteen through to 100 guests in three well-appointed and equipped business suites. Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages. Secure parking, Wi-fi, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 1401 41 St. Albans Ave, Craighall Park

22

BULK HANDLING TODAY

April 2019


BELTCON 19

Aramid In Operating Conveyor Belts

Henk Van De Ven

Heidi Beers

Wang Jinglei

Extended lifetime, energy savings and environmental effects

I

n recent years, aramid fabric as a reinforcement in conveyor belts has gradually found its position among traditional textile and steel cord reinforcement materials. Due to its unique properties, such as corrosion and heat resistance, aramid has been used on over 400 belts for more than three decades, in applications such as phosphate mines and steel production plants. This paper provides some background to aramid reinforcement in conveyor belts and gives an overview and analysis of various installations. Advantages of the already installed belts include extended lifetime and energy savings. These advantages in turn have significant financial implications, with low cost of ownership and short payback periods, in addition to the positive environmental effects of lower carbon dioxide and particulate matter emissions as a consequence of reduced energy usage. Several recent cases of belts running in hard rock mining and wood log operations in South America are described. Using similar belt covers, they show a lifetime increase of up to four times compared to traditional textile reinforced belts, and some of these belts have by no means reached the end of their life. The paper also describes the experience of the Baodian

Carlos Martins

Enrique Mendez

Coal Mine, part of the Chinese Yanzhou Coal Mine Company (YCMC). In a pilot installation, Baodian used aramid in a 666 metre-long belt, with a 6o incline. Based on ease of operation and reported energy savings of 8%, YCMC group concluded that an aramid reinforced conveyor belt is a technically and economically viable alternative to steel reinforced belts. Positive results in this first pilot site led to the installation of a second aramid belt on a 3.4 km newly built system, installed in combination with optimised idlers. A 43% reduction in current absorbed by the system has been observed compared to a similar steel cord reinforced belt system. It is estimated that approximately 15% of energy savings can be attributed to the use of an aramid belt. The environmental benefits, in terms of reduced emissions of carbon dioxide and particulate matter, have been determined using a certified customer benefit model1.

Introduction

The properties of aramid will only be briefly described here, since these have already been covered previously at Beltcon by Arts and Lodewijks2,3. For the sake of completeness, however, the relevant details are summarised. Poly-paraphenylene terephthalamide, also known as ‘aramid from aromatic amide’ is a very strong and lightweight synthetic fibre. It has a high modulus, is thermally stable, and is highly resistant to impact and chemicals. It is used in conveyor belts in two different ways: 1. As aramid reinforcement fabric in the carcass 2. As a chemically treated aramidbased additive to the bottom cover compound in order to reduce rolling resistance. For the carcass, the so called straight warp fabric construction is most commonly applied. A schematic view of the fabric embedded in rubber is shown in Figure 1.

Figure 1. Schematic representation of a straight warp aramid DPP fabric construction.

It consists of aramid cords in the warp direction, polyamide 6.6 in the weft direction, held together by a polyamide binder yarn in the warp. Similar to the commonly used textile fabric (EP), the

BULK HANDLING TODAY

April 2019

23


BELTCON 19 aramid fabric is treated with a resorcinol-formaldehyde-latex (RFL) dip formulation to obtain sufficient adhesion between the fabric and skim compound. For this reason, the nature of the cover compound to be applied is identical to current solutions. A key advantage of using an aramid-based fabric instead of a steel cord carcass is its lightness, as shown in Figure 2. Aramid fibres have a density of just 1.44 g/cm3 and are five times stronger than steel on a weight-to-weight basis. Other parameters, such as belt sag and transition length, are similar to those defined for steel cord reinforced belts. Due to the low elongation characteristics of aramid, if the substitution concerns an EP textile belt, the transition length of the conveyor system may need to be checked and adjusted. Belt sag is the distance between the line joining two adjacent centre idler rollers and the bottom of the belt and is a function of belt mass. It is normally expressed as a percentage (Figure 3). Sag is controlled by the amount of tension in the belt. The force applied by the take-up system must be great enough to keep sag down to an acceptable limit.

over steel and textile fabric belts. These are summarised below:

Aramid fabric vs steel cord (ST 630 – 3150 N/mm)

Less weight at same strength — Reduced energy consumption Reduced CO2 emissions Higher flexibility — Smaller pulleys No corrosion — Easier maintenance, higer durability Thinner belt design — Better flexibility, fewer splices Breaker functionality — Impact and slitting resistance Aramid fabric vs Textile fabric (EP 630 – 3150 N/mm) High ply strength — Single- vs multi-ply fabric concept

Like steel cord construction, idler junction failure with an aramid reinforced belt is unlikely to occur if belt sag is limited to a maximum of 3%.

Thinner belt design — Bending resistance, impact

Aramid reinforced conveyor belts offer a number of advantages

Low dynamic belt growth

Take-up length

Because of the aramid belt’s greater flexibility compared to steel cord reinforced belts, pulley diameters can be significantly smaller. Optionally, the pulley diameters could be in the range of 20-25% smaller compared to steel cord belts4, 5. Since a single-ply aramid fabric construction should always be applied, compression of the aramid cords, and consequently a drop in tensile strength, is negligible. In Figure 4, recommended pulley diameters from a manufacturer are listed5. These are in line with those reported by others4.

Overview of selected aramid belts in operation

As far as is known, the first aramid reinforced belts were installed in 1978. Since then, several hundreds of aramid reinforced belts have been installed around the world, covering a wide range of applications. Figure Figure 2. Tenacity and elongation characteristics of reinforcement materials

Figure 3. Belt sag definition. Dunlop Industrial Products PTY 4

24

BULK HANDLING TODAY

April 2019


BELTCON 19

End-customer Mine

Anglogold Ashanti

Anglo-American

Votorantim

-

Mantoverde

-

Brazil – Goiás State

Chile – Copiapó region

Brazil – Federal District

Primary Crusher

Stacker

Primary Crusher

Gold

Copper

Limestone

Correias Mercurio

Correias Mercurio

Correias Mercurio

EP1250/4 12x5 48” Din X

EP900/3 48” 6x3 Din W

Extrabelt PL440 12x5 48”

Short lifetime due to cuts, Short MTBF particularly due to rubber upper cover repair

Short lifetime due to high abrasion of the ore conveyed

Short lifetime due to huge impact conditions and constant rip accidents

Original belt’s average lifetime

6 months

4 months

4 months

Recommended aramid belt

EAS DPP1600 12x5 48” Din X

XEAS DPP1000 6x3 42” DIN W

EAS DPP1600 12X5 48”

Country Application Ore/material Belt manufacturer Belt specification (According to O&M conveyor belt project) Customer complaint

Belt length (m)

128

286

165

Date of aramid belt installation

10-10-2014

5-6-2015

4-10-2015

Aramid belt average life time

25 months and still in operation

6 months

12 months (expected)

400% Aramid belt still in operation with no change scheduled

50% longer lifetime

400% Aramid belt still in operation with no change scheduled

8% less energy consumption (with 12 o inclination)

Not measured

Not measured

No cuts during the life of the belt

No preventive and corrective maintenance needed during the period tested

Results Lifetime increase

Energy consumption

Other

Far fewer rubber upper cover repairs Much longer MTBF and Table 1. Overview of selected shorter aramid MTTR reinforced belts

5 provides an overview of selected aramid reinforced conveyor belts, some of which are discussed in detail in this paper.

Case studies: lifetime

The high, single-ply strength of aramid fabrics enables belt manufacturers to produce a more flexible belt compared to a multiply EP belt. This feature has been utilised to test the aramid belt’s lifetime in primary crushers and stackers. The results of several pilot belts are described in this paper. Table 1 is an overview of selected installations in South America, where aramid belts were chosen to extend the lifetime of textile reinforced belts, which needed continuous repairs and had short lifetimes. The aramid belts were manufactured and installed by a Brazilian belt manufacturer6. Of these, the Anglogold Ashanti case is described in more detail. This is an AngloGold Ashanti gold mine in the Goiás State of Brazil. AngloGold Ashanti Limited is a global gold producer with 21 operations on four continents and 62 000 employees. The mine asked for an impact-resistant crusher belt to transport minerals up to 500 mm. Multi-ply EP solutions need constant repair and have very short lifetimes (~6 months). The crusher operation, using the original EP four-ply belt, had experienced regular unscheduled stops almost on a weekly basis, generating high monthly costs. The pilot belt offered was an aramid reinforced belt DPP1600, with equal thicknesses and compound grade for bottom and top covers. Figure 6 shows the belt in operation.

Figure 4. Recommended pulley diameters. Metso Minerals

BULK HANDLING TODAY

April 2019

25


BELTCON 19 Following the introduction of the aramid belt, incidents of cutting or tearing were reduced to almost zero. Inspection of the top cover after the first year, in a 24-hours-per-day operating regime, showed that it was visibly intact, with no repairs having been required during this entire period. This exceptional result could only be explained by the flexibility of the aramid belt. According to the belt manufacturer6, the multi-ply EP is a rather rigid belt. Thanks to the greater flexibility of the thinner single-ply aramid belt, the energy of a large lump impact can be absorbed more easily on a flexible surface than on a rigid surface. The fairly loose construction of the straight warp fabric also contributes to better impact

Figure 5. Overview of selected aramid reinforced conveyor belts

Figure 6. Aramid reinforced belt at Anglogold Ashanti, Brazil

26

BULK HANDLING TODAY

April 2019

resistance compared to plain weave fabric constructions7. In addition to its superb impact performance, the aramid belt showed a reduction in energy consumption of approximately 8%, with a 12o inclination in the belt.

Case studies: energy savings and environmental impact

The reduced energy consumption stemming from the use of aramid fabrics instead of steel cords has been described extensively in the past3. The gain is a result of the lighter weight of the carcass, a uniform load distribution from flat fabric as opposed to steel cords, and the use of a thinner


BELTCON 19 bottom cover compound. The effect of the weight can be quantified by using the equations set forth in DIN 22101. Where

This paper describes two conveyor belts with an aramid carcass recently installed in an underground coal mine in mainland China. The Baodian Mine of the Yanzhou Coal Mine Corporation (YCMC), which in turn is part of Yankuang Group, is the fourth-largest state-owned coal mine in China. It is engaged in underground mining, coal preparation and sales, as well as coal transportation services by rail. Its products are mainly low-sulphur coal, which is suitable for large scale power plants and for use in pulverized coal injection. The belt manufacturer is part of the YCMC group8.The results, which were presented at a CRIA conference in China in 20169, are listed in Table 2.

Required power:

The belt mass, m’G, is proportional to F and thus affects the required power. With an inclination of the belt, the angle of inclination cosθ and the factor (H.g.m’L) will start to influence the total motional resistance and the influence of the belt weight will decrease.

The first (short) belt was installed on an existing line, replacing an ST 1600 belt. Cover thicknesses of the reference steel belt were 6+6 mm, weighing 38.6 kg/m. A weight reduction of 44% was achieved. This led to a reduction of the Total Motional Resistance component (2m’G + m’L) of 19%. By reducing the bottom cover thickness from 6 mm to 5 mm, the friction coefficient, f, in the Total Motional Resistance should have been positively influenced3. However, due to the 6° incline, the second part of the equation, where belt mass is not taken into account, H.g.m’L becomes a major factor in the Total Motional Resistance Mine and thereby in the total power consumption, P.

End-customer

Yanzhou Coal Mine Corporation

Yanzhou Coal Corporation

Mine

Baodian coal mine

Baodian coal mine

Country

China

China

Application

Transport in underground mine

Transport in underground mine

Ore/material

Coal

Coal

Belt manufacturer

Tangcun Industry

Tangcun Industry

System specification (According to O&M conveyor belt project)

Belt strength: 1600N/mm Belt width: 1200mm Running speed: 3.55 m/s Capacity: 1300t/h Power installed: 1×400kW Belt inclination: 6°

Belt strength: 2250N/mm Belt width: 1400mm Running speed: 0~4m/s Capacity: 2500t/h Power installed: 3×315kW Belt inclination: 0°

Customer goals

No corrosion from water; anti-slitting; good belt tracking; easy to transport and install

No corrosion from water; anti-slitting; good belt tracking; easy to transport and install

Belt Length (m)/ weight (kg/m) / cover thickness (mm)

666 / 21.8 / 7+5

3400 / 27.3 / 7+5

Date of aramid belt installation

March 2015

April 2016

Energy consumption

9% energy savings measured

Estimated energy savings: 30- 40%. Derived from ampere readings (40A vs. 70A full load). See explanation in text below.

Other

Higher trough ability, which leads to higher transport capacity

Higher trough ability, which leads to higher transport capacity

No corrosion

No corrosion

Easy to transport and install

Easy to transport and install

Less maintenance. Saving mainly due to good running condition of aramid belt, with lower weight and better flexibility. Better belt tracking also contributed to less maintenance.

Very satisfied with initial results on energy savings and running behavior.

Results

Table 2. Results of two aramid belts in China

Both situations, the ST1600 vs DPP1600, were monitored, and the usage was 244 vs 222 kW respectively. Despite the incline, which reduced the effect of the belt mass, a 9% reduction was measured. The mining company was very positive about the higher transportation capacity of the aramid belt which they attributed to the higher flexibility of the belt compared to the more rigid steel cord belt. Moreover, looking at the other features, such as ease of installation, good troughability and running behaviour, the results from the first belt were regarded as extremely positive. The mining company commented that the installation was easier compared to a steel belt. In addition, maintenance was less intensive with the aramid belt: the steel belt required four to five people, while the aramid belt only required three people. In addition, the aramid belt did not corrode, which was a critical issue for the mine. Based on the first installation, the mining company decided to install an aramid belt on a newly built system. Two identical lines had been operating for some years, equipped with a steel reinforced ST2000 belt. In contrast to the first operating system described above, these lines have a zero inclination. The weight of the ST2000 reference belt is 47.6 kg/m vs the 27.3 kg/m of the DPP 2000 belt, a reduction of 42%. Figure 7 illustrates the installation. Since the second aramid belt was installed on a new system, comparison with the existing lines is not straightforward, because it is not a replacement on the same conveyor system. However, the setup of the three lines (2 x ST2000, 1x DPP2000) is identical in terms of dimensions, BULK HANDLING TODAY

April 2019

27


BELTCON 19 capacity and running speeds. The readings of the current steel and aramid system showed 70A versus 40A during use, a reduction of 43%. The current is proportional to the power via the formula:

parameter, but is assumed to be equal for both cases (steel and aramid). Therefore, conservative energy savings between 12% to 15% can be estimated from the belt weight with zero incline. In addition, higher energy savings could be expected due to the lower friction coefficient caused by the thinner bottom cover3.

Case studies: customer benefit model

Since the efficiency of the drive and the power factor are unknown, it is difficult to quantify the exact contribution of the aramid belt properties. However, the energy savings can be estimated based on the weight differences of the belt, the running speed and the capacity of the system. The difference between the ST2000 and DPP2000 belts is 20.3 kg/m. The reduction of the Total Motional Resistance component (2m’G + m’L) in the DIN formula is 15%. Idler weight is an unknown

Air pollution, or smog, is a serious problem in various parts of the world, particularly in China. The production of electricity generates a vast amount of carbon dioxide (CO2) and particulate matter (PM10), the levels depending on the source used (e.g., coal or oil). The aramid belt concept with its lower energy consumption compared to steel reinforced belts contributes to emission reduction. Teijin Aramid has developed a calculation tool to quantify the positive environmental impact of using an aramid belt1. The customer benefit model (CBM) aims to provide a comprehensive overview from the perspective of the end user, showing that environmental and financial best practices can

Figure 7. Aramid DPP 2000 belt in Baodian Coal Mine (YCMC), China

Figure 8. Results of CBM calculation of the 666 m Chinese belt in Baodian Mine

28

BULK HANDLING TODAY

April 2019


BELTCON 19 go hand in hand. The model is based on ISO 14040 and 14044, and is TÜV-certified. The model analyses the ecoefficiency-related gains for end users, providing a complete overview of the environmental and financial impact of the belt in the use phase, benchmarked against traditional solutions. Based on energy use, energy prices, and belt costs, the CBM model calculates a wide range of key indicators for each situation: carbon dioxide (CO2) and particulate matter (PM10) emissions, in addition to traditional financial indicators, such as payback period, net present value (NPV), and internal rate of return (IRR). The CBM model was applied to the first (short) belt in the Yanzhou Coal Mine. In terms of energy consumption, a saving of 9% was measured, which can be completely attributed to the use of the aramid belt. The results of the CBM are shown in Figure 8. The carbon dioxide and particulate matter reductions are in the same magnitude as the power savings, i.e., 9%, since the source of the energy produced in this case was coal. The lower cost of ownership of the aramid belt vs the steel cord belt facilitates a more favourable payback period. In this particular case, the payback period is estimated at <1 year for a belt, assuming a 20% increase in initial financial outlay than the equivalent belt reinforced with steel cord.

Summary

The case studies presented in this paper describe the performance of aramid reinforced conveyor belts compared to steel and textile EP alternatives. Several belts running in crusher and stacker applications showed a significant extension of belt lifetime – up to four times the average of the original belts. This appears to be due to the greater flexibility of an aramid reinforced belt in combination with the straight warp construction of the fabric reinforcement. Energy savings and, consequently, a lower environmental impact were measured and demonstrated in two belts in an underground coal mine. The excellent running behaviour, ease of installation and less maintenance as reported by the end user also show that aramid reinforced belts offer a good alternative to the traditional steel cord reinforced belts in long haul conveying systems.

3-4, 2011. 4. Dunlop Industrial Products (Pty) Ltd, PowaMax_VerX8 brochure, 2016. 5. Metso Minerals, Brochure number 1139-12-01WPC/ Trelleborg-English, 2002. 6. Correias Mercurio, based in Jundiaí, State of São Paulo, Brazil. 7. Fenner Dunlop ECS, https://www.youtube.com/ watch?v=JHbA_HGdpnE, August 13, 2012. 8. Tangcun Industry Co. Ltd is based in China and it is part of YCMC. Tangcun and TCMC are part of Yankuang, a global organization with 94 600 employees and listed in NY, Hong Kong, Shanghai and Sydney. 9. Ma Gang, Vice General Manager of Baodian Coal Mine, Yanzhou Coal Mine Corporation, presentation at annual meeting of the China Rubber Industry Association, Hose and Belt Branch, September 20, 2016. This paper was first presented at the Beltcon Conference in 2017. Copyright is vested with IMHC. www.beltcon.org.za Presented papers at Safecon 1 – “Splicing Methodology” and Beltcon 18 – “Technology and conveyor belting.” André van Staden Dunlop Industrial Products (Pty) Ltd Tel: (011) 740-2500/2603 Mobile: 083-283-7806 Email: Andre@dunlopindustrial.co.za

LMI ACADEMY cc. Merseta Accreditation No: 17-QA/ACC/0637/11 Reg. No. 2001/075895/23

P.O. Box 5907,Weltevredenpark 1715 E-MAIL: info@lmi-academy.co.za website: www.lmi-academy.co.za

Acknowledgements

We would like to thank belt manufacturers Correias Mercurio6 and Tangcun8 for their assistance and their data from the aramid in conveyor belts described in this paper. In addition we want to acknowledge the support of Mr Rainer Hinkelmann of Metso Minerals and Mr Dave Pitcher of Dunlop Industrial Products for their permission to publish company data and for giving technical advice.

Training offered at the LMI Academy or on site.

References

1. Ven H.J.F.M., Beers H., Lodewijks G, Drenkelford S. (2015), “Aramid in conveyor belts; Extended lifetime, energy savings and environmental effects”, Proceedings of the Beltcon 18 conference, Johannesburg, Republic of South Africa, August 6-7, 2015. 2. Arts K. (2009), “Case study: aramid reinforced conveyor belt in Maritsa Istok power plant”, Proceedings of the Beltcon 15 conference, Johannesburg, Republic of South Africa, September 2-3, 2009 3. Lodewijks G. (2011), “The Next Generation Low Loss Conveyor Belts”, Proceedings of the Beltcon 16 conference, Johannesburg, Republic of South Africa, August

• • •

Lifting Machinery Inspector Qualification (LMI). Registered CPD Training. The Rigging trade. DMR 18 training. Tackle training. For further details contact: +27(011) 475 5876 Member of: LEEASA No. 810051

BULK HANDLING TODAY

April 2019

29


30

BULK HANDLING TODAY

April 2019


CONVEYING

At Any Speed A contact-free conveyor belt skirting system significantly reduces material spill, dust formation and explosion hazards at transfer points and other critical sections in the conveyor chain.

B

ecause this system hovers freely above the conveyor belt, skirt friction and belt damage is eliminated and service life is extended.

“The AirScrape system, from BLTWorld, encompasses inward facing, hardened-steel diagonal blades, and operates according to a new principle where it hovers 1-2mm, on the left and right side above the conveyor belt. These blades deflect larger particles inwards, while using the air-flow of the conveyor belt and conveyed material to create an inward suction, flowing any dust and fine particles back into the product flow,” explains Ken Mouritzen, managing director, BLTWorld. “Through these diagonally fitted plates and the speed of the running belt, air is drawn from the outside inwards. As a result, neither the dust nor material can escape."

Regular maintenance

Conventional skirting is pressed against a conveyor belt to keep dust and material in the middle of the belt, but after a period, wear of the skirting and belt can be so severe, that material and dust escapes. Material spillage at transfer points needs to be removed and regular maintenance of belt

skirting and transfer points is necessary. “With our dust-free and contact-free, side sealing system for belt conveyors, there is no skirt contact and therefore no belt wear or damage. Motor power requirements are reduced as there is no belt-skirt friction and because there is continuous skirting with no gaps, product loss is minimal," Ken explains. This system is available in pairs of left and right hand 2m, inter-connectable pieces, to form any required length and is available in two different base widths of 90 mm and 60 mm, to suit various belt widths and chute sizes. For flexibility on site, this system is completely extendable.

Operates according to a new principle where it hovers 1-2mm, on the left and right side above the conveyor belt AirScrape is fitted using spacers, floating the blades just above the belt and is attached to the outside of the chute by utilising existing skirt clamps or a simple bolt and nut system. It is longitudinally adjustable to follow the contours of conveyor belt rollers and the belt trough angle.

Approved materials

This durable system consists of non-flammable and anti-static polyurethane materials and blades made from Hardox/stainless steel. FDA-approved materials are also available for specific conveyor handling applications. This system, designed and manufactured in Germany by ScrapeTec Trading, to the highest quality standards, is available throughout Africa and the Indian Ocean Islands. The BLTWorld team provides an assessment and solutions service for planning and implementing each project. Correct installation of suitable equipment ensures cost efficiency, optimum performance and safety, reduced risk of breakdown and extended service life of the conveyor system. BLTWorld Ken Mouritzen, Managing Director Tel: (031) 274-8270 Email: ken@bltworld.com www.bltworld.com

Contact-free conveyor belt skirting system significantly reduces material spill, dust formation and explosion hazards at transfer points and other critical sections in the conveyor chain.

BULK HANDLING TODAY

April 2019

31


CONVEYING

Making Its MARK With Belt Cleaners Well-known for its mechanical conveyor belt fastening systems, Multotec company Mato Products is now also leading the charge in innovative belt cleaning systems.

M

ato Products has long been a household name in clip fasteners for conveyor belts, especially in the underground coal sector. The company operates one of only three high production Mato machines in the world, and significantly the only one outside of Germany.

Designed to eliminate lengthy maintenance downtime and ensures blade alignment is 100% true across the entire conveyor belt width After over 30 years of operation, the unit was overhauled in 2016 in an intense six month refurbishment. It was upgraded from 180 tonne to 360 tonne capacity, speeding up production and ensuring both ongoing cost-effectiveness and reliability of supply for customers.

The company’s exciting line of belt cleaning equipment has for some time now been gathering momentum. Its popularity has extended well beyond the coal sector into other materials handling and mineral processing applications, even in diamond mining. According to Benjamin Sibanda, managing director of Mato Products, over-feeds at transfer points often lead to material build-up on the inside of a belt. “As mines and other industrial facilities raise their environmental standards, they want to avoid problems like duff heaps under conveyors, which can cause pollution,” adds Benjamin.

Constant contact

The Mato MCP3-S primary cleaner, installed at the head pulley is designed to be an aggressive head pulley cleaner, yet friendly to the conveyor belt surface and suitable for use with mechanical fasteners. It offers a high level of cleaning due to its blade profile, and the spring tensioning system ensures the blade is in constant contact with the belt for the life of the blade while achieving up-to a maximum of 75% cleaning. “The secondary Mato MUS2 belt cleaner is one of our latest design belt cleaners and offers a M-Trak slide-on cushion and blade for easy installation and maintenance.” The unique M-Trak is designed to eliminate lengthy maintenance downtime and ensures blade alignment is 100% true across the entire conveyor belt width. Blade replacement is also very simple with the design of the slide-on and slide-off principle, eliminating the need for special tools or training when maintenance is performed.

Angle of attack

Benjamin Sibanda, managing director of Mato Products

“The unique design of our MUS2 cushion is based on the principle of a parallelogram whereby the cushion also stays true to the conveyor belts surface ensuring the angle of attack is maintained,” Benjamin advises. “This cleaner’s primary duty is to remove fines and duff, to almost zero carry-back.” Blades on the cleaners come in a range of materials suited to different applications, including polyurethane and tungsten. While the application in South Africa was initially mainly underground, equipment variations for surface have now also been developed and introduced to market. The plant tail-end cleaner is based on the same concept but is mounted on channels rather than on stringer pipes.

The polyurethane primary belt cleaner is designed as an aggressive head pulley cleaner, which is also friendly to the conveyor belt’s surface

32

BULK HANDLING TODAY

April 2019

“This product includes innovative blade stoppers. When the blade is worn to a certain level,


the mounted flat plate does not touch the belt, for better protection.”

While the application in South Africa was initially mainly underground, equipment variations for surface have now also been developed and introduced to market

Benjamin concludes by highlighting that all the offerings in Mato Product’s conveyor belt systems range help to improve the lifespan of equipment at loading points. The energy of ore transfer is absorbed, and wear resistance is increased by Multolag ceramic products. Multotec, Vivienne Murray Tel:(011) 923-6000, Email: marketing@multotec.com www.multotec.com

Closer integration

Leveraging its technical expertise and experience in the market, Mato Products has also engineered closer integration between its fastener clips and the belt cleaners. “For instance, we have added a profile to the clip which optimises the life of both the clip and the tungsten tip on our secondary belt cleaner,” says Benjamin. “The skiving process embeds the clip slightly into the belt ensuring the mechanical splice is on the same surface as the conveyor belt thereby minimising the impact on the tungsten tip as well as lowering noise levels. Longer life of both means less downtime for the customer and greater reliability.”

The MUS2 belt cleaner offers the new M-Trak slide-on cushion and blade for easy installation and maintenance

Multotec’s line of belt cleaning equipment

BULK HANDLING TODAY

April 2019

33


High security welded mesh

Pallisade

Gates

Gate Automation

Razor wire and more ....

What is High Security Weld Mesh HIGH Security Weld Mesh is wire fused and welded at a Horizontal distance of 76.2mm and a vertical distance of 12.7mm also known as 35B/3510 where 3 denotes 3”(distance between vertical wires), 5 denotes 0.5” (distance between horizontal wires), and B or 10 denotes gauge of wire

Salient Features • Difficult to Climb: The spaces between the Horizontal wires are too narrow for fingers to have grip • Impregnable: Extremely difficult to cut with a hand cutter as the beak of a wire cutter will not be able to penetrate the horizontal wires • Excellent Replacement option to Solid Wall as: 1. More economical than a solid wall 2. Faster to install than a solid wall 3. CCTV Camera has a clear view • Further upgrade possible with electric security system • Anti-corrosive & low maintenance

Standards

• Manufactured according to BS EN 10016-2 • Wire Sizes in accordance with BS EN 10218-2 • Tolerance on Mesh Size in accordance wiht EN 10223-7 • Tolerance on Panel Size in accordance with EN 10223-4 • Welding Strength in accordance with BS EN 1461 • Zinc Coating in accordance with EN 10245-1 • Anti Corrosion in accordance with BS En 3900 E4/F4

Tensile Strength • Wire has a tensile strenght of min 550 MPA

MARK: 083 454 6488 34

Email: mark@palifence.co.za

www.palifence.co.za

BULK HANDLING TODAY

April 2019


MARKET FORUM

Easing financial stress As the size of South African coal deposits shrink and operations expect shorter

mine lives, miners look to reduce capital expenditure on infrastructure. B&E International’s build-own-operate-transfer (BOOT) plants offer the solution. “Our expertise and equipment in crushing and screening takes the pressure off the customer and relieves them of considerable production risk,” says Ken Basson, director plant and engineering at B&E International. This allows the business to flexibly fit in to customers’ value chains,

maximising production performance and machine uptime while taking on the risk of meeting the agreed output targets. “Our R&D focus has allowed us to develop our own primary coal crushing plant; a high capacity, track mounted unit that is currently under construction and will soon be launched,” says Ken. “The design is aimed at further reducing unit costs that we can achieve when conducting a contract for a customer. Its high volume capacity means better efficiencies while being able to serve multiple small deposits on the same mine site,” he concludes

Track mounted mobile coal crushing solution.

B&E International Ken Basson Tel: (011) 966-4310 Email: kbasson@ beinternational.co.za www.beinternational.co.za

Improving lives

In celebration of last Month’s International Women’s Day, Engen showed off its efforts to achieve a balance across its business, including their female bulk truck drivers. One such example is Phindile Sithole, one of 16 female bulk truck operators employed by Engen. She says that while she fully supports Engen’s drive to secure a more gender-balanced world, she always knew she wanted to be a truck driver and nothing was going to stand in the way of achieving her dream. As a professional driver who often has to work long hours, Phindile says she feels honoured to have been given the opportunity to work for Engen and enjoys every one of her shifts. “Believe it or not, I love the sound that trucks make and their size,” she says.

Moving copper Transmin, a provider of engineered equipment, supplies and services the resources and bulk materials handling industries, recently completed the fabrication and assembly of a leach precipitation and flotation process (LPF) in South Africa. This is part of an initiative to incorporate local content into their products and provide clients with the benefit of lower cost fabrication.

Engen’s Head of Transformation and Stakeholder Engagement, Unathi Njokweni-Magida believes it is incumbent upon large corporations to address the ‘barrier’ that continues to exclude emerging black, and especially black female talent. Unathi Njokweni-Magida Tel: 086 003 6436 www.regency.global/engen

The unit, built for a client on the copper belt in Zambia, has a belt width of 2 100mm and is designed for a nominal feed rate of 2000 tph with a P80 of 177mm. The unit comes fitted with an automatic lubrication system and has a bespoke rail system to facilitate the removal of the unit when required. The feeder weighs in just over 41 tons and was shipped to site in one piece to reduce logistics costs and to eliminate the need for on-site assembly. Carmaky Carne Reed Tel: (011) 867-6040 Email: carne@carmaky.co.za www.armaky.com

BULK HANDLING TODAY

April 2019

35


MARKET FORUM

Attach and accessorise Smith Power Equipment has extended its product offering with Cangini’s range of attachments. To remain competitive in today’s challenging environment, equipment owners are looking at how they can squeeze more margins from their fleets of excavators, skid steers and backhoe loaders, with

many looking at the attachments market. With that in mind, in late 2017, Smith Power acquired the southern African distribution rights for Cangini’s range of attachments. Cangini is an Italian-based manufacturer of a wide range of attachments. Tom Bloom, GM of Construction at Smith Power Equipment, says most

of the attachment units have been sold to owners of compact excavators, TLBs and skid steers. The range is extensive and includes the 4-in-1 bucket for excavators, AR fast locks, augers, broom sweepers for excavators, CR twin locks, Twist 180°s, extension arms, jointed brushes, mixing buckets for the safe discharge of excavators, mulchers multi-screening buckets, pallet forks for excavators, screening buckets, sharp-cut branch cutter bars, single-force and multi-force rippers, sorting grapples, and wood grabs. Tom believes that a key component to succeeding with any fleet of equipment, whether heavy or compact, is getting the most out of the machines. “Whether you have a mix of excavators, skid steer loaders, telehandlers or TLBs, implementing various tools and attachments can expand your assets from one-dimensional pieces of equipment into multipurpose and adaptable machines,” he concludes. Smith Power Equipment Robert Keir Tel: (011) 284 2000 Email: robertk@smithpower.co.za Web: www.smithpower.co.za

SKF Multilog On-line System IMx-8

More data capture opportunities. Even in a limited space. Configure your IMx-8 and monitor your data wirelessly from your iOS or Android device. The IMx-8 can be fully configured via luetooth, and can use existing template configurations stored in the SKF Cloud. Machine data can then be viewed on your iOS or Android device. And with direct access to world-class software, analytics and support through SKF @ptitude or SKF Enlight, it’s the cost-effective route to high performance.

SKF South Africa (Pty) Limited Tel: +27 11 821 3591, Fax: +27 86 677 7876 Email: sales.za@skf.com, Web: www.skf.co.za ® SKF is a registered trademark of the SKF Group. | © SKF Group 2018

36

BULK HANDLING TODAY

April 2019


MARKET FORUM

Africa’s largest Mining-services company E&J Construction of eMalahleni has acquired a Sany SY750H excavator from Goscor Earth Moving (GEM) for a coal strip-mining contract in Mpumalanga. The giant 75 ton excavator is the latest addition to the fleet of Sany equipment owned by E&J Construction, which includes two SY956H front-end loaders, a SMG200 grader, a SY500H excavator, and a SY335 excavator. Director, Jerry Mnisi, reveals that the company plans to supplement the SY750H excavator with Sany rigid dump trucks in order to offer client a total mining solution.

GEM MD, Barry Owen, has been instrumental in assisting E&J Construction with its procurement strategy over this period, facilitating finance and strengthening its aftermarket support and technical back-up. The Sany SY750H features an Isuzu 6WG1X engine, with a maximum torque of 2 138 Nm at 1 500 rpm. “The Isuzu engine brand, known for its durability and fuel economy, is an integral part of Sany’s strategy to source only the best components for its equipment. Kawasaki pumps are also used to ensure constant

hydraulic flow,” Barry highlights. In addition, the Sany SY750H boasts a self-diagnostic system that flags any technical issues, thereby reducing downtime. The standard warranty allows for care-free digging for the first yearand-a-half, or 3 000 hours, whichever is achieved first. Goscor, Debby Marx Tel: (011) 230-2600 Email: dmarx@goscor.co.za www.goscor.co.za

Reaching for the sky All over the world urbanisation continues apace, and the construction of more housing and office buildings intensifies the demand on industrial equipment. Customers want safe and durable vehicles. Horyong meets this need by designing aerial lift cranes that combine the highest level of design with the highest level of quality.

ings, lifting heavy material and moving heavy objects. With 28 years of R&D efforts, Horyong produces the tallest ladder and aerial lift vehicles in South

Korea, the highest of these reaching up to 75 metres. SSAB, Fei Ying, Email: fei.ying@ssab.com www.ssab.com

“Most of the steel that we use in our vehicles is SSAB’s high-strength steel. When we design our truck-mounted aerial lifts and ladder cars for operations in high places, we use 90 to 95 percent Strenx steel in the equipment,” says Soo-jeong Lee, Senior Researcher at Horyong. Truck-mounted aerial lifts are mainly used in construction and other work sites that are situated in high places, such as building maintenance. The vehicles improve access to high buildBULK HANDLING TODAY

April 2019

37


MARKET FORUM

Keeping drivers safe MiX Telematics will be providing an earthmoving equipment provider with a telematics solution to help improve the efficiency of their vehicles and the safety of their customers’ drivers. Operating across South Africa, the company needed 418 of its earthmoving vehicles to be fitted with a reputable telematics solution allowing their customers an accurate view of driver behaviour.

very remote areas, so MiX’s solution provides much-needed visibility and control. MiX Telematics Monica O’Neil Tel: (011) 654-8000 Email: monica.oneil@mixtelematics.com www.mixtelematics.com

By monitoring the whereabouts and driving style of their drivers, the company’s customers are now empowered to make the right decisions when it comes to operating more efficiently and identifying poor driving behaviour. Additionally, they are able to bill their customers more accurately as they monitor engine hours, thereby only charging for when the vehicles are actually being used. The vehicles and equipment are spread across the country, often in

A step above the rest “Today most machinery available on the market is good but what differentiates a brand is the company itself and the level of service it delivers. Kemach JCB is the number one reason we stick to the brand, the service we receive from the team is truly extraordinary,” comments Natie Ferreira who, together with Marius Brink, co-owns BF Hire. Natie and Marius have been dealing with Kemach JCB since 2016, when they stumbled upon a good deal on two new JCB 3CX TLBs. With the assistance of Kemach JCB they acquired both machines which led to the formation of BF Digger Hire.

and they rate Kemach JCB machinery to be the best on the market. Marius advises that when buying a new machine, the first thing a customer must consider is the quality of the aftersales service. “Bad service will turn even the best into a poor product. Fast and efficient aftersales service and maintenance are crucial to extending the lifespan of machines and reducing production standstill. Any downtime of a machine is costly to both us as well as to our customers. To minimise production losses, our machines are serviced over weekends and afterhours,” he adds.

Natie is a particular fan of the efficiency of the 3CX TLB which is one of the best-selling TLBs on the markert. Equipped with the ‘Torque Lock’ Powershift gearbox option, the 3CX TLBs can travel up to 55km/h on the road.

Natie is impressed with the dedication shown by De Wet Pretorius, Branch Manager of Kemach JCB in Cape Town and his Service Manager, Jaco Brand. “Despite being situated approximately 120km from the Kemach JCB branch, they send someone out immediately whenever we require assistance. Consequently, the downtime of our fleet is kept to an absolute minimum. Not only is their commitment to our business a step above the rest but their parts supply and technical assistance is on a different level.”

Operator comfort and safety are among the first factors Natie and Marius take into account before buying a new machine

De Wet Pretorius, Kemach Equipment, Tel: (011) 826 6710 www.kemachjcb.co.za

BF Hire currently caters primarily to the agriculture and construction industries in the Western Cape region and Natie and Marius agree that Kemach JCB machines are famous for their quality, performance, reliability, efficiency and ergonomics.

38

BULK HANDLING TODAY

April 2019


Gear units and motors from SEW-EURODRIVE Pty (Ltd) have always set the trend and established new standards in drive technology. For this reason, the quality label “made by SEW” has become a hallmark of quality in the drive industry. Market-orientated products developed and manufactured in-house, as well as uncompromising quality, are the cornerstones of our success.

COME VISIT OUR STAND AT THE AFRICA AUTOMATION FAIR STAND NUMBER: H07 40

BULK HANDLING TODAY

April 2019

4TH-6TH JUNE 2019

STAND NUMBER: H07

Profile for Promech Publishing

Bulk Handling Today April 2019  

Bulk Handling Today April 2019  

Profile for promech