Bulk Handling Today March 2018

BULK

HANDLING

T O D A Y

REDUCING FREIGHT CONGESTION LIGHT WORK OF PORT CARGO

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

T O D A Y

March 2018

BULK

HANDLING

T O D A Y

REDUCING FREIGHT CONGESTION LIGHT WORK OF PORT CARGO

Copyright

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

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

The monthly circulation is 3 673

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Chief Editor: Lara de Matos Advertising Sales: Linda Patricio DTP: Anne Rotteglia Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas.

Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)

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March 2018

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The South African Institute of Materials Handling

Sample

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.

Company Affliates as at May 2017 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

Tel: (011) 867-0902  Fax: (011) 867-0036  Email: saimh@global.co.za  www.saimh.co.za

BULK HANDLING TODAY

March 2018

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Dave Pitcher

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ENDORSER OF “BULK HANDLING TODAY”

LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA

• A recognised ECSA Voluntary Association (VA) •

LEEASA is a fully-fledged association devoted to the lifting industry across Southern Africa. Members hale from the crane, forklift, mobile elevated work platform, aerial and suspended access platform, chain hoists, rigging and lifting tackle arenas, etc. Primarily devoted to the LMI’s (Lifting Machinery Inspectors), and LME’s (Lifting Machinery Entities), the association considers safety paramount. As such it serves in an advisory capacity to the SABS, the Department of Labour, various training bodies and the industry at large. LEEASA is recognised by ECSA as a voluntary association.

What’s in it for you:

As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year).

and other training courses accredited by the association attract ECSA CPD points.

ECSA registered LEEASA members are awarded one Continuing Professional Development (CPD) credit each year. CPD is an ECSA requirement to retain registration.

Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry.

Members obtain a discount on LEEASA seminars. Both these

LEEASA has some 650 members (Individuals and Companies).

• • •

LEEASA Occupational Health & Safety Act and Regulations LEEASA Mine Health & Safety Act and Regulations LEEASA Lifting Equipment Inspection & Legal Compliance Register

Available for purchase online at www.leeasa.co.za

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LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SOUTH AFRICA Head Office: 8 Boris Road, Bordeaux, Randburg, Johannesburg Tel: 074 900 8378 • www.leeasa.co.za Secretary: Arni Sommer • email: arni@leeasa.co.za

BULK HANDLING TODAY

February 2012

BULK HANDLING TODAY

March 2018

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Piecing together your success.

12415/E

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There are certainly parallels between the South African and Australian scenarios

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March 2018

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The table indicates the availability of citrus fruit See full document from the department of Agriculture, Forestry and Fisheries.

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March 2018

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We drive Industry

Quality. Innovation. Efficiency.

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

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March 2018

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BELTCON 19

Craig Wheeler

Figure 1. World’s longest single flight belt conveyors Continuous 10 1

Discontinuous 10

Pneumatic Conveyor Vibrating Conveyor Sliding Belt

10 -1

Belt Conveyor (Idlers, Air)

10 -2

Pipe Line (Liquid, Slurry

1 Aeroplane Truck Train

10 -1 10 -2

Ship

10 -3

10 -3

Figure 2. Loss Factor of Transportation for bulk material handling systems

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Figure 3. Cost analysis for truck, rail and overland belt conveyors

BULK HANDLING TODAY

March 2018

Figure 4. Rail Conveyor concept

Figure 5. Side-by-side configuration

Figure 6. Carry side beneath return side

Figure 7. Horizontal carriage turnaround configuration

Figure 8. Loading point and carriage turnaround

Figure 9. Discharge point and drive layout

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BELTCON 19

Figure 11. 1:10 Scale model system

Figure 12. Two way transportation

Figure 13. Vertical turnover scale model system (shown in foreground)

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BULK HANDLING TODAY

March 2018

Figure 15. Conveying section of prototype system with carry side above

Figure 16. Carriage of prototype system before belt feeding section

Figure 17. Cable tension measurement on prototype

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BELTCON 19

Figure 18. Cable tension for one track cycle

Figure 19. Laboratory test equipment to measure rolling resistance

Figure 20. Laboratory test equipment to measure track wheel wear and friction

Figure 22. Track wheel friction versus radial load

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BULK HANDLING TODAY

March 2018

Figure 21. Rim drag testing apparatus for track wheels

Figure 23. Schematic of forces acting on carriage through horizontal curve

Figure 24. Track wheel axial load measurement

Figure 25. Track wheel friction versus axial load

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BELTCON 19

Design Specifications

Belt Conveyor

Bulk Material

ROM Coal

Rail Conveyor

Bulk Material Density

850 kg/m3

Design Capacity

1000 t/hr

Belt Speed

3.5 m/s

3.5 m/s

Belt Width

1,200 mm

1,200 mm

Horizontal Length

1,000 m

1,000 m

Lift

0m

0m

Table 1. 1 km Long Belt and Rail Conveyor Specifications Design Specifications

Belt Conveyor

Bulk Material

ROM Coal

Bulk Material Density

850 kg/m3

Design Capacity

1000 t/hr

Rail Conveyor

Belt Speed

3.5 m/s

3.5 m/s

Belt Width

1,200 mm

1,200 mm

Horizontal Length

10,000 m

10,000 m

Lift

0m

0m

Table 2. 10 km Long Belt and Rail Conveyor Specifications

(a) Belt Conveyor

(b) Rail Conveyor Assumptions: 1. Costs based on a 30 year service life.

2. Costs based on an 80% utilisation.

3. Costs in US dollars and excludes inflation.

4. Costs based on manufacture in China.

5. Site construction and civil costs excluded.

6. Labour maintenance costs excluded.

7. Carry side idler roll life = 3.2 yrs (22 500 hrs).

8. Return side idler roll life = 5.1 yrs (35 500 hrs).

9. Track wheel life = 6 yrs (42 000 hrs).

10. Rail life = 30 yrs.

11. Belt life = 10 yrs.

12. Energy costs based on 5c/kWh. Figure 26. Cost comparison for a 1 km long belt conveyor and Rail Conveyor system

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BULK HANDLING TODAY

March 2018

Figure 27 (a) Belt Conveyor

(b) Rail Conveyor Assumptions: 1. Costs based on a 30 year service life.

2. (2) Costs based on an 80% utilisation.

3. Costs in US dollars and excludes inflation.

4. Costs based on manufacture in China.

5. Site construction and civil costs excluded.

6. Labour maintenance costs excluded.

7. Carry side idler roll life = 3.2 yrs (22 500 hrs).

8. Return side idler roll life = 5.1 yrs (35 500 hrs).

9. Track wheel life = 6 yrs (42 000 hrs).

10. Rail life = 30 yrs.

11. Belt life = 10 yrs.

12. Energy costs based on 5c/kWh. Figure 27. Cost comparison for a 10 km long belt conveyor and Rail Conveyor system

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BELTCON 19

Figure 28. Cost comparison between belt conveyor and rail conveyor

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General Manager, Rodney Young

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LEGAL CONSULTING FOR YOU AND YOUR BUSINESS

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