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BULK HANDLING TODAY

July 2013

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BULK HANDLING TODAY

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Simon Curry

2013 Calendar of Events, Functions and Meetings Month August

September

October

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Date

Day

Venue

Beltcon

06 and 07 August

Wednesday and Thursday

Birchwood

CMA AGM weekend

13 - 15 September

Friday - Sunday

Drakensberg

1 day Beltsmen course

20 September

Thursday

Ferndale Lodge

6 day Diploma in Design & Operation of Belt 30 September to conveyors 07 October

Monday to Monday

Ferndale Lodge

Continued / 6 day Diploma in Design and 30 September to Operation of Belt conveyors 07 October

Monday - Monday

Ferndale Lodge

CMA members meeting

Tuesday

Bryanston CC

08 October

3 day Conveyor certificate course

21 - 23 October

Monday - Wednesday

Ferndale Lodge

1 day Beltsmen course

24 October

Thursday

Ferndale Lodge

BULK HANDLING TODAY

July 2013


The South African Institute Of Materials Handling

SAIMH

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions. The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques. For the SAIMH and the industry as a whole to prosper requires the support of companies such as yours and key individuals from within your organisation who share the same passion and vision within the Bulk Materials Handling industry. The advantages of being a corporate member of the Institute are as follows: • To make the industry aware of the professional standards that our members provide, • To encourage the interchange amongst members of the institute of knowledge, experience relating to all aspects of the bulk materials handling, • To promote education, training to all levels of employees within the industry, To introduce and encourage the utilisation of leading world class material handling methods and techniques, • To be able to transfer and obtain additional knowledge at the bi-monthly joint Forum lectures, • To be able to communicate through the monthly official journal (which is sent to member free of charge). These are just a few of the advantages that you will benefit from by being a corporate member. Just give us a few minutes of your valuable time and view our website, www.saimh.co.za, or email us on saimh@global.co.za and we will assist with your enquiry.

MEMBER COMPANIES Afripp Projects cc Bateman Engineered Technologies Bearings International (Pty) Ltd Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear Industries (Pty) Ltd Deebar Mining & Industrial Supplies East Rand Engineering Services ELB Engineering Services (Pty)Ltd Engicon Systems (Pty) Ltd Facet Engineering cc GMR Hydraulics Goba Consulting Engineers Group Line Projects (Pty) Ltd Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Africa (Pty) Ltd Illustech

Kimrae Engineering Projects Macsteel VRN Martin Engineering Melco Conveyor Equipment Morris Materials Handling SA (Pty) Ltd Osborn Engineered Products (Pty) Ltd PD Engineering Services cc PDNA M&I (Pty) Ltd PH Projects Holdings (Pty) Ltd Quadrant PHS Renold Crofts (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Hanlding Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Shatterprufe a Div. of PG Group Pty Ltd Spar Western Cape Super Dock Systems Unitek Engineering Zest Electric Motors (Pty) Ltd

UPCOMING MEETINGS UPCOMING EVENTS SAIMH SAIMH Golf Day Golf Day

11 October 2012

10 October 2013 ERPM Golf Club

ERPM Golf Club

PO Box 1047 Southdale, 2135

Tel: (011) 867 0902 Fax: (011) 867 0036

saimh@global.co.za • www.saimh.co.za BULK HANDLING TODAY

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September 18 -21 Gallagher Convention Centre Johannesburg

MEET. CONNECT. EXPAND.

more than 500 exhibitors over 60 000 square metres of exhibition space G E RE N I L ON FOR E ster C AN re g i / R T m a.co E EN afric FRE a m .bau www

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IS

TION TRA

HAVASWW8656/E

AFRICA’S PREMIER CONSTRUCTION AND MINING SHOW

S!

INTERNATIONAL TRADE FAIR FOR CONSTRUCTION MACHINERY, BUILDING MATERIAL MACHINES, MINING MACHINES AND CONSTRUCTION VEHICLES

www.bauma-africa.com


COVER STORY

Belt Splicing Made Easy Conveyor belt splicing techniques fall into two main categories, vulcanising or mechanical, each with its own advantages and disadvantages. But these techniques, more often than not, compete for market share in certain applications.

T

he pro’s and con’s of each method have to be weighed against each other given the circumstances: for example, how long the splice needs to last, how quickly the belt needs to be fixed and the costs, etc. Vulcanising is a long process requiring heavy equipment, but the splice lasts very long. On the other hand, mechanical systems are quick, requiring few hand tools, but are not always suitable for all applications.

Donovan Scott, general manager of BMG’s belting division

“The Super-Screw splice is a patented product from MLT in France, originally brought in as a temporary A splicing method developed by the French may just alternative to hot and cold splicing,” he explains. “Since then, however, it has be the answer to bridge this developed into a mature proddivide between the two techIt has developed into a uct which has proved to be nologies, making mechanical mature product which has strong enough to be used as splicing an equally balanced proved to be strong enough a permanent splice, replacing general choice against vulcato be used as a permanent both hot and cold traditional nised splicing. “Bulk Handling splicing on several test sites splice, replacing both hot and Today” speaks to Donovan on mines in South Africa. Scott, general manager of cold traditional splicing BMG’s belting division. On trial

Steel screws are screwed into an embedded nut inside the material, forming a sandwich effect of the top and bottom cover that clamps onto the belt carcass

The plant’s in-house maintenance team can efficiently install this product using an electrical screw driver or battery-powered screwdriver

BULK HANDLING TODAY

“We launched Super-Screw as an exclusive product locally in 2011, first installing it on trial at multiple mining sites,” adds Donovan. Various belt classes and widths have been used to trial this unique product. “We have carried out tests at the SABS on 100mm wide belts and Super-Screw proved to come out tops against all other joining methods. Our next step is to have various July 2013

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Global Leaders in Bulk Materials Handling

• • •

Hundreds of complete systems and equipment supplied globally Offer feasibility studies to turnkey and project-managed materials handling contracts African projects include Mozambique coal sector One of the longest single flight belt conveyors in the southern African region The largest number of Rapid Train Loading Systems and dome covered circular stockpiles in southern Africa

Tenova TAKRAF is a key supplier of equipment and systems for open pit mining & underground solutions, materials handling and mineral processing to the global mining and general industries

1 Kramer Road, Bedfordview, Johannesburg, South Africa Phone +27 11 201 2300 – Fax +27 11 455 4547 – Enquiries.TMM@za.tenovagroup.com www.tenovagroup.com

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BULK HANDLING July 2013 TENOVA is a worldwideTODAY supplier of advanced technologies, products and engineering services for the iron and steel and mining industries


COVER STORY

belt classes, widths and different belt thicknesses independently tested in order to underpin the integrity of this splice against other splice types. This will also give the end user peace of mind when using this splice method.”

How it works

The rubber material, containing tensile fabric, used for this splice is manufactured in rolls of up to 25 metres in length and is available in various strength ratings from Class 315 up to Class 2000 conveyor belting. The belt covers are stripped to expose the belt carcass. Steel screws are screwed into an embedded nut inside the material, forming a sandwich effect of the top and bottom cover that clamps onto the belt carcass.

Regular cold splicing, for example, requires up to three times the preparation time required to prepare a belt, compared with the time required to prepare a belt for SuperScrew fitment. Donovan elaborates, “A cold splice Whether it’s also needs to cure for up to four hours before the for joining a conveyor belt is operational belt, repairing a again. In addition, ambilongitudinal rip or ent conditions have to be a puncture in the considered before a cold belt, the splice splice can take place; if is compatible the humidity levels are too high, the adhesive may not with small pulley perform as expected.” diameters and

Comparison

is scraper and V-plough friendly

Vulcanised, or hot splicing, takes a couple of hours to do, requiring special cumbersome presses to be positioned correctly to ensure a good joint. Donovan asserts, “In our field test, for instance, a hot splice took over seven hours while a cold splice took over eight hours (including curing time). Compared with the 58 minutes it takes to do a Super-Screw splice, the downtime for a belt repair is dramatically reduced. Above all, the repair crews can now undertake several repairs a day rather than just one, or two at a stretch.”

This mechanical joining technique is simple and quick, requiring no special skills in terms of repair crews. “The plant’s in-house maintenance team, after a quick training session from us, can efficiently install this product, using an electrical screw driver or battery-powered screw driver. Whether it’s for joining a belt, repairing a longitudinal rip or a puncture in the belt, the splice is compatible with small pulley diameters and is scraper and V-plough friendly. “We are also carrying out tests on steel cord belting. Internationally, there are encouraging reference points for steel cord repairs that ensure production costs are kept in check until planned maintenance can be performed.

The splice does not stand proud of the belt covers. This ensures that the surface of the splice is level with the two ends of the original belt, making the splice surface as even and as thick as the belt itself. It is fitted at a bias like regular splices to ensure optimal strength and flexibility around pulleys.

All belts are available in materials that are abrasion resistant, heat resistant or heat retardant up to 200 degrees C. The heat retardant type has been used successfully for clinker belts in cement works. They also come in a FDA (food) grade, and an oil resistant grade. The non-magnetic version has non-magnetic steel screws and inserts specifically for magnetic conveyors.

Over the last two years, various field tests in different mining applications in South Africa have shown that the Super-Screw splice is as durable as any of the traditional splicing methods

Tests

Over the last two years, various field tests in different mining applications in South Africa have shown that the Super-Screw splice is as durable as any of the traditional splicing methods. “We’re confident enough now to promote this technology as a permanent splice,” Donovan says in conclusion. “Apart from the fact that it is inexpensive enough to have handy at all times, it is still the quickest way to repair any belt in an emergency. This splice will reduce total cost of ownership as far as bulk materials conveying is concerned. This technology is set to change any scepticism out there about mechanical splicing systems.” Donovan Scott, BMG Belting Division, Tel: 0800-022-224, (031) 576-6212, Email: donovans@bmgworld.net, www.bmgworld.net

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technoloGy

Breakthrough productive solutions. Long recognised for our ability to engineer productive equipment, Joy Global is taking production to even higher levels through the enhancement of cost-focused technologies. Our proven productive solutions are setting the standard for surface and underground mining world wide.

Steeledale, Johannesburg South Africa Š 2013 Joy Global Inc. or one of its affiliates. All Rights reserved.

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BULK HANDLING TODAY

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JoyGlobal.com


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Tega offers value added consultancy services and solutions

in Mineral Beneficiation, Bulk Solids handling, Wear and Abrasion customised to suit specific applications. With focus on core engineering applications in the Mining and Mineral Processing Industry, Steel plants, Power, Port and Cement Industries.

Tega Industries (South Africa) Pty Ltd P.O Box 17260, Benoni West, 1503, South Africa, Phone: (011) 421 - 9916/ 7, 421 - 6714, 421 - 6761, Fax: (011) 845 1472, Email: info@tegaindustries.co.za, www.tegaindustries.com

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TOTAL : Solution

TM


Hatch Goba director of Mining and Metals for Africa Lister Sinclair

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Everyday we move mountains for our clients. We d o th is w i t h t h e l a test a n d b e s t e qu ipme nt t ha t is p ur p o s e d esi gn ed f o r t he ir s p e cif ic ne e ds. O p e ratin g gl o b a l l y we re - d ef i n e wha t it me a ns to move th e e a r t h f o r o u r c l i en t s.

w w w. A RDBEL . com 14

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BELTCON 17 EXHIBITION

DirtWhacker

Conveyor Belt Cleaners & Automation t/a Lesa Mining Equipment & Conveyor Belt

Clip-Avoidance System 1

1 2 3 4

4

Day 1 - Tuesday 6th August

3

07h00-08h40 08h40-09h10 09h10-09h50 09h50-10h00 10h00-10h30 10h30-11h10 11h10-11h50 11h50-12h00 12h00-13h00 13h00-13h40 13h40-14h20 14h20-15h00 15h00-15h30 15h30-15h50 15h50-16h10 16h10-16h20

Inductive Sensor Signal Line Control Power Compressed Air

2

DirtWhacker Primary

New blade

Beltcon Programme Registration & Exhibition Keynote Address (Lou Kilian) Paper 1 Announcement (The new SANS 971) Tea & Exhibition Paper 2 Paper 3 Announcement (Belt Splicing training) Lunch & Exhibition Paper 4 Paper 5 Paper 6 Tea & Exhibition Paper 7 Paper 8 Announcement (TBSA)

Worn blade

Day 2 - Wednesday 7th August

The system automatically compensates for blade wear

07h00-08h40 08h40-09h20 09h20-10h00 10h00-10h30 10h30-11h10 11h10-11h50 11h50-12h00

Big Ben Skirting Clamp

12h00-13h00 13h00-13h40 13h40-14h20 14h20-15h00 15h00-15h30 15h30-16h10 16h10-16h50 16h50-17h00 17h00-18h00

DirtWhacker Secondary

Registration & Exhibition Paper 09 Paper 10 Tea & Exhibition Paper 11 Paper 12 Announcement (Static shaft pulleys with internal bearings) Lunch & Exhibition Paper 13 Paper 14 Paper 15 Tea & Exhibition Paper 16 Paper 17 Evaluations (Lucky Draw) Exhibition

CMA 40th Anniversary

Promech Publishing will be putting together a special self-standing publication in October 2013 to mark the 40th anniversary of the CMA.

New blade Worn blade Predetermined belt-to-blade angle remains constant

With the valued assistance of Simon Curry and Chris Townsend, this prestigious publication, “Commemorating CMA’s 40th Anniversary” will take readers from 1973 to the present-day and through to CMA’s plans for 2014 and beyond.

DirtWhacker Diagonal

1

No-Load Device

1 2 3 4

3

Ultrasonic Sensor Signal Line Compressed Air Control Power

4

2

Tel: (011) 762-2560, Fax: (011) 762-2015 Email: info@dirtwhacker.com www.dirtwhacker.com

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Characterised by a strong focus on excellence in belt conveying, the CMA has grown from 7 to over 70 members. Its reputation for leadership among its member companies and the industry at large has led to its training courses commanding industry-wide respect, both locally and internationally. The CMA’s sterling work on standards, its adherence to high ethics and safety, complemented by a healthy balance of popular social events, augurs well for the next 40 years ahead! Surita Marx will be in touch with you to participate in this publication to mark your involvement with this highly-respected body. Surita Marx, “Bulk Handling Today”, Tel: (011) 781-1401, Email: bulkhandling@promech.co.za


Experience Counts Make Ours Count For You

C O A L C H R O M E U R A N I U M N I C K E L G O L D P L AT I N U M ZINC DIAMONDS COPPER MANGANESE IRON ORE

From concept to production, our expertise in mine design and mineral processing projects have earned us a sterling reputation on some of Africa’s biggest projects.

C O A L C H R O M E U R A N I U M N I C K E L G O L D P L AT I N U M ZINC DIAMONDS COPPER MANGANESE IRON ORE

w w w.DRAinternational.com Tel: +27 11 202 8600

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2013/07/11 11:23 AM


ELB Engineering is an internationally recognised total solutions provider to the mining, power, port, construction and industrial sectors from Source to Sea in the field of materials handling and 18 appropriate process plants. BULK HANDLING TODAY

July 2013


Contact: +27 (0) 11 772-1400 sales@elb.co.za www.elb.co.za

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BELTCON 17 EXHIBITION

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BELTCON 17 EXHIBITION

Dunlop Industrial Products, manufacturers of Plied, PVC & PVC Nitrile and Steelcord conveyor belting, make materials handling easier and more cost effective. Their full hose range offers products to meet virtually every industrial and general hose application. Their commitment to quality and service ensure that their customers’ business will keep on rolling. Dunlop Belting Products (Pty) Ltd, Tel: (011) 741-2500, Email: myrnab@dunlopbelting.com, www.dunlopbelting.com

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BELTCON 17 EXHIBITION

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BELTCON 17 EXHIBITION

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BELTCON 17 EXHIBITION

Osborn is a member of the Astec Industries Inc. group of companies. The company provides the African mining and quarry markets with a full range of crushers, feeders, screens and conveyor idlers. Osborn’s core products are: jaw crushers, cone crushers, double roll crushers, rotary breakers, conveyor idlers, vibrating screens and feeders. Osborn, Charisse Fallows, Tel: (011) 820-7743, Email: cfallows@osborn.co.za, www.osborn.co.za

Rubber materials manufacturer Rema Tip Top South Africa is not letting the global economic downturn put a dent in its growth plans. Instead, it is committed to making the most of the opportunity to review its procedures and products with a view to enhanced innovation and service levels. Tel: (011) 741-2500, Email: info@rematiptop.co.za, www.rema-tiptop.com

Idlers July 2013.indd 1

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With these conveyors, extra efficiency and savings are no pipe-dream

Totally Enclosed Conveying - The material transported is completely enclosed minimising pollution, protecting the product and preventing theft

Curved Transport - Conveyor can curve horizontally and vertically thus replacing several conventional belt conveyors

Steep Inclined Conveying - Able to convey 50% steeper than conventional conveyors

Space Saving - Pipe conveyor gantries are narrower than conventional conveyors with equal capacity

Tenova TAKRAF is a key supplier of equipment and systems for open pit mining & underground solutions, materials handling and mineral processing to the global mining and general industries

1 Kramer Road, Bedfordview, Johannesburg, South Africa Phone +27 11 201 2300 – Fax +27 11 455 4547 – Enquiries.TMM@za.tenovagroup.com www.tenovagroup.com

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BULK HANDLING TODAY July 2013 technologies, products and engineering services for the iron and steel and mining industries TENOVA is a worldwide supplier of advanced


BELTCON 17 EXHIBITION

Beltcon Exhibitors Sandvik Mining Systems is a single source multi-disciplinary design, project construction and management company specialising in bulk materials handling systems with a strong base of references. These include underground, inplant and long complex overland conveying systems, crushing and screening plants, total stockyard systems complete with stackers and reclaimers, spreader systems, IPCC systems, shiploaders and export terminals. Sandvik Mining Systems, Rudi Pieterse, Tel: (011) 657-4600, Email: rudi.pieterse@sandvik.com, www.mc.sandvik.com/za

Leading drive engineering company SEW Eurodrive has built further on its reputation as a market leader in small conveying applications. With the X-Series range of helical and bevel-helical invertible gearbox the company now also have solutions for larger conveying solutions, paving the way to fast becoming the preferred supplier to Original Equipment Manufacturers (OEMs) in a variety of commodities including iron ore, gold and coal in southern and other parts of Africa.

Tega Industries designs, manufactures and installs a wide range of rubber linings suitable for use in most processing plants. Research and development of products in partnership with clients improves the costs of milling. Other products include screens, wear liners and conveyor loading points for the majority of mining companies in Southern Africa. Tega Beruc South Africa (Pty) Ltd, Tel: (011) 421-9916, www.tegaindustries.com

Tenova Takraf is a key supplier of equipment and systems for open pit mining and underground solutions, bulk and specialised materials handling, milling and crushing, and air pollution control to the global mining and mineral processing industries, and general industry. A comprehensive after sales service is provided. Tenova Mining & Minerals, Philip le Roux Tel: (011) 201-2300, Email: philip.leroux@bateman.com www.tenova.com

SEW, Tel: (011) 248-7000, www.sew.co.za

While SKF maintains its leadership as the hallmark of quality bearings throughout the world, new dimensions in technical advances, product support and services have evolved SKF into a truly solutions-oriented supplier, creating greater value for customers. These solutions bring greater productivity to customers with breakthrough application products and leading-edge design simulation tools, plant asset efficiency maintenance programmes, and industry’s most advanced supply management techniques. SKF, Tel: (011) 821-3500, Email: sales.za@skf.com, www.skf.co.za

Timken, a global industrial technology leader, applies its deep knowledge of materials, friction management and power transmission to improve the reliability and efficiency of industrial machinery and equipment all around the world. The company engineers, manufactures and markets mechanical components and high-performance steel. Timken bearings, engineered steel bars and tubes — as well as transmissions, gearboxes, chain, related products and services — support diversified markets worldwide. Lynda Krebs, Timken South Africa, Tel: (011) 741-3877, Email: lynda.krebs@timken.com, www.timken.co.za

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BELTCON 17 EXHIBITION

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BELTCON 17 EXHIBITION

Learn how

can work for you.

BULK HANDLING TODAY

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Dean Harty of Tega Industries’ Industrial rubber division

POWERFUL, EFFICIENT AND SAFE POWER TO PUT MATERIALS IN MOTION. Since 1974, Martin® Air Cannons have been used around the world to overcome bottlenecks and boost flow through high capacity vessels by preventing buildup and improving material flow.

Martin offers a full line of air cannon technologies representing both established traditional designs as well as the latest leading-edge innovations in advanced valve design, hybrid systems and multiplevalve and -port technologies.

call +27(0)13 656 5135 | visit martin-eng.co.za email service@martin-eng.com A global company. Est. 1944 ® Registered trademark of Martin Engineering Company in the US and other select locations. © 2013 Martin Engineering Company. Additional information can be obtained at www.martin-eng.com/trademarks.

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COST

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LOCATION AND APPLICATION OF DECKPLATES

The Flat Bag Filter range includes: • Insertable Bag Filters such as bin vents and transfer points • Stand alone Bag Filters employed in ducted systems

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One Source

One Source for all your material handling needs FLSmidth delivers a complete line of reliable material handling systems designed for enhancing performance, increasing energy efficiency and safety, while helping to reduce emissions and operating costs. Rely on the brands you’ve come to trust – ROYMEC, RAHCO, KOCH, MVT, Buffalo & ABON. ROM TIPS • CONVEYORS • STOCKYARDS • PORTS • LOADOUT STATIONS • WASTE HANDLING SYSTEMS

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For further information please contact us at: Tel: +27 (0)10 210 4000 • www.flsmidth.com BULK HANDLING TODAY

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Schmidt-Seeger SMATM – the compact, attractively-priced screening machine. The line of SMA screening machines is ideally suited for the pre-cleaning and main cleaning of grain and other bulk materials. It improves the quality of the product to be cleaned, prevents disease and enhance production reliability. Buhler has innovated these machines to be optimally suited for applications in plants for the reception and storage of grain and other bulk materials, port facilities, mills, silo and storage plants, seed processing plants as well as malting plants.

Bühler (Pty) Ltd. 5 Star Business Park Cnr Beyers Naudè Drive and Juice Str. Honeydew, Roodepoort 2040, South Africa T + 27 (11) 801 3500, F + 27 (11) 801 3503 buhler.johannesburg@buhlergroup.com, www.buhlergroup.com

Schmidt-Seeger SMATM. Compact, attractively-priced screening machine. Customer value: - High operational reliability - Isolation of metallic material - Easy maintenance - Optimum cleaning

Technical data -Capacity intake of 3 t/h to 50 t/h

Commodities: Wheat, maize, feed barley, legumes, malt, rapeseed, soy beans, paddy, white rice, coffee

Innovations for a better world. 40

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Figure 1: Components of the conveyor pulley

Figure 2: T-bottom and turbine type end disks

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Figure 3: Measurement positions on the inside and outside diameter As-welded Weld Pos.

Stress-relieved

S t r e s s - X X Stress-YY Weld (MPa) (MPa) Pos.

Description

Stress-XX S t r e s s (MPa) YY(MPa)

Roll-Bent Plate

Inner Dia.

NSR3

142.7

75.0

SR3

50.3

37.6

Outer Dia.

NSR6

-175.8

-117.8

SR6

11.1

7.4

Weld Toe Inner Dia.

NSR1

330.2

166.6

SR1

62.5

61.4

Inner Dia.

NSR2

361.0

332.5

SR2

47.1

45.8

Outer Dia.

NSR4

174.9

73.5

SR4

-49.8

-6.7

Outer Dia.

NSR5

244.2

-35.2

SR5

61.2

40.2

42

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Figure 4: Overall geometry of pulley

Figure 5: Simplified geometry of the pulley used for the analyses

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R q2 q1 q T

T2

1

q=0 T2

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T1

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Circumferential Position (Degrees)

Radial Pressure (MPa)

0 15 15.001 360

0.495 0.495 0.000 0.000

Table 2: Circumferential belt pressure for the mesh sensitivity analysis Circumferential Position (Degrees) 0 172.499 172.499 187.5 187.501 360

Radial Pressure (MPa) 0.000 0.000 0.495 0.495 0.000 0.000

Table 3: Circumferential belt pressure for the final Fourier analysis Mesh Size (mm) Element Interpolation Maximum Radial Displacement (mm) 16 Linear -0.17264 8 Linear -0.17503 8 Linear -0.17487

Time (min) 0.383 15.250 41.200

Table 4: 3D mesh sensitivity results

Tension, T

1st order sinusoidal

3rd order sinusoidal Linear uniform

z = b/2 z = 0 z = b/2 Figure 7: Various functions used to apply the belt pressure over the belt width

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Result Quantity Maximum Radial Displacement (mm) von Mises Stress (MPa) Stress-XX (MPa)

Value of the Result -0.351 35.5 21.0

Table 5: Results of the final analysis

Figure 8: Belt pressure applied to the model

Figure 9: Locking element interface pressure applied to the model for the end disk and shaft

Coralynne & Associates +27 (011) 422 1949

ABSOLUTE MATERIAL FLOW CONTROL

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• • • • • •

Optimum material flow Up to 80% decrease in material degredation Reduced dust and noise levels Virtually maintenance free Great reduced spillage Significant reduction in belt damage

Tel: +27 (0) 11 827-9372 Fax: +27 (0) 11 827-6132

w w w . w e b a c h u t e s . c o m

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w e b a @ m j e n g . c o . z a


Figure 12: Quarter model for the 3D analysis

Type of Stress

Current FEA Design method

Hoop stress in the shell 32.4 MPa due to the locking element

Position of Stress Range Shell Longitudinal Seam Weld Shell to End Disk Circumferential Weld

33.4 MPa

Current Design FEA Method 13.2 MPa 34.82 MPa 23.9 MPa

38.50 MPa

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Component

ISO Designation

Surface Roughness (Îźm)

Locking Element

N7

1.6

End Disk

N8

3.2

Shaft

N8

3.2

Shell

N10

12.5

Position Figure 14: Contour plot of the von Mises stress in the pulley shell

NSR6

NSR3

NSR6

NSR3

Stress Range (MPa) 30.340 30.610

34.820

35.600

Endurance Limit 52.327 52.327 (71) (MPa)

52.327

52.327

Fatigue Ratio

67%

68%

58%

ROMECH PUB p - T, O, G 2/20/11 9:54 PM Page 2

omposite

C

48

BULK HANDLING TODAY

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M

Y

CM

MY

CY CMY

K

59%


Position Stress Range (MPa) Endurance Limit (71) (MPa) Fatigue Ratio

Position Stress Range (MPa) Endurance Limit (71) (MPa) Fatigue Ratio

NSR4 NSR5 30.100 7.320

NSR1 NSR2 38.500 14.700

52.327

52.327

52.327 52.327

58%

14%

74%

28%

SR6 21.140

SR3 SR6 SR3 26.966 24.500 31.240

52.327

52.327 52.327 52.327

40%

52%

47%

60% Figure 15: Constant amplitude bending stress range Position Stress amplitude (MPa) Endurance limit under zero mean stress (MPa) Mean Stress (MPa) Ultimate Tensile Strength (MPa)

Position Stress Range (Mpa) Endurance Limit (71) (Mpa) Fatigue Ratio

Sr4 25.300 52.327

Sr5 Sr1 5.644 29.180 52.327 52.327

Sr2 11.484 52.327

48%

11%

22%

56%

MS1 19.300 110.782

MS2 MS3 26.300 39.600 110.782 110.782

MS4 35.000 110.782

9.576 479.530

-50.183 -86.927 479.530 479.530

-72.012 479.530

Endurance limit under mean stress 108.569 (MPa) Fatigue Ratio 18%

110.782 110.782

110.782

24%

32%

36%

Table 10. Fatigue ratio for BS EN1993-1-9 in the axial direction for the stress relieved condition

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Figure 16: Weld measurement position of the pulley

Position Stress amplitude (MPa) Endurance limit under zero mean stress (MPa) Mean Stress (MPa) Ultimate Tensile Strength (MPa) Endurance limit under mean stress (MPa) Fatigue Ratio

MS1 5.545

MS2 4.495

MS3 13.750

MS4 15.700

110.782

110.782

110.782

110.782

57.836

33.390

108.478

129.487

479.530

479.530

479.530

479.530

97.420

103.068

85.721

80.867

6%

4%

16%

19%

Figure 17: Weld measurement position of the pulley

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Metso’s big bulk solutions are far more than mechanical muscle. With an emphasis on global interaction and brain power, we have the resources to handle big bulk material handling challenges.

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Bulk_216X146_3ml bleed.indd 1

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Livio Talocchino of Sandvik Mining Systems

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The tip and rock breaker, underground

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Bucket Elevators Tenova Takraf Africa recently supervised the commissioning of the bucket elevators it supplied to Aveng EPC, the main EPC contractor for the plant at Moma Sands, the minerals sands mine in Northern Mozambique. The bucket elevators are used to elevate heavy mineral concentrate in the dry circuits of the mineral separation plant from the lower floors to the gravity distributors situated on the top floors of the building. Tenova Takraf’s scope of work included project management and planning, the design, engineering, procurement, manufacture, inspection, painting and documentation of the bucket elevators, as well as loading them onto the client’s transport. The total number of new elevators that Tenova Takraf supplied was five. It also made modifications to another 15. “These modifications involved changing the elevator dynamics to enable them to be used at the increased tonnage rates,” says Tenova Takraf project manager, Hector Matake. “We achieved this by making modifications to the head stations and changing the discharge characteristics by modifying the speed and bucket design.” Tenova Takraf, Hector Matake , Tel: (011) 201-2300 Email: Hector.Matake@bateman.com www.tenovagroup.com

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EDEM BulkSim Solution™ for Mining Simulation-based design optimization of capital intensive, production-critical bulk materials handling equipment, such as conveyor transfer points and chutes. • Optimize equipment performance • Increase equipment reliability and uptime • Increase productivity of ore transport and processing plant • Improve worker safety Used by leading Mining Companies and EPCMs - EDEM BulkSim® is an industry-first DEM software solution tailored for engineers designing bulk materials handling equipment used in mine operations that uniquely does not require knowledge of DEM physics to use. For more information about EDEM BulkSim Solution, email info@dem-solutions.com or contact: Authorized Distributor Phone: +27 12 809 9500 http://www.esteq.co.za/ 58

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MARKET FORUM

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View of the processing plant construction works in Russia

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MARKET FORUM

Five Ordered Kibali’s 20/5-ton crane under test at Condra

August Lamos and Carlos Andrade next to the laboratories sample splitter

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A TRUSTED INDUSTRY LEADER For 90 years, SCAW, a South African industry leader, has partnered with leading mining houses to ensure safety critical

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