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BULK HANDLING TODAY

August 2011

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BULK HANDLING TODAY

August 2011


August 2011

Contents

Featured on the cover: Melco Conveyor Equipment, Tel 011 255-1627, gavinh@melco.co.za

Cover Story

Trucking

Project Management

Transport

Lifting

Mining

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Well set for the future

25 Interchangeable fuel tanker

Results speak for themselves

27 RFA Convention

11 Arresting the impact 13 Working in Chile

31 Mining’s supply chain 34 Market Forum

New Entrant

Endorsing Bodies

15 Setting up on our shores

CMA (Conveyor Manufacturers Association)

16 The function and specification of deckplates on belt conveyors

LEEASA (Lifting Equipment Engineering Association of South Africa)

Crushers, Screens, Chutes & Liners

SAIMechE (SA Institution of Mechanical Engineering)

SAIMH ( SA Institute of Materials Handling)

Conveying

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.

21 Chutes: An engineered product 23 Appeals to customers

The monthly circulation is 4 016

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

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers

Advertising Sales: Surita Marx Production: Zinobia Docrat DTP: Lilian Kemp and Yolanda Flowerday Printed by: Typo Colour Printing Tel: (011) 402-3468

BULK HANDLING TODAY

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CONVEYOR MANUFACTURERS ASSOCIATION

From the Chairman’s Desk It’s all over for another two years! Beltcon 16 was a wonderful experience with so many delegates registering that there was the danger that not everyone could fit into the venue. So the organising committee put a “sold-out” banner on the website, halting further registrations – for the first time in the IMHC’s thirty year history!

T Simon Curry

he keynote address was given by a stalwart of the industry – none other than Mel Cohen, who flew out from Israel especially for this. There was a strong contingent from Australia among the speakers: old faithfuls Craig Wheeler, David Hastie and Paul Munzenberger were reinforced in numbers by John Spreadborough, Bernie Halpin and John Hill (now living in Australia). Another Beltcon stalwart,

CMA Members List as at August 2011 All members subscribe to the CMA Code of Ethics ABB Industry Afripp Projects Actom Atlanta Manufacturing Bateman Engineered Technologies Bauer BMG Bearings International Belt Reco Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CKIT Conveyor Engineers Conveyor Watch CMG Electric Motors South Africa CPM Engineering CPI Technologies CT Systems David Brown Gear Industries Delras Engineering DRA Mineral Projects Dunlop Belting Products Dymot Engineering Company ELB Engineering Services Facet Engineering Fenner Conveyor Belting (South Africa) Flexible Steel Lacing SA FLSmidth Roymec Hägglunds Drives South Africa Hansen Transmissions SA Hosch - Fördertechnik (SA) Iptron Technology Joy Global (South Africa) Lesa Mining Equipment and

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BULK HANDLING TODAY

Gabriel Lodewijks was here from the Netherlands. Not to be outdone, thirteen South African experts in their field presented papers on a variety of topics. The Beltcon 16 programme included some very impressive stuff. Just in case you missed being in the audience, I will give you a brief overview. Lorinda Lakay is the first South African lady to present a paper at Beltcon. Her topic was “Practical factors affecting gear unit bearing life”. Other interesting papers included case studies on Zibulo, RG Tanna Coal Terminal, and RBCT phase 5. Informative papers on idlers and pulleys included the noise caused by interaction of idler rolls and conveyor belts; idler troughing profiles; the effect of the manufacturing process on fatigue performance; and pulley practicalities.

Conveyor Belt Lorbrand M & J Engineering Martin Engineering Melco Conveyor Equipment Moret Mining MS Conveyor Pulleys SA Nepean Conveyors OE Bearings Oriental Rubber Industries SA Osborn Engineered Products PH Projects Holdings Read Swatman & Voigt Rema Tip Top South Africa Renold Crofts RSV ENCO Consulting Rula Bulk Materials Handling Sandvik Materials Handling SA Schaeffler South Africa Secrivest SENET SET Agencies SEW Eurodrive Shaft Engineering Shaw Almex Africa SKF South Africa ThyssenKrupp Materials Handling Transmission Components Transvaal Rubber Company Unitek Engineers Veyance Technologies Africa Voith Turbo Zest Electric Motors

August 2011

Impressive stuff

Papers on saving power using VSD controlled drives; magnetic drive technology; high or premium efficiency motors and energy saving by speed control were all topics of high interest as were papers on low loss rubber technology; chute design; high lift conveyors and indentation rolling resistance measurement. Last, but not least, the impact of worsening steam coal qualities on the Eskom coal and ash handling plants; an overview of the use of flywheels; an insight into the new solid woven national standard SANS 968; the home-grown South African conveyor handbook; and the effectiveness of safety interventions in the field of bulk materials handling, were covered. I would like to congratulate my fellow committee members: Carlos Andrade, Roy Barbour, Alan Exton, Adi Frittella, Wilton Monnery, Paul Nel, Dave Pitcher, Vaughan Rimbault, Graham Shortt, Anton Verster and Gavin White for a job well done, knowing that as soon as the dust has settled over Beltcon 16, this committee will be hard at work setting up Beltcon 17 in 2013. Simon Curry Chairman


COVER STORY

Well Set for the Future

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perating from its factory in Germiston, Gauteng, the company has been supplying South African as well as world markets since 1970. In December of 2006 Melco became a wholly owned subsidiary of the Rulmeca group, significantly strengthening its existing operations and enhancing its already formidable technical expertise. Rulmeca, based in Italy and with operations across the globe, is the world’s leading manufacturer and supplier of rollers, motorized pulleys and components for the global bulk materials handling market.

Melco Conveyor Equipment is South Africa’s premier supplier of conveyor idlers, structure, and motorized pulleys. As an ISO 9001: 2008 rated manufacturer together with SANS 1313 accreditation, the company has a well established reputation for delivering quality products and providing reliable after sales services.

All Melco products, apart from motorized pulleys are manufactured locally. These are conveyor idlers, conveyor structure, top rollers and replacement (drop-in) rollers. The range of conveyor idlers is comprehensive. In order to maintain direct control over the cost, quality and availability of idler components, and to facilitate efficient product development, Melco has invested heavily in plant and equipment. Melco components and products are produced to the highest quality standards, using state of the art technology and design techniques including Finite Element Analysis (FEA) and Computer Aided Drawing (CAD). One of the cornerstones of the company’s success is the ability to design product in accordance with specific applications and duties. Using in-house developed computer software, all the parameters are considered within which a specific conveyor operates, such as environment, belt tensions, misalignment, throughput, idler pitch and the like, to ensure that the correct roller size, shaft, bearing, sealing system and frame design are utilised.

Winning combination

Among the most critical aspects affecting the life of a conveyor idler, are the design, manufacture and assembly of the sealing system. If the design is such that the seal effectively prevents the ingress of contaminants into the bearing, but increases frictional resistance of the roller, then increased wear on the tube will result in premature shell failure. On the other hand, utilising a seal, which limits frictional resistance to a minimum, but does not adequately protect the bearing, will result in contamination, and eventually premature bearing failure. After many years of development and refinement, the Melco roller offers the most suitable combination of both, effectively protecting the bearing to limit contamination, without unduly increasing the rolling resistance, thus ensuring that the designed life is achieved.

Melco rollers and conveyor structure

Appealing range

Melco’s extensive range of greased and sealed-for -life non-rubbing seals, are suitable for any application. The Supreme HDPE roller offers an additional labyrinth seal in the Stoneguard. The Melco High Humidity Sealing System, which contends with high humidity and temperature fluctuation, is fast being added to users’ specifications around the world.

All Melco products, apart from motorized pulleys are manufactured locally The unique Melco Turnback Housing Design is a result of the combination of many years of experience in the conveyor industry and the knowledge of the art of deep drawing of steel. Utilising 6 and 7 stage forming processes on 200-ton machines, Melco produce bearing housings of the highest quality ensuring correct bearing alignment and fits. BULK HANDLING TODAY

August 2011

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ROMÊTip StrongÊGrizzlyÊwithÊ ReplaceableÊPanels OptimisedÊMaterialÊFlow OptionÊofÊVariousÊConstructionÊ TipÊWalls PrimaryÊCrushingÊOptions

1ÊKramerÊRoad,ÊBedfordview,ÊJohannesburg,ÊRepublicÊofÊSouthÊAfrica ForÊyourÊbulkÊmaterialsÊhandlingÊrequirements,ÊcallÊusÊat:

Telephone:Ê+27-11-201-2300ÊÊEmail:Êsales@bateman-bet.comÊÊWeb:Êwww.bateman.com BlowIn315/09


COVER STORY

The company designs around and uses only the best materials available, including tubing, shafting and bearings, many of which are designed and manufactured specifically for use in conveyor idlers. Deep groove ball bearings are sized to meet applicable duties, and provide long, maintenance free life. Tubing supplied in accordance with SANS 657 Part III (Conveyor Tube) is accurately manufactured with ovality, straightness and wall thickness being controlled to tolerances as specified by Melco to improve the end product. The company supplies a wide variety of modular conveyor structure, for overland, plant and underground conveyors, roof slung or floor mounted. The company designs structure for underground applications, and manufactures to customer’s drawings for above ground applications.

A Melco installation site

Motorized pulleys are an exciting product range with application uses that appeal to a wide range of customers. Manufactured by Rulmeca (Germany), they have proven popular thanks to the quality of materials used and durability as well as long service interA cutaway of a Melco steel roller vals. Garland impact beds, pulleys, training idlers, retractable V returns, low friction impact beds and roller-brakes are also on offer.

Winning philosophy

The company’s philosophy on maintaining its competitive position is based on three key points; quality of design, quality of materials used and quality of the manufacturing process. Research and development are vitally important and Melco continues to invest heavily in this area, allowing the company to continue trading as preferred supplier to the bulk handling industry. Competition in the market is ongoing and for Melco to maintain its position, materials research, manufacturing improvements and design efficiency are just some

of the fields continuously being studied. Ongoing investment in plant and equipment continues to pay dividends with efficiencies and productivity showing commensurate improvements. The skills, knowledge and expertise of the staff at Melco are an important differentiator, especially in today’s market. Melco employees have a combination of qualifications in various fields such as mechanical engineering, industrial engineering, mining and management under their belts, which stands the company in good stead when participating in the bulk materials handling industry and which assists in providing specialised services when meeting customer needs and providing value added services.

Materials research, manufacturing improvements and design efficiency are just some of the fields continuously being studied Two Melco employees possess the prestigious Conveyor Design Diploma offered by the CMA. Melco also employs a wide range of highly qualified artisans who produce top quality idlers and structure to suit any project’s need. In addition, field service personnel, all of whom are very experienced and qualified, are employed and are on call to assist end-users with trouble-shooting and ensuring they obtain the lowest total cost of ownership possible. Melco is well positioned to continue supplying the bulk handling industry, providing high quality products with exemplary service. Gavin Hall, Melco Conveyor Equipment, Tel 011 255-1627, gavinh@melco.co.za

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Sandvik full page


PROJECT MANAGEMENT

Results Speak for Themselves “Our vision is to become a recognised centre of excellence in project controls,” states MD and CEO of Johannesburg-based Planning and Cost Engineering (PaCE) Services Nic Bennett. “We offer an all-inclusive range of project management and control services to assist companies in completing projects on-time and within budget. Project success is further ensured by combining the best available tools with the latest techniques, while aiming to exceed set goals and targets where possible.”

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his aim is also underpinned by PaCE’s direct involvement in providing project controls as part of the project team, on a day-to-day basis. “Add client personnel training in project control disciplines and the supply of relevantly developed computer software and support systems - and you have the winning combination,” he asserts.

Significant saving when you’re talking about multi-billion Rand projects Cost savings

Nic further explains that the main benefit of putting effective best practice cost controls in place on a project is their capacity to save companies up to 20% of total project cost, a potential saving corroborated at a Global Benchmarking Conference held in 2006 in Singapore, hosted by Independent Project Analysis (IPA), a global projects analytics company. The end result is a significant saving when you’re talking about multi-billion Rand projects. He explains that if you consider that project control costs on engineering projects normally run at between 1,5 and 2% of the total project, then the initial cost versus benefit realised really speaks for itself. PaCE’s project experience to date has included involvement across a range of business sectors from mining, sugar and petrochemicals, to materials handling, paper, power generation, and also on infrastructural and building developments. Although the company supplies project services primarily in South Africa, it has also worked globally as far afield as Hawaii, Mauritius, Malaysia, Swaziland and Ghana.

Source: Eskom PaCE has been involved with Exxaro at Medupi on the extension to the mine and the addition of 6 000 houses to the town of Lephalale

In every way

Setting it apart in the industry, is the company’s long history in the supply of services since its establishment in 1984 with various roles on multibillion Rand capital expansion projects for blue chip clients, including the likes of Exxaro at Medupi on the extension to the mine and the addition of 6 000 houses to the town of Lephalale; Sishen Iron Ore on the Sishen mine expansion projects; Anglo Gold Ashanti on project control services, Anglo Platinum on the RBMR project assurance, and Simmer & Jack Mines on project control systems implementation. A closer look at service tools offered by PaCE includes the development, marketing and support of a range of project management software to complement its services in every way. “We use primary products from the Eigasoft stable in Switzerland to ensure data consistency, and are regional agents for their products in southern Africa,” states PaCE director: Operations and Technologies, Mike Purves. “Costrac, ePIMMS and PM-ProSys are all complementary, although each has a different function to fulfil.” Costrac mainly addresses project cost management, while the Enterprise Project Information Management and Monitoring System (ePIMMS) contains additional project management functionality such as the project risk register, dashboarding and document management among others. PM-ProSys on the other hand consists of the entire range of project BULK HANDLING TODAY

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PROJECT MANAGEMENT

management processes with process instructions that can be used as a PM process template to ensure standardisation in any organisation. Source: Simmer & Jack PaCE has previously assisted Simmer & Jack mines on project control systems implementation

obtain accredited qualifications and competency certification,” says Nic. Over the years, PaCE has developed from its initial cost engineering platform to cover the full range of project services and project management, while adding a further expansion into project analysis and diagnostics, risk management, strategy management as well as business development.

More hands-on

Things inevitably had gone wrong on a project and the client was the last to find out Latest thinking

PaCE also delivers high quality, customer- specific project controls training to satisfy both individual and corporate requirements. The PaCE Training Academy was established in 1992 and is based on the broad spectrum of experience gained over the years, coupled with the latest thinking in project management and controls practice. “We are also corporate members of the South African Project Control Institute (SAPCI), and the South African section of the US-based Association for the Advancement of Cost Engineering (AACE), as well as the UK based Cost Engineering Association (ACostE), in terms of which we are able to offer courses to

Looking at the industry and prospects going forward, MD Nic Bennett notes that the outlook is positive as we come out of the recession. “On the back of this, there is now a worldwide trend whereby client organisations are starting to take back the primary control role on projects from EPCM’s with a view to being more hands-on in controlling expenditure. The main motivation being to prevent or at least restrict the impact of unexpected costs within a project,” he says, concluding that where in the past things inevitably had gone wrong on a project without a good controls system and the client was the last to find out, the question that always remains is whether the situation could have been prevented with a decent control system being in place? Pace Services, Tel 031 584-6937, Fax 031 584-6936, www. paceservices.co.za

One Source

One Source One Company Bringing you the world’s leading brand names, over 100 years experience, and an aggresive product development program, FLSmidth is your One Source for all of your mineral processing needs. We offer solutions for crushing, grinding, material handling, flotation, sedimentation, filtration, classification, pyroprocessing, metallurgical testing and engineering. All of these technologies and services are available and supported in your local area around the globe. For further information please contact us at: Tel: +27 (0)10 210 4000 • www.flsmidth.com

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HANDLING fls BULK bulk handling ad jul11.indd 1 TODAY

August 2011

2011/08/01 10:47:57 AM


LIFTING

Arresting the Impact Failure in a winder control system, train brakes, weights suspended from a hoist or a counterweight suspended from a conveyor belt will create high impact energy. Whether this energy is directed horizontally or vertically, if it is not absorbed it will result in damaged machinery and equipment, serious injury and probably death. There will also be lost production.

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o “Bulk Handling Today” visits the Horne Group, a specialist engineering company which manufactures a whole range of equipment used to arrest the fall of hoisted equipment and to stop run-away equipment on rails. “Our Technogrid systems provide predictable impact energy absorption outcomes with controlled deceleration and predicted reaction forces,” explains Andre du Preez, managing director of Horne. “This system prevents costly damage to equipment and surrounding infrastructure as it acts as a safety net against a wide range of motion energy impacts in a wide range of applications.”

The rungs of the ‘ladder’ will thus be bent after use The Technogrid system can be designed to suit various applications where a controlled impact energy absorption is required. Basically the system consists of a series of multi-bar units connected in a stag-

gered grid shape which, when we first saw it in the workshop in Spartan, looked a bit like a ladder where the rungs are the round bars fitted into flat steel sections that overlap each other to form the sides of the ‘ladder’ on the ends of the bars. One end of each complete section is Andre du Preez, Horne Group fixed to a suitable static structure. The other end is fixed to a catch frame or mechanism suitable to the application, in order to place the Technogrid in tension.

Energy absorption

On impact, the staggered flat steel sections will pull apart from each other in the direction of the arrested motion thereby bending the round bars. The grid bars, in fact, yield and deform under double curvature bending and, it’s this yielding of the bars, which allows the section units to open up while the strain hardening of the bars absorbs the energy. The rungs of the ‘ladder’ will thus be bent after use and the unit will look more like a big piece of chain. Each unit is built into a steel box with lightlywelded ends which allows it to tear open during the stretching of the unit as the bars bend to absorb the energy.

Precise calculation

Technogrid sections, ready to be fitted into the boxed holder

“Technically our system is without equal in terms of impact energy absorption because it can be calculated accurately for each individual application,” says Andre. “We can calculate and predict the outcome of an arrest in each application very accurately which gives mining engineers confidence that they’re installing a safe system. An engineer told me once that he loves Technogrid because it comes with numbers, the outcome can be worked out exactly beforehand on paper and then everything else in terms of structures around it can be designed accordingly.” BULK HANDLING TODAY

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LIFTING

The section inside the box and before it’s light welded to close the box

The Technogrid system can absorb any impact provided the crash/catch framework is designed to put the system into tension. “We have various examples of framework designs,” says Andre.

An engineer told me once that he loves Technogrid because it comes with numbers “They range from simple hook systems to more complicated compression legs to absorb the energy from granulation tank explosions. The system is maintenance free as there are no moving parts,

The Technogrid unit once it is placed in the lightly welded box

and impact energies which can be accommodated range from 24kJ to greater than 50MJ and more, while high velocities can be catered for. Andre explains, “The optimum configuration of the units is achieved by combining the grid units in series or parallel in order to match the requirements of different applications. For example, for bigger energies, multiple units can be added in parallel so that two units double the reaction forces while in series, two units double the stroke.”

Conveyors

Horne’s application range includes over-wind protection in vertical mine shafts, arresting run-away ship loaders and stacker reclaimers, run-away conveyance arresting in decline shafts, station stoppers and conveyor belt counterweight arrestors. “One of the more cost-effective applications of Technogrid is in arresting the potential fall of gravity take-up conveyor counterweights,” Andre elaborates. “In some applications, if the belt snaps and the counterweight falls to the ground, there is the potential for damage to occur to structures or equipment below, so counterweight arresting needs to be considered in these cases.

Local product

“We provide the ideal solution not only by reducing expensive downtime, but also by providing design engineers with more scope,” adds Andre. “They can now design conveyor systems stacked over each other and not be forced to design side by side for fear of the counterweight falling on the structures below.” The Technogrid system is a born and bred South African product. “The bars are specially made to our specifications by a local company and everything else is made in our workshop in Spartan,” says Andre in conclusion. “Our installation base reaches across the globe with the latest interest coming from China where there literally are hundreds of mines that can utilise all of our safety systems.” Andre du Preez, Horne Group, Tel: (011) 974-1004, Email: andre@horne-group.com, Website: www.horne-group.com

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BULK HANDLING TODAY

August 2011


LIFTING

Working in Chile Accelerating export sales of hoists and crane components to Chile, from 2006 orders of just 20 000 US dollars to an order book in 2010 of USD½ million have been reported by Condra.

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he increase is attributed to active management of the company’s Santiago subsidiary and Chile-based agent. Represented in that country since 1988, Condra received only sporadic orders until Kyle Kleiner took over responsibility for the South American portfolio in late 2005. He spent six months defining the region’s needs, then developed the methods and means to service and satisfy them. Besides daily communication, he visits every three or four months.

Similar to South Africa

In five years, Condra’s sales have grown 25-fold. An analysis by value reveals that 40 percent of orders are placed by mines and quarries, with engineering and general industry contributing another 10 percent each. The bulk of the remainder is made up of sales into hydroelectric power generation projects. Kyle says that Chile’s mining environment is similar to that of South Africa, with harsh conditions requiring a robust product. “Our first sale was to a mine,” he says, “a 25-ton maintenance crane for which we supplied the design and all components except the girder, which was manufactured locally. This crane is still operating 22 years later.”

We choose the sales that we want to win. We don’t try to win every single one. We focus and stay flexible with the pricing in spite of the exchange rate Building a reputation

Kyle speaks highly of Condra’s local agent, Santiagobased Mantex, appointed in 1988. “Mantex allowed us to begin developing a reputation for solid agent support,” he said, “paving the way for other agency agreements in the Middle East, Zambia, Botswana, Kenya, Bulgaria and Canada.” Kyle himself manages sales into Canada, the Middle East and Chile. “Managing any agent requires constant reassurance, follow-up and support,” he explains.“You have to instil belief in the product. You have to quickly and reliably answer any queries that the agent may have. You have to create confidence. Which takes time.”

Coax and guide

According to Kyle, Chile’s light industry is not as developed as that of South Africa. “There is heavy industrial engineering and largescale mining, but very little intermediate or light engineering. But this may change, and we are

Kyle Kleiner

watching that particular sector with an eye to growing with it.” Condra’s K-Series hoist range forms the backbone of the company’s sales to Chile, the result of product adaptability. “The K-Series can be made to move and fit into almost anything, including high-lift applications,” Kyle explains. “The hoists are easy to service. We can change the voltages and loads to suit local specs, plus we have vast experience with this range in all conditions over the past 40 years locally in both mining and industry.” He emphasises that an excellent product is of little use without the support of the agent. “To get that support, we go out of our way to give the agent the exact product that he needs. “We coax and guide and constantly follow up to convince the agent that natural growth will follow his partnership with us.” Kyle admits that the strong Rand is an obstacle to even greater success. “The exchange rate is a problem. Markets have been driven by price since the recession began in 2008, and if you are not competitive, you simply don’t make headway. We are also subject to fluctuations in copper and other mineral prices, which determine when the mines are buying, and when they are not.

Win what we really want

“So what we do is choose the sales that we want to win. We don’t try to win every single one. We focus and stay flexible with the pricing in spite of the exchange rate, and we win the orders that we really want.” To help the agent, Condra holds stock of components and spares in Santiago, making it easier to gain an edge by minimising potential customer downtime. “We plan to keep on supplying our agent and the end customer with product, back-up and knowhow into the future. These are proven methods of sustaining and increasing foreign growth,” Kyle concludes. Josef Kleiner, Condra, Tel 011 021-3712, Fax 086 6692372, condra@mweb.co.za

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Excavating

Loading

Drilling

Longwall Systems

Bolting

Cutting

Haulage

Crushing

Conveying

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NEW ENTRANT

Setting up on our Shores Wamgroup, which is an internationally-recognised specialist in the manufacture of screw conveyors and various other bulk material handling and processing equipment, recently established a distribution branch in South Africa, in order to better serve the local market

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he Johannesburg-based distributorship was officially opened in June as the 53rd international subsidiary of Wamgroup, and will focus predominantly on three local target markets; namely, building and construction, food and agriculture, and renewable energy.

WAM South Africa general manager, Emilie Marchand,

Wam South Africa general manager, Emilie Marchand, points out that the establishment of the new branch will substantially benefit original equipment manufacturers (OEMs) and engineers in these industries. “In the past, South African clients have had to import all products manufactured by Wamgroup from Italy. With the establishment of the new distributorship, however, we can now ensure that a comprehensive stockholding will ultimately reduce overall purchasing costs. Customers are also ensured that language barriers are eliminated when dealing with a local company.”

Over a year to meet the stringent requirements for trading in South Africa On demand

Emilie notes that turnaround times will also be dramatically reduced. “When importing a product, the entire ordering process typically takes around eight weeks. Products are now available through the local distributorship on demand, and are immediately available to clients,” she continues. “Another advantage of establishing a new subsidiary

is the availability of spare parts, which was a major challenge in the past. The immediate availability of spare parts now reduces the client’s risk of costly and prolonged downtime periods.” What’s more, Emilie notes that Wamgroup’s unique price-to-quality ratio makes it the most competitive distributor in the market. “With a strong focus on the requirements of the market, our team of industry experts strives to ensure that all local clients are provided with the best value-for-money, by offering unrivalled after-sales and technical support on the entire Wamgroup product range.” She points out that Wamgroup’s core focus for 2011 will be the distribution of screw conveyors to batching plant manufacturers, original equipment manufacturers (OEMs) and engineers in the building and construction industry. “The South African construction industry is key to developing our local branch, as we already have a number of established customers in this sector. As a result, we will be looking to consolidate on this current success, before expanding into new markets in the short-term future.”

The perfect base

Emilie notes that South Africa was identified by Wamgroup as the ideal location to set up a new subsidiary, in order to gain ground in one of the world’s fastest emerging economies. “Africa is one of the fastest developing regions in the world, and we believe that the market has unlimited potential. South Africa serves as the perfect base, as the country is seen as the gateway to the rest of the continent, thanks to a strong and well-established market and infrastructure.” She does, however, point out that it took Wamgroup over a year to meet the stringent requirements for trading in South Africa. “The registration process in establishing a new business proved to be long and challenging, as a result of red tape and bureaucracy with regards to the various licensing procedures. Having met all these requirements, we will now be focusing on the development of our African footprint,” she continues.

Significant marketshare

Looking to the future, Emilie notes that Wamgroup will continue to expand its local stock item offering, which currently consists of screw conveyors, silo dust filters, valves and mixers. “As markets continue to develop, the stock item offering for additional industries will increase, and I am confident that we will gain significant marketshare across Sub-Saharan Africa within the next three years,” she concludes. Concrete plant

Emilie Marchand, Wam South Africa, Tel: 011 822-2623, info@wamgroup.co.za, www.wamgroup.co.za

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CONVEYING

The Function and Specification of Deckplates on Belt Conveyors The traditional approach to the structural design and detailing of belt conveyors is to place deckplates under the carrying strand of the belt. The purpose of the deckplates is ostensibly to prevent any spillage which may occur from landing on the return strand and then finding its way to the tail pulley. Once the material reaches this point, it is circulated around and around the pulley, until it may or may not find its way off the belt, to manifest as spillage at the tail pulley.

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f course, material that circulates around the pulley in this manner will not only damage the belt, but will also result in belt tracking difficulties. This will exacerbate the incidence of spillage and a vicious cycle of spillage and belt tracking will be set up. The fact that this spillage is the basic cause of belt tracking is often overlooked.

Spillage is often held from causing massive damage to the systems, by good fortune alone The specification of the deckplates ranges from 16 gauge (approximately 1,6 mm or 1/16�) galvanized sheets, to 3 mm stiffened plates. Various details for the actual deckplates have been developed over the years, the most common being a flat 3 mm plate with up-turned ends across the line of the belt. Interestingly, the bolting detail of these deckplates was often quoted using M16 bolts and nuts for the flanges! The flange bolts for deckplates should be no more than M10 or even M8, bearing in mind that the rest of the deckplate is held in place by the idler bracket fixing bolts and these are usually about M12 in any event. For wider belts, the deckplates have had stiffeners welded to the surface. Sometimes the stiffeners were welded underneath the plate (to present a smooth face for the cleaning of spillage) while other details had the stiffeners welded to the top surface. Still other details relied on cross-bending the deckplate panels, similar to water tank panels, with the crossbending assisting in the shedding of water from the surface of the deckplates.

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Costly demise

A major mining house at one time specified deckplates as an integral part of the structure, with the ends cold-formed to create the actual stringers and the deckplates formed with a 20° to 30° slope and the apex of the slope at the centre-line of the conveyor. Needless to say, since the plates were typically 3-5 mm thick, the brutal cost of the structure very quickly led to the demise of the specification. With all that being said, it is clear that spillage may be prevented from reaching the return strand of the conveyor, in the event of deckplates being installed. As can be seen on many installations, spillage is often held from causing massive damage to the systems, by good fortune alone.

Spillage on stringers


CONVEYING

Costs

Considering the cost of fabricated steel estimated at a conservative R35/kg, the cost of 3mm deckplates, with an allowance for some minimal stiffening, can be estimated at about R1000/m². For a 1050 mm wide conveyor system, the width across 160×65 channel stringers (with centres in accordance with SANS 1313/1) will be about 1365 mm. For a structure (say) 200 m long, the additional cost to the project will be about R270 000. When it is considered that the deckplates cannot be considered as structural members, the cost will need some spin to be justified! For example, if the same structure is used on an in-plant overland conveyor that is (say) 800m long, the cost of the deckplate component of the structure will escalate to just about R1,1 million. This is clearly not justifiable and the blanket specification of deckplates will need to be very carefully considered. A further cost that cannot be easily quantified is the loss as a result of corrosion. There are many instances where the deckplates, subject to some spillage and high moisture levels, will simply corrode away.

Spillage waiting to fall onto the return strand

Loading points

Since the majority of spillage occurs at loading points, (for any number of reasons), it is prudent to consider deckplates at the loading point of each

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CONVEYING

are extended at least one further full idler pitch beyond the termination of the skirts or loading boot. Where the skirts are very short, it may be more appropriate to specify the deckplate length as 2 seconds of travel (twice belt speed), measured from the loading point. It should be noted that the belt line will be altered as a result of the deckplates and this must be taken into consideration when the stringers are detailed in this area, particularly since impact idlers are likely to be installed here as well.

Corroded decking, creating dangerous conditions. Note the conveyor deckplates above the stringers

conveyor. The deckplates in this area would need to extend for the full length of the skirtplates, to ensure that the return strand is protected over the whole of the turbulent area. For added protection, it is recommended that the deckplates

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Nevertheless, in spite of the deckplates (and possibly because of them) it is important that a well-designed and installed plough system is applied just inbye of the tail pulley. This will protect the pulley from any fugitive material entering the pinch zone and causing damage to the belt and the pulley. It is useful to consider specifying the plough as a single-bias unit, as opposed to veeploughs, since the removal of any carry-back at the tail plough is simplified by the material all being on one side of the belt. This is especially relevant in underground systems, where the conveyor is often set against the side-wall and access for the removal of ploughed spillage is often impossible and always dangerous.


CONVEYING

Take-up areas Vertical gravity take-up It is common to find deckplates located at areas over the bend pulleys at vertical gravity take-up units. This is important, in order to prevent any spillage from falling into the take-up and being trapped between the pulley and the belt. The length of the deckplates in these areas should be at least the distance between the take-up bend pulleys, plus the pulley diameters, plus 1,0 m each side. As with the loading point and the tail end, it is prudent to locate a plough just inbye of the leading take-up bend pulley, to remove any material being carried on the return strand and prevent it from entering the take-up area. The specification of the plough may be either single-bias or vee, to suit access to the area. Should the stringers and walkway be elevated above a roadway or personnel access-way, it is required that the structure is designed with suitable decking to prevent any material from falling onto the roadway or access-way. These decks are separate from conveyor deckplates and must not be confused with them. In the case where the take-up area is over or adjacent to a roadway, it is important that the decking is installed in

the structure in addition to the conveyor deckplates, because the two decks serve different purposes. Horizontal take-up Where the take-up is designed as horizontal, there is often more than one strand of belting that is exposed to fugitive material. In the case of horizontal take-up units, particularly underground conveyor systems, deckplates should be specified over the whole of the take-up area that may be exposed to spillage. Again, the location of a plough on the return strand needs to be carefully considered. For surface conveyors, the horizontal take-up units are generally located some distance below the nominal belt line. In this case, it may be more appropriate to provide the structure with decking, since the belt line will be always located at or near personnel access. Of course, the system may be specified with both structural decking and conveyor deckplates, depending on the location of the take-up and the type of material being conveyed.

Discharge areas

Since the belt is always subject to a transition distance at the head (or discharge) end of the conveyor, the material will again acquire some turbulence as it approaches the discharge pulley. Apart from the turbulence, the belt profile will be transition-

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CONVEYING

finding its way onto the return strand. The deckplates in this area should be dimensioned such that they extend at least as far as the transition plus one full trough pitch. Again, fugitive material that may find its way onto the return strand can be ploughed off at a convenient location on the return strand. The most likely location would be at the take-up area or inbye of the first pulley encountered on the return strand.

Fabrication

Deckplates are fabricated from sheet steel and should not be thicker than 3mm. Unless the deckplates are formed from galvanized sheeting, it is important that the plates are not galvanized after fabrication, to prevent distortion. Non-galvanised deckplates are to be painted to the same specification as the stringers and the conveyor structure. Potential loss of earnings from trapped material

ing to flat and the material will start approaching the edge of the belt. Since conveyor systems may often be somewhat overloaded, it is common to see material being discharged over the edge of the belt before it reaches the discharge pulley. While deckplates in the discharge area will not prevent the material from being discharged in this way, they will at least prevent most of the material from

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The welding procedure for the attachment of stiffeners etc, onto the deckplates must take distortion into account. It is recommended that all bolt holes in the deckplates are over-sized, to facilitate assembly without causing unnecessary distortion. This implies that flange bolts would need to be specified with washers to cater for the oversized holes. Graham Shortt, brevissg@telkomsa.net


CRUSHERS, SCREENS, CHUTES & LINERS

Control of material from the transfer point will optimise belt life

Chutes: an Engineered Product Conveyor belt life can be extended by up to three or four times if transfer points are correctly controlled. Conventional chute systems or transfer points generally drop the material from point A to point B, and more often than not the height of the drop is not taken into account. “This is one of the most critical factors when it comes to conveyor belt life,” says Mark Baller, managing director of Weba Chute Systems.

D

ropping ROM product, with lump sizes up to 500 mm, directly onto an outgoing conveyor belt will create a massive impact which could result in belt damage over a very short period of time.”

Chute Systems is not as simple as it appears to the layman. More than fifteen years of experience with transfer points and different materials has resulted in an extensive database of information being available to the company.

Another factor which adversely affects the life of conveyor belts is the foreign objects which move through the system. Where new underground shaft mining operations are being established these can include concrete, iron, pillars and steel ropes.

Mark explains that prior to beginning design work on a transfer point, a vast amount of information is required to ensure that the concept proposed will meet all the requirements. This information includes product type and consistency, outgoing conveyor trajectory curve, transfer height and distance.

Not as simple as it appears to the layman Topic for discussion

Commercial chutes are often designed without taking the need to remove foreign objects into account. Not only do foreign objects cause excessive impact on the belt, but they are often also the cause of blockages and stoppages. “Controlling the flow of material onto conveyor belts to minimise impact has become quite a topic for discussion with numerous solutions being proposed,” Mark continues. “Pressure from end-users has resulted in a situation where manufacturers of conventional chutes are being forced to mimic the design principles of our system in an attempt to achieve the same result.”

Vast amount of information

Implementing the design principles of the Weba

“Just obtaining this information is not sufficient,” Mark warns. “It is necessary to do an on-site assessment to verify the data. This also allows our engineers the opportunity to address other issues which could be causing impact damage to the conveyor belt.” Mark adds that other areas which could cause damage include uneven conveyor belt loading, flooding of the belt and blockages. “We allow ample access to remove foreign objects should these become stuck. Through the correct and careful design of the transfer point, the impact on the conveyor belt can be minimised and major savings realised by mines. However, it is important to deal with a company which understands exactly what is required,” Mark concludes. Mark Baller, M & J Engineering, Tel 011 827-9372, Fax 011 827-6132, www.mjeng.co.za

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CRUSHERS, SCREENS, CHUTES & LINERS

Assembled mine crushers help customers save time and improve safety. A fully-assembled MP1000 recently made a successful trip on wheels to the concentrator of the Karara iron ore project in Western Australia.

Appeals to Customers The MP1000 cone crusher traveled 250 km from Geraldton to Karara on a trailer with 16 axles and eight wheels per axle

T

he Karara project involves the integrated development of the world-class magnetite deposit to produce both high-grade magnetite concentrate on-site and blast furnace quality pellets in north-eastern China. Karara is a world-class ore body in terms of its scale, quality, consistency and extremely low waste. Its ore stripping ratio means relatively low mining costs. Karara is being developed by Gindalbie Metals Ltd, an independent Australian iron ore company based in Perth, through a fifty-fifty joint venture with AnSteel, one of China’s leading steel and iron ore companies. An integral part of the Karara operation is the use of three MP1000 secondary cone crushers supplied by Metso. Part of what makes this delivery so interesting is that the crushers were delivered fully assembled to the site, which was possible because there are no logistical restrictions.

Workers are familiar with their surroundings and potential local hazards “Crushers are typically supplied in various pieces, sourced from around the world, and assembled on site,” explains Neil Rackham, project manager at Metso’s Perth office. “In this case we consolidated the parts in Geraldton on the west coast of Australia so that the crushers could be pre-assembled, and then delivered to the site already assembled.”

Several customer benefits

Neil points out the many benefits the customer derives from this process. “First and foremost,” he says, “there is the element of safety. Assembly work is safer in a workshop environment where

workers have better control and are familiar with their surroundings and potential local hazards. And obviously they have all the necessary equipment for assembling the parts and preparing the finished crusher for shipping.” Equally important is the cleanliness of the work environment, allowing the assembly to be conducted without delays due to rain or other adverse weather conditions. The clean workshop is also better suited to the assembly of high precision parts which need to be assembled free of dust.

Reducing expenses

An important cost-saving aspect of Metso’s approach is the elimination of expensive on-site labour costs, as well as travel and lodging expenses involved in putting an assembly crew at the concentrator. “It can take up to four months to assemble a crusher onsite with Metso’s assistance,” says Neil. “But with pre-assembly it only takes a day or two to position the crusher once it’s delivered. With so many different people trying to access the cranes and other equipment at the site, the benefit to the customer in terms of planning and time management is invaluable. Plus, many of the typical hazards of assembling on-site are eliminated.”

Elegant solution

Once the crusher is assembled, the job of transporting the 157-metric-ton machine then becomes the challenge. Metso already had experience with this, having already delivered five assembled crushers to other customers in Western Australia. “Our method is quite simple, but it’s elegant,” explains Neil. “We assemble the crusher on elevated BULK HANDLING TODAY

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CRUSHERS, SCREENS, CHUTES & LINERS

stands that are wide enough to straddle a trailer. We reverse the trailer, which has a hydraulic loading system, under the stand. We then raise the trailer until it takes the load, then lower it back down to road level again once the crusher is secure. We don’t even need a crane and the whole operation only takes a couple of hours.”

Different people trying to access the cranes and other equipment at the site We’re the best

When speaking of the customer’s reasons for choosing Metso, Neil notes that it was largely the crusher’s reputation and their experience that made the sale. “We’ve been in the business for a long time,” he says, “and we care about what we do. We have the most experience with these types of large crushers and we feel we’re the best. Then our product is backed up with world-class support and service.” He goes on to point out that the customer was also influenced by their ability to deliver a preassembled machine. “Knowing that any issues would be handled directly by us was an important consideration for the customer,” he says. “We could save them time, money and logistical headaches.” Neil Rackham, Metso, neil.rackham@metso.com

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TRUCKING

GRW’s interchangeable new Imvubu fuel tanker

Interchangeable Fuel Tanker

A

A new 50 000 litre tanker will allow fuel transporters to interchange their tankers.

new 50 000 litre tanker will allow fuel transporters to interchange their tankers between SPD, metered delivery and bridging vehicles through a few minor adjustments in plug and play style. The Imvubu will thus bring unprecedented flexibility and interchangeability to tanker fleets and is also the country’s first branded fuel tanker. As the latest addition to GRW’s standard product range, the Imvubu is basically a combination of existing configurations. Customers will initially order their preferred configuration, but the tanker is designed in such a way that only a few adjustments could effectively mean a newly-purposed vehicle.

A few adjustments could effectively mean a newly-purposed vehicle Manifold pipe system

Creating this multipurpose vessel was mainly possible thanks to a manifold pipe system, which made it feasible to install and uninstall components in a relatively uncomplicated process. This, in turn, results in a significant saving in cost and increase in tanker availability, says Ivan Terblanche, engineering executive at GRW. He adds that the substantially reduced cost of ownership, taking into account its residual value, might be the biggest benefit of the new design. The flexibility allows for tankers to be adapted as

the needs within businesses change, while re-sale possibilities, especially in an economic environment where second-hand is in demand, are increased significantly.

Second look

Through taking a second look at the shell configuration, Ivan says engineers managed to reduce the number of operational components (and therefore the production costs), to standardise compartment sizes and to ease loading and off-loading. Furthermore a lower centre of gravity means improved safety on the road. All this while increasing payload. Turnaround times on maintenance services and repairs will also be reduced as critical components have been placed with accessibility and serviceability always in mind. The result is an innovative new pneumatic pipe and electric cable routing and clamping system that allows direct access for improved ease during diagnostic testing and replacement.

Improved drainage

According to Ivan, a particular challenge was to achieve improved drainage even with this new layout, but the GRW engineers found a way and are now proud to announce that excellent product drainage is guaranteed. Other minor but significant changes include consistency in the parts and operating systems from configuration to configuration, a homogeneous

GRW customers and members of the media got the first glimpse of the new Imvubu fuel tanker at the Rand Airport in Germiston in May

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TRUCKING

Gerhard van der Merwe, CEO of the GRW group, introduces the Imvubu, South Africa’s most versatile and only branded fuel tanker, to customers and the media

control panel on all the individual units and a fresh look that portrays an image of neatness and professionalism wherever the tanker travels.

extended warranty and maintenance contract, supported by GRW Services branches in Johannesburg and Cape Town.

“It is important to emphasise, however,” says Ivan “that we are still using our proven, structurally sound concepts and technology; tried and tested construction methods in the manufacturing process.”

An improved operator’s manual is included to ensure the safe use and correct maintenance programme, and driver training comes part and parcel with the sale of each new unit.

Part and parcel

Gerhard van der Merwe/PA Sharni de Klerk, GRW, Tel: 023 348 6318, grw@grw.co.za, sharni@grw.co.za

The Imvubu tanker is sold with an optional

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TRANSPORT

RFA Convention Truckers and fleet owners from across the country gathered for the 2011 Road Freight Association Convention, held at the Gaborone International Convention Centre in Botswana, to share solutions to problems facing the industry.

All the major truck manufacturers were represented at the 2011 RFA Convention

F

oremost on the agenda was the proposed tolling of Gauteng’s freeways and other national routes, as well as concerns raised over the implementation of the Aarto law enforcement system that is due to be rolled out across the country imminently. True to the theme of this year’s conference was road safety. Issues and initiatives debated were aimed at improving the state of road safety in South Africa and across its borders.

, nications d Commu e c h o n n a rt o p s n ng spe ter of Tra h a rd -h it ti a's Minis v e re d a li Botswan e d , n e amsd F ra n k R ty ro a d s a fe

A n im p re ss

iv e li n e -u p

The ups …

Inspirational news is that SADC governments are working on imminently easing congestion at national border posts by consolidating separate operations on each side of the border into a single, shared and cooperative border post operated by both countries’ officials. Let’s hope that this move puts a stop to corruption at the border posts.

C-Track was one of the headline sponsors of the 2011 RFA Convention

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TRANSPORT

Dr V ic R FA t o r a n d t h Conv e n t io e R a s t a R n 's c o c k t a e b e ls p r o v id e il p a r d en ty ter Delegates spill out onto the lawns for a welcome tea break during the proceedings of the convention.

t a in m

ent f or th e

Deputy minister of Transport, Jeremy Cronin, promised closer working relationships with his and other departments involved in transportation matters and even went so far as to set up monthly forums between his department and the RFA. It seemed that even while he spoke he was coming to the realisation that closer ties are required between road freighters and government. His speech was, however, well received and his sometimes scathing comments directed at some government departments and their ability to plan (or not plan) for the future was greeted with sighs, laughs and applause.

Getting down at the evening function

Trucking delegates were made to feel right at home at the registration desk of the 2011 Road Freight Association Convention held in Gaborone, Botswana recently Mercedes Benz's Ian Riley

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TRANSPORT

T h e ta b le s h u ff le

MixTelematics introduced its all-encompassing Intellichain system at the 2011 RFA Convention in Gaborone.

The downs …

Despite the high spirits of delegates and the proclaimed success by RFA convention organisers, there were some dampeners placed on the overall smooth running of the event. First and foremost was the fact that one of the major sponsors was blatantly asked for a bribe to get their promotional items, such as brochures and small give-aways, across the border into Botswana. A bad start some might say! Then there was the shockingly poor service that seems to have manifested itself across that part of Botswana, from rude petrol attendants (at least they’ve still got petrol), to lack-lustre hotel check-in clerks. Golfers on the first day of the event were also in for some of that ghastly Gaborone service

when they arrived, as scheduled, only to find that nothing had been organised, because, evidently someone forgot to make the necessary arrangements.

The verdict …

While some delegates were sceptical that the convention would achieve anything, others remained upbeat and felt that by raising the same subjects year after year something will eventually be done about it. One thing is certain though - any gathering of likeminded people from all sides of the debate has got to be good for business. In addition, when government officials, like Jeremy Cronin, start pushing for a louder voice for our truckers we can be assured that some of the issues may finally get the attention they deserve. Road Freight Association, Tel: (011) 974 4399, Fax: (011) 974 4903, Email: enquiries@rfa.co.za, Web: www.rfa.co.za

To y o ta 's Ig n a ti u s M u th ie n s h w it h C h a o w s o ff h rl e e n C la is m o v e s rk e o f “F o o n th e d a cus on T n c e fl o o r ra n s p o rt ”

Ray Schulz of UD Trucks leads proceedings

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MINING

Mining’s Supply Chain A new South African research study into the mining sector’s supply chain strategy reveals the industry’s responses to the shifts in the global resources market, and in particular, the competition the local industry is experiencing from other emerging economies such as Russia and China.

S

upplychainforesight, an independent study initiated and sponsored by Barloworld Logistics since 2003, is now conducted by respected international research specialists Frost & Sullivan. It samples the opinions on supply chain strategy of hundreds of senior executives in global South African companies each year.

dollar hedging and energy markets have become focal points for global business in the wake of the recession means that commodities are in high demand. South African mining commodities like coal, iron ore and more specialised commodities have therefore become very important to the local industry.

The South African mining industry has had a tougher time than most in the last decade. Cash costs have increased in that time, the currency has fluctuated widely, and production has slowed for various reasons. The industry now faces the challenge of global competition more than most, with the resource rich economies of Russia and China, among others, opening up to global trade. How is the local industry addressing these challenges?

But in order to be competitive, the sector needs to focus both on efficiencies and on beneficiation. The research this year demonstrates that a particular emphasis on squeezing supply chain efficiencies and costs predominates. While Russia and China in particular are lower-cost producers, they also have logistics advantages in their proximity to their major markets, with China still a major consumer of its own commodities.

Planning and forecasting has increased in importance Highs and lows

After a century as the world’s number one gold producer, South Africa has now slipped to fifth place – falling behind two of its key partners and competitors in the BRICS grouping, China and Russia. The constraints on the industry are not helped by the ongoing political debate about nationalisation, which undoubtedly has a negative impact on foreign direct investment. Yet despite this, the fact that

Potential freight that could be transported by rail

The survey this year shows a strong focus on increasing service levels to customers as the top objective for the industry. By contrast, the top mining objective is lowering procurement costs, at 62% of the sample, versus the 39% of the total who opted for this. Increasing service levels to customer is a distant third as an objective, with 38% as opposed to 53% of the total sample. Reducing order lead times appears as a new objective this year, in second place overall. This undoubtedly reflects the increased competitiveness of the global mining landscape, since volatility in demand and fluctuation in price makes it imperative that the supply chain can respond. This is difficult when the lead time for much mining equipment can be measured in years.

Immediate returns

The industry’s challenges are largely unchanged from last year, except in two important respects: planning and forecasting has increased in importance, to become the leading industry challenge – as it is for the general sample, but at a significantly higher level in mining. The second biggest challenge did not feature at all last year, and that is the return on capital investment in the supply chain. This tallies with the objective to reduce order lead times in this year’s industry objectives.

In this scenario, only 28% of companies would move less than 10% by rail, whereas 17% would move over 50%

The upturn in demand across the board for mining resources – either as a currency hedge for precious metals or as construction and infrastructure commodities in a post-recession environment – is likely to be driving the need for additional investBULK HANDLING TODAY

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MINING

60% of companies expect increases to their freight volumes this year, but only a 25% increase is expected in rail freight volumes

projected rail freight figures with fully 45% of respondents willing to move over 40% of their total freight by rail. Transnet, predictably for this key sector, is once more seen as failing to provide the necessary infrastructure and freight management capacity. James Sey, Barloworld Logistics, Tel 011 4451600, Fax 011 445-1630, info@barloworldlogistics.com, www.barloworld-logistics.com

ment in delivery mechanisms and equipment, and the need to mitigate the risk of large investment in equipment and mining infrastructure by seeing more immediate returns.

Fully 45% of respondents willing to move over 40% of their total freight by rail Massive move to rail

Encouragingly, as with the overall economy, the sector can see freight volumes increasing appreciably this year – with 54% of mining respondents expecting freight increases of some proportion. The proportion of this freight that could be moved by rail from the current dominance of road freight transport is not surprising. A massive move to rail if capacity existed would be driven by the movement of export bulk commodities, as seen by

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Market Forum Located versus non-located

While the bearing industry is familiar with the need for one located and one non-located bearing on a shaft, it appears turnkey engineers and end-users are not so familiar. For example the fabricated steel work assembled on site has loose tolerances on the bolt holes for a conveyor on a new plant under construction.

Cumulatively these tolerances could change the position of the centre line of the bearing housings, with the net result that the non-located bearing is displaced to one side preventing thermal growth or contraction. The inner race of a bearing runs at 10 to 15 degrees hotter than the outer race; this leads to thermal growth of the shaft, which must be accommodated by the non-located bearing. If the non-located bearing cannot move to accommodate this thermal growth, the bearing life will be dramatically reduced. Split Roller Bearings (SRB) are becoming the standard on new plants and OE Bearings, as a service to their customers, has been inspecting their bearings prior to commissioning. In all cases, a very high percentage of the non-located bearing needs to be adjusted to allow for thermal growth, in spite of the fact that the bearings were fitted on the correct position on the shaft. Monica Ulgheri, OE Bearings, Tel 011 493-04463, Fax 086 502-4307, mailto:monica@oebearings.co.za, www.oebearings.co.za

Bulk material facilities

Aurecon has been designing bulk materials handling systems for a range of industries for over 50 years. Since the late 1970s and early 1980s, major projects such as the Lucinda Bulk Sugar terminal and Dalrymple Bay Coal Terminal in Queensland, Australia, have grown their expertise in materials handling facilities. Since that time, Aurecon has developed an extensive track record in the successful design of bulk materials facilities for various mines, mineral processing facilities and especially bulk export terminals. They are able to provide a fully integrated service across all engineering disciplines to deliver complete materials han-

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Market Forum dling projects from feasibility to detail design to construction management and commissioning. The design of bulk materials facilities requires specialist knowledge beyond that which is normally taught in the traditional disciplines of civil, structural, mechanical and electrical engineering. This specialist knowledge typically relates to the particular product being handled or the type of handling process involved. Some typical processes for which Aurecon offers specialist knowledge includes: belt conveying; crushing and screening; dust control; feeding and dosing systems; high-lift conveying; hot product conveying; liquids pumping; loading and unloading from road, rail, and ship transportation; pneumatic conveying and powder handling; product sampling; slurry pumping, stacking and reclaiming for open stockyards and sheds; and storage in bins and silos. Jody Boshoff, Aurecon, Tel: 012 427 2066, Fax: 086 606 0671, jody. boshoff@aurecongroup.com

Sound advice

Wearcon is the developer and manufacturer of several innovative wear and corrosion-resistant epoxy ceramic products especially designed to offer maximum abrasion protection. These modified epoxy ceramic linings, containing sapphire hard alumina ceramic beads, provide an abrasion resistant surface designed to withstand the mining and industrial industry's requirements for wear control, corrosion, abrasion and protection to water lines, slurry lines, sewer lines, pipe

56 Moore Ave. Benoni Industrial Area ext.7 Benoni, Gauteng Tel: +27 (11) 421-0008 Fax: +27 (11) 422-1899

bends, pump casings, conveyor pulleys, chutes, launders, fan casings, feeder boxes, ducting fans, cyclones, hoppers, valve bodies and high impact surfaces. Wearcon is also the leader in the latest pipelining technology and the inventor of the new ceramic diamond pulley lagging. In today's competitive environment, customers need to be very sure about achieving the best return on investment possible. Wearcon has therefore played a major part in assisting the mining industry throughout Southern Africa and Epoxy ceramic smooth pulley lagging various countries in Africa to save on their downtime and bottom line. With 15 years experience in the development and manufacturing sector, the company remains committed to manufacture and supply a high quality product that is effective and capable of withstanding maximum wear, corrosion and abrasion as well as the best possible advice together with high quality workmanship. Andre Vorster, Wearcon, Tel: 011 814 2983, andre@wearcon.co.za, www.wearcon.co.za

P.O. Box 59892 Kengray, 2100 Gauteng, Rep. of South Africa E-Mail : engineering@baldmin.co.za www.baldmineng.edx.co.za & www.baldmin.co.za

BRINGING SOUTHERN AFRICAN A TOTAL CRUSHING AND MILLING SOLUTION

Innovative winning impact crushing E v o l u t i o n of C r u s h i n g

Maximum particle reduction with one pass

TERTIARY APPLICATION “PRIMUS� SYSTEM AND ITS ADVANTAGES :-

A) Impact system allows for producing varied particle sizes by adjusting the rotor speed. Either by changing the pulley or using a variable speed drive. B) Substantial reduction in wear and tear thanks to the innovative impact system. Moreover the wear and tear of the hammers is homogeneous, with a full frontal impact on the hammer as opposed to the tip wear on alternative brand hammer. C) Recirculation of crusher runs are minimal since all material is crushed via a double impact through the flinging action onto the incoming hammer then the subsequent impact on the crusher Different grades obtained wall. from filler to grit. D) Improved shape index of the finished product.. E) Produce uniform fine materials ( - 2mm ) . F) Lower power consumption G) Ideal Pre-Ball Mill crusher.

From Primary Crushing to final particle reduction Skid mounted Jaw Crusher

New & Reconditioned Cone Crusher

Refurbished : Complete Supply of Ball & Rod Mills

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SUBSCRIPTION RATES FOR 2011 SA  11 Issues a year

SA

Africa/ Overseas

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Should you wish to do an electronic transfer or a bank deposit, our banking details are as follows: Account Name: Promech Publishing cc Account No: 5144 005 1848 Bank: First National Bank of South Africa Branch: Cresta (25-49-05) All cheques to be made out to: Promech Publishing cc, P. O. Box 373, Pinegowrie, 2123, South Africa.

Our Guides: R50 each (incl postage and VAT) Distribution will commence upon clearance for a calendar year. (Back copies for the monthly magazines will be posted if payment is made during the year). Requests for past issues made six months after the original distribution date will not be fulfilled.  AAAMSA Buyers Guide

 Bulk Handling Buyers Guide

 Lifting Guide

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 Forklift Guide

 Rack Users Guide

Buyers Guide

Tel: (011) 781-1401 · Fax: (011) 781-1403 Email: accounts@promech.co.za Website: www.promech.co.za

 Supply Chain

Buyers Guide


Market Forum Thermal camera

SKF Maintenance Products has released the new SKF Thermal Camera TKTI 20. Specially developed for use by technicians and thermographers, the new TKTI 20 enables users in numerous industries to find potentially troublesome hot spots quickly and easily. With a 19200 pixel (160x120) infrared resolution and the ability to display thermal, visual or a blend of both images, including picture-in-picture, the user can easily view the results on the bright, sharp 3.5” screen. “The TKTI 20 boasts the following useful built-in features; four moveable cursors (with individual emissity settings), cursor temperature difference display and laser sighting to mention just a few”, states Steve Gething, SKF Business Development Manager, Reliability Systems. “For knowledgeable thermographers, there is a whole suite of powerful thermal analysis tools available which include isotherms, temperature gradients, area analyses and automatic hot and cold spots.” Steve continues, “Intermittent fault conditions can often be difficult to detect, but the TKTI 20 can be of great assistance in these situations. Simply mount the TKTI 20 on a tripod and set to automatically save pictures, or sequences, when a user defined temperature level is breached. This feature can greatly assist technicians to capture useful thermograms, even when the TKTI 20 is unattended - really helping with root cause fault analysis.” Samantha Joubert, SKF South Africa, Tel: 011 821 3500, samantha. joubert@skf.com, www.skf.co.za

Successful placement

Johnson Crane Hire (JCH) has successfully completed the lift and placement of an 85 ton, 45 metre deodoriser unit at food manufacturer and distributor Isando Foods’ new food plant in Isando.

The vessel is vertical, the tailing crane operation discontinued and the full weight is carried by the main lift crane.

On arrival in South Africa, the deodoriser unit was transported to the Isando Foods site by Lovemore Brothers, who sub-contracted JCH to lift the unit onto the client’s site and place it in position vertically on a concrete plinth. After several site visits, JCH compiled a comprehensive technical rigging study outlining how the operation would be carried out. The main lift crane was a 440 ton LTM 1400 crane rigged with 120 tons of counterweight and a “Y” guy, and the load was tailed by a 220 ton LTM 1200 crane rigged with 72 tons of counterweight. The carefully planned exercise began when the LTM 1200 was backed into position, followed by the larger LTM 1400 crane. The load was then brought into position and a spreader beam attached to the trunnions. The unit was offloaded from the truck in a horizontal position using the 440 ton crane and then topped and tailed into a vertical position with the help of the 220 tonner, balancing the weight between the two cranes and placing it squarely on the concrete plinth. Alison Dickson, Johnson Crane Hire, Tel: 011 455-9258, www.jch.co.za

BULK HANDLING TODAY

August 2011

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Market Forum What about counterfeits

In 2004, the Schaeffler Group executive management board set up a department to coordinate all its activities related to combating product and trademark piracy. Legal proceedings range from raids at manufacturers’ premises, investigations and legal action against sales channels to preliminary injunctions. The Schaeffler Group has a zero-tolerance policy for all forms of product and trademark piracy and protecting customers remains their top priority. The group has, therefore, been examining suspicious components for several years, irrespective of the source of that request.

Raids are only successful if all the goods are actually destroyed: counterfeit packaging is being destroyed here - with the bearings melted down in the steel mill in the meantime

In return, if the parts concerned are counterfeit, the company expects information about the origin of the parts and background information available. They can only successfully prevent the distribution of counterfeit bearings if everybody works together. In addition to these legal and organisational steps, the Schaeffler Group is involved in several associations that have made combating product and trademark piracy one of their objectives. Most recently, they were involved in the WBA’s campaign to raise awareness. Staff also visit trade shows, conduct internet research and much more. This continuously improves their understanding of how the trade in counterfeit bearings works and how they can prevent counterfeit bearings from entering the market. Schaeffler Industrial South Africa, Tel: (011) 225-3000, Fax: (011) 334-4378, Email: tlhalefang.mtombeni@schaeffler.com, Website: www.schaeffler.com

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BULK HANDLING TODAY

August 2011

Index to Advertisers

Afzelia 38 AJM Engineering 30 AST Inside Front Cover Barloworld 22 Bateman 6 Bearings International 34 Baldman Engineering 35 Clyde Bergemann 19 DG Materials 26 Dunlop 12 Engineer Placements 38 FL Smidth 10 Horne SA 33 ILS 32 Joy Global 14 Ludowici 26 MBE Minerals 20 Melco Outside Front Cover Multotec 24 Quadrant 37 Rema Tip Top 24 Rio-Carb 18 Sandvik 8 Scania Inside Back Cover Scaw Metals Outside Back Cover ThyssenKrupp 17


Stop for coffee. Just coffee Enjoy the sweet taste of great fuel economy.

When your Scania helps you to push your fuel consumption down, it’s easy to lean back, relax and just enjoy the ride. Smiling at the fact that you are surrounded and supported by more than 100 years of fuel economy expertise. Just one thing. Take a sip yourself once in a while. Even if your truck doesn’t need a refill, you might. Driving a Scania, you can afford it.

Pressing fuel consumption and emissions down – paired with previously unseen levels of power and torque – is a top Scania priority. It takes a lot of determination to solve the equation, but it pays off! See for yourself at www.scania.com

Scania. Destined to Lead. Scania Southern Africa For more information contact your nearest Dealer. Details available on www.scania.co.za

Angola, Botswana, Malawi, Mozambique, Namibia South Africa, Tanzania, Zambia, Zimbabwe

BULK HANDLING TODAY 2011 39 Trucks / Buses / Engines / Finance Solutions / August Services


Concerned about safety and productivity?

If safety and productivity are your primary concerns then SCAW should be your number one mining product partner. For 90 years SCAW has partnered with leading mining houses to ensure safety critical standards and productivity targets are consistently met. Whether it’s hoisting, grinding or excavating, Scaw produces an extensive range of products that drive mining safety and productivity. Backed up by teams of qualified engineers with extensive experience in all aspects of grinding media, steel wire rope, chain and cast products, Scaw’s product specialists are available to advise on the design, selection, installation and maintenance of safety critical and mining products manufactured by Scaw. Join Scaw’s global safety and productivity drive, call: Grinding Media: Tel: +27(11) 842 9322 ® Haggie Steel Wire Rope: Tel: +27(11) 620 0000 Chain Products:

Tel: +27(16) 428 6000

Cast Products:

Tel: +27(11) 842 9524

Ground Engaging Tools:

Tel: +27(11) 749 3600

website: www.scawmetals.com


Bulk Handling Today August 2011