Bulk Handling Today September 2018

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

T O D A Y

September 2018

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BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

T O D A Y

September 2018

BULK

HANDLING September 2018

SA CRANE MANUFACTURER MAKES INROADS IN RUSSIA

Contents

INNOVATIVE GEARLESS DRIVE FOR CONVEYING APPLICATIONS Transforming Freight Logistics

On the cover: Transnet www.transnet.net

T O D A Y

LEEASA News CMA News SAIMH Rigid Haulers

Beltcon 19

4 5 7

30 Active Winch Take-up System on Conveyor Dynamics 40

Market Forum

10 Expecting a Strong Following

Lifting

Endorsing Bodies

12 European Market Share

The South African Institute of Materials Handling Aspasa

20 Joining Forces

Huge Potential

15 Positive Economic Outlook

Large Thickeners

16 Economic Options

•

CMA (Conveyor Manufacturers Association)

•

LEEASA (Lifting Equipment Engineering Association of South Africa)

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set (SA up with an objective to Lifting • SAIMechE Institution of encourage the transfer of knowledge associated within the fi elds of Bulk Materials Handling (conveyors, stacker, Mechanical Engineering) 18 Looking After 260 Cranes and Hoists reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

• (SA Institute of Materials Moving Machinery The SAIMH is made up of professional engineers, each practising their tradeSAIMH in a variety of organisations who 22 Spring Cable Reels volunteer their time to execute the SAIMH’s objective. The main aim is thus Handling) to promote the advancement of the art, science, theory Conveying and practice of the Bulk Materials Handling principles techniques.

• alsoand mailed to members of the RFA

Sample

26 Gearless Technology

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

(Road Freight Association)

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 Advertising Sales: Linda Patricio DTP: Anne Rotteglia Administration: Belinda Siegruhn Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas.

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

BULK HANDLING TODAY

September 2018

3

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

1

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

CONVEYOR MANUFACTURERS ASSOCIATION

From The Chairman’s Desk

T

he Annual General Meeting of the Association was held in August when we had an opportunity to review the major achievements and events of the past year. The CMA motto to promote the excellence of belt conveying is behind everything we do, be it research, training, standardisation or providing information to the industry.

Research projects

The two idler research projects that the CMA has heavily invested in are progressing well and more research topics have been identified. These could provide an opportunity for post-graduates to do some useful work towards a master’s degree or similar, and at the same time furthering data that can be incorporated into national standards or guidelines for the industry.

The election at the Annual General Meeting brought some new faces onto the Board of Directors. Henk Brink, Willem Niemandt and Willem Sullivan retired

The election at the Annual General Meeting brought some new faces onto the Board of Directors

after completing a two-year term of office. Newly elected Directors are Simon Curry, Jim Kiewiet, Jacques Swart and Mpho Tshidzumba. The complete Board therefore comprises: • Simon Curry • Trevor du Toit • Jim Kiewiet • Wilton Monnery • Jay Pillay (Chairman) • Dave Pitcher • Graeme Skeen (Deputy Chairman) • Jacques Swart • Mpho Tshidzumba Jay Pillay, Chairman

Membership at September 2018 All members subscribe to the CMA Code of Ethics Acrow Limited Actom Afripp Projects Altra Industrial Motion South Africa (Pty) Ltd Bauer Bearings International Belt Brokers Belting Supply Services BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CedoTech cc Closeal Manufacturing Collisen Engineering ContiTech South Africa (Pty) Ltd Conveyor & Engineering Equipment CT Systems David Brown Gear Industries DRA Projects SA (Pty) Ltd Dunlop Belting Products Dymot Engineering Company

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

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

BULK HANDLING TODAY

September 2018

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Distribution and Product Support

The South African Institute of Materials Handling The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to theInstitute transfer of associated withinisthe fields of Bulk Materials Handling (conveyors, stacker, Theencourage South African ofknowledge Materials Handling (SAIMH) a Non-Profit organisation set up with an objective to reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions. encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, The SAIMH is made up of professional engineers, eachapractising theiroftrade in a variety of organisations who reclaimers, tipplers, train, loading systems, ect.) through combination seminars and networking sessions. volunteer their time to execute the SAIMH’s objective.

The main aim is thus to promote the advancement The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who of the art,their science, theory andthe practice of objective. the Bulk Materials principles and the techniques. volunteer time to execute SAIMH’s The mainHandling aim is thus to promote advancement of the

art, science, theory and practice of the BULK Materials Handling principles and techniques.

Sample

Update

We have to date organised two joint venture talks, which we are very pleased to report were well attended. A conscious effort was made to include more general topics that would be of interest to a broader spectrum of members and guests, intertwined with technology specific talks for the engineers among us.

Sprinkle the occasion with a dash of beverage and a few culinary delights and we have what appears to be a recipe for success. More of the same is planned for later in the year, maybe with a slight change for a mining specific audience.

You will be surprised what a set of young eyes can notice and improve

Our quest to engage university students in the field of materials handling has also taken off. We managed to place a number of students within our industry for vacational experience during their holiday periods. They were thrown in at the deep end of both the manufacturing and design/project management spheres. We thank those who opened their doors to facilitate this venture and know for

a fact that the experience gained by the students was exceptional.

Student body

We have also conducted a number of lectures/talks at the University of the Witwatersrand, under the guidance of the faculty professors, which have also proved to be beneficial to both the students and the Institute. By making the students aware of what our field of engineering can offer, the popularity was such that we were able to form a Wits student body for the sole purpose of interaction with the institute.

During these lectures, it is also very evident that many students are unaware of how they could fit into the greater engineering world once qualified.

To this end, we have conducted the first classroom presentation on this subject, using a typical work breakdown structure for a process plant turnkey project. It proved to be a real positive eye-opener for the students. Now that we seem to have a working format, we will be rolling this presentation out to other universities and Technicons.

In the not too distant future, we hope to be able to assist the materials handling industry should any member or corporate company require qualified engineers and technicians. Having been a part of their learning and training, we will have a good

Dymot Engineering Company (PTY) LTD Specialist Designers & Manufacturers of Winching Systems

WORLD OF WINCHES 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

Market leaders in conveyor tensioning equipment Take up winches with Overload Protection Company Affliates as at May 2017 Gravity Counterweight Handling Osborn Engineered Products Hagglunds Drives SA (Pty) Ltd Braked(Pty)Ltd Capstans PD Engineering Services cc Hansen Transmissions SA (Pty) Ltd Screw Take Ups PH Projects Holdings (Pty) Ltd Hatch Goba (Pty) Ltd Hand & Motorised Winches Rio Carb (Pty) Ltd lllustech Electrical Control Panels & Systems Sandvik Materials Handling Africa J & A Engineering Services Screw Conveyors & Material Handling Sheaves Kimrae Engineering Prolects Senet Loadtech Load Cells (Pty) Ltd11 DERRICK ROAD, SPARTAN, KEMPTON PARK SEW Eurodrive MacsteelVRN SOUTH AFRICA Spar Western Cape Martin Engineering SSAB South Africa (Pty)+27 Ltd 11 970 1920 Melco Conveyor Equipment Tenova sales@dymot.co.za Morris Material Handling SA (Pty) Ltd Zest Electric Motors (Pty) Ltd www.dymot.co.za

BULK HANDLING TODAY  September 2018 7 Tel: (011) 867-0902  Fax: (011) 867-0036  Email: saimh@global.co.za www.saimh.co.za

The Local Manufacturing Expo Aims to:

21 – 23 MAY 2019

Promote local manufacturing

EXPO CENTRE, NASREC,

Demonstrate Southern Africa’s export potential

JOHANNESBURG, SOUTH AFRICA

Provide access to global markets

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

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

Manufacturers across a variety of sectors, including:

Agriprocessing

Automotive

Business Process Outsourcing

Capital Equipment

Chemicals

Construction

Engineering

Food and Beverage

Furniture

ICT and Electronics

Metals

Mining

Plastics

Textiles/ Clothing/ Footwear

Transport

www.localmanufacturingexpo.co.za In association with:

Endorsed by:

Implemented by:

Brought to you by:

of Materials Handling

Sample

he South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to ncourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, eclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions. he SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who olunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of he art, science, theory and practice of the Bulk Materials Handling principles and techniques.

SAIMH

insight into the students capabilities, attitude and ability to work in our industry.

In a similar vein, we have produced basic conveyor and associated equipment training documents.

Now that we have your attention, we would be grateful to hear from further volunteer companies who would be willing to accommodate similar students in the future. The cost is minimal but the feedback is priceless. You will be surprised what a set of young eyes can notice and improve. This has been experienced firsthand by the Institute tutors who have taken students on site visits to Kendal Power Station and the Afrisam cement blending and bagging plant in Brakpan. Further visits are planned for later this year.

The objective here is to make the more 'basic' user aware of how the equipment operates, improve any fault finding and stoppages etc, which in turn will hopefully improve operations, maintenance and profitability

Training courses

We are presently producing primary materials handling operating and maintenance training documentation, so as to offer such courses to the industry. It is our hope to have these courses accredited in the near future, but we can still offer them in the interim should the need arise. We have already had interest fromCompany a few mining companies.

Affliates as at

.

The objective here is to make the more 'basic' user aware of how the equipment operates, improve any fault finding and stoppages etc, which in turn will hopefully improve operations, maintenance and profitability. The need for this type of tuition has also come about from industry feedback.

If you have any requirements for help with training where you believe the institute can be of assistance, our doors are always open and our rates are outrageously reasonable!!

Kind Regards

Your SAIMH May 2017Committee

.

Hagglunds Drives SA (Pty) Ltd fripp Projects cc Hansen Transmissions SA (Pty) Ltd relko Conveyor Products (Pty) Ltd Hatch Goba (Pty) Ltd ulkcon Tel: (011) 867-0902 Fax: (011) 867-0036 lllustech PM Engineering J & A Engineering Services T Systems cc Kimrae Engineering Prolects onveyor Watch (Pty) Ltd Loadtech Load Cells (Pty) Ltd avid Brown Gear lndustries (Pty) Ltd MacsteelVRN LB Engineering Services (Pty) Ltd Martin Engineering ngicon Systems (Pty) Ltd Melco Conveyor Equipment acet Engineering cc Morris Material Handling SA (Pty) Ltd exco (SA) (Pty) Ltd

.

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Email: www.saimh.co.za Rioinfo@saimh.co.za 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

el: (011) 867-0902  Fax: (011) 867-0036 find Email:out saimh@global.co.za  www.saimh.co.za if you qualify

to #joinourtable at pps.co.za

PPS is an authorized Financial Services Provider.

BULK HANDLING TODAY

September 2018

9

RIGID HAULERS

Expecting a Strong Following The new Volvo Construction Equipment hauler range consists of the 45-tonne R45D, 60-tonne R60D, 72-tonne R70D and the flagship 100t/95-tonne R100E, a completely new rigid hauler featuring new technologies and a striking new design.

D

avid Vaughan, Managing Director for Babcock’s equipment business, attended the launch at Volvo’s Motherwell facility in Scotland earlier this year where guests had the opportunity to test drive the R100E and see it in action at a nearby quarry.

David says that the R100E rigid hauler, built for surface mining and quarrying applications where operational costs are critical, took centre stage at the event, and expects the machine to attract a strong following in southern Africa.

“Despite the fact that the R100E will be competing in one of the most contested segments of the rigid hauler market, this top-performing machine with optimal production and minimal operational costs will be a strong contender in the mining and quarry market segment,” he claims.

Industry-recognised load profile policy enables the operator to meet a consistent average target payload of 95 tonnes

David Vaughan

The groundbreaking R100E is engineered to perform and is built on strong Volvo DNA. Offering a true 100t/95-tonne payload, t he R100E allows operators to meet production rates faster while simultaneously providing low cost of ownership and ease of serviceability.

With a 60.4m3 capacity V-shaped body for optimum load retention and minimal material carry-back, customers can expect to spend less per haul, while the industry-recognised load profile policy enables the operator to meet a consistent average target payload of 95 tonnes.

Drivetrain

Central to its powerful and efficient performance is the new fully electronic 783 kW Cummins QST30 engine for superior power and fuel efficiency, backed

10

BULK HANDLING TODAY

September 2018

by an improved ‘connected’ drivetrain delivering high torque capabilities, excellent pulling performance and class-leading rimpull.

The Volvo Adaptive Shift Control provides automated adaptive shift schedules for excellent performance and fuel efficiencies in all operating conditions.

Intelligent monitoring systems such as the On-Board Weighing (OBW) option ensure the machine moves the optimum safe payload to further boost production and minimise operational costs.

Other features that make the R100E more durable, cost-efficient and comfortable include a speedy body-tipping system ensuring fast cycle times for an all-round efficient performance; a new suspension design and wheel track configuration to absorb high levels of ground impact shocks; and an ergonomic cab layout for improved operator experience and a 360-degree visual system for safe and efficient operation.

Extensive field testing

David says that the R100E has undergone extensive field testing at mining sites in both Sweden and South Africa, a key market for rigid haulers, with

the machine tested in both cold and hot climates and in hard rock and coal environments.

Babcock expects the new Volvo R100E, with its focus on low total cost of ownership at the forefront of its design, to be a hard hitter in the southern African mining and quarrying sectors.

The R100E and the D-Series machines will be backed

by the same aftersales support, immediate access to parts and qualified service technicians, and well laid-out service points for quick maintenance and increased machine uptime that is standard for all Babcock-distributed machinery.

Babcock, David Vaughan Email: David.Vaughan@babcock.co.za

BULK HANDLING TODAY

September 2018

11

LIFTING

European Market Share

Cranes under manufacture in Condra’s Johannesburg factory

Condra Bulgaria Ltd, fledgling European subsidiary of South African crane manufacturer Condra, has received orders worth some €½-million in the past six months, and secured further contracts for the ongoing supply of endcarriages to crane manufacturers in England and Spain.

Marc Kleiner

T

he subsidiary’s latest order comprises components for a 10-ton overhead travelling crane recently delivered to a Russian company, where customer support is being supplied by Energoprofit Moscow, Condra’s newly-appointed agent in that country.

This took place in 2008 and, combined with Condra’s German origins and connections, it provided the correct platform from which to address Russia, employing skilled staff from the pool of artisans left underemployed by a Bulgarian crane industry much troubled after the opening up of the region to global competition.

These successes are independent of orders worth several million Euros placed by Russian companies directly with the South African parent in recent years.

Marketing

Overhead cranes at Kazakhstan’s Varvarinskoye gold mine afforded potential Russian customers the opportunity to visit working examples of the company’s capabilities Twin obstacles

The latent potential in Russia’s lifting equipment market was identified by Condra as far back as 2000, but it posed the twin obstacles of widespread Russian scepticism of any and all capital equipment of African manufacture, and an ingrained confidence in traditional supply from Poland and Bulgaria, designated suppliers of lifting equipment to the former USSR. When Bulgaria entered the European Economic Community in 2007, legislated acceptance of foreign subsidiary companies paved the way for establishing a subsidiary in Pazardzhik, an industrial town outside the country’s second city of Plovdiv with an acceptable national address.

Participation in a Plovdiv exposition in 2010, and in two expositions in Moscow in 2011, resulted in the subsidiary’s first orders as well as a working relationship with the Russian NGO, Vniiptmash.

The installation of Condra overhead cranes at Kazakhstan’s Varvarinskoye gold mine afforded potential Russian customers the opportunity to visit working examples of the company’s capabilities, and orders from Vniiptmash followed soon afterward; first the components needed for two 100/20/5-ton cranes, then four complete machines: two 90/20-ton machines and two 38-metre span 70/12,5/5-ton double girder electric overhead travelling cranes.

The combined value of these four cranes was just short of €3-million, though this number was excluded from Bulgarian sales figures on account of manufacture being executed in the South African factory to meet the exacting demands of machine complexity that included lift heights of 28 metres and lift speeds of up to 12 metres per minute.

Local foundry

The next step was for Condra Bulgaria to seek out

LIFTING a foundry ahead of the start of local production.

A working relationship was established with the Tisina foundry in Dryanovo, which in turn led to a partnership between the two companies and the construction in 2015 of a production facility of some 3 000m2 in Gabrovo.

of adapted V-belt technology already tested and proven in the motor vehicle industry.

“Component manufacture in South Africa has for several years made use of high quality materials, such as a 36B case-hardened material on most pinions,” he adds.

Early last year, Condra Bulgaria moved from Pazardzhik to Gabrovo, with Nicolai Dyankov, Tisina’s owner, heading up the company as managing director.

“This is an expensive material, but it is beneficial in extending crane lifespan.

By December 2017, the Gabrovo operation had already supplied four double girder electric overhead travelling cranes to Bulgarian veterinary supplies giant Biovet, with capacities ranging from 3,2 tons to 25 tons and spans of between 14 metres and 30 metres These successes were quickly followed by orders taken early in 2018 for four 18-metre span single girder machines with capacities of 3 tons, 5 tons (two of) and 8 tons.

Component manufacture in South Africa has for several years made use of high quality materials, such as a 36B case-hardened material on most pinions “A further example can be found in the high tensilestrength ropes fitted to hoists. These have a smaller rope diameter, which enables use of a reduced drum diameter and a more compact gearbox and motor, T all of which help contain costs.

BULK

O benefits are now available to the European “These D through Condra Bulgaria, where I believe market A will contribute to a sustainable competitive they advantage into the future,” Nicolai concludes.

Y

Asked to comment on the subsidiary company’s achievements to date, Nicolai Dyankov says that the drive for Russian market share is helped by the certifiably lower overall lifetime costs offered by the Condra product.

Lifespan

HANDLING

Condra

He points to BEST examplesIN of cost-lowering product Marc Kleiner THE BUSINESS improvements such as the use of live-axle drives Tel: (011) 776-6000 Email: sales@condra.co.za in place of ring-gear designs, and the introduction “Bulk Handling Today” is the only publication endorsed by: • The SA Institution of Mechanical Engineering • The SA Institute of Materials Handling T • The Conveyor Manufacturers Association O endorsed by the • The magazine is also D Lifting Equipment A Engineering Association Y of SA. Endorsed by: CMA l LEEASA l SAIMechE l SAIMH JJJJ 2018 An endorsement gives us the ring of approval as well as regularly updated membership lists. As such, “Bulk Handling BEST IN THE Today” has the most comprehensive and bona fide readership in the industry.

BULK

BULK

HANDLING

HANDLING Make sure you are receiving a printed copy of this independentlywritten, wellresearched and respected publication or go online to read each issue.

T O D A Y

BUSINESS

“Bulk Handling Today” is the only publication endorsed by: T • The O SA Institution of Mechanical Engineering D A SA Institute of Materials Handling • The Y • The Conveyor Manufacturers Association • The magazine is also endorsed by the Lifting Equipment Engineering Association of SA.

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

NEW FOCUS ON BELT SCRAPERS

August 2016

An endorsement gives us the ring of approval as well as regularly updated membership lists. As such, “Bulk Handling Today” has the most comprehensive and bona fide readership in the industry. GU CONVEYING

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HUGE POTENTIAL

Positive Economic Outlook Africa’s population is growing at a rapid pace, and according to the United Nations is expected to double to 2.5 billion people by 2050. The continent also has the fastest rate of urbanisation in the world. Within the next ten years, it is expected that 187 million Africans, equivalent to half the US population, will live in cities.

T

his means growing demand for drive and control solutions for industrial machinery, for mobile machinery such as construction vehicles, and for major construction projects.

Bosch Rexroth and its marketing partner Hytec are successfully collaborating to serve the African market in areas such as power engineering.

In one major project, for example, the two companies renewed the entire hydraulic equipment of the Roseires Dam in Sudan. At 1 800 megawatts, the output of this dam on the Blue Nile is comparable with that of a nuclear power station.

The company’s focus is on affordable solutions and services for local requirements Expertise on tap

Bosch has been working with its marketing partner Hytec for more than 50 years. Hytec has about 40 branch operations, not only in South Africa, but also in Mozambique, Namibia, Zambia, Botswana, Ghana, and Kenya.

In a first phase, Bosch Rexroth acquired a 50 percent stake in its marketing partner Hytec in 2014. In February this year, the remainder of the acquisition was completed. “The complete acquisition of Hytec gives us a welcome opportunity to extend this successful collaboration and to grow further

in Africa,” says Tillmann Olsen, general manager of Bosch Rexroth in South Africa.

In Africa

In recent years, the Bosch Group has systematically expanded its presence on the African continent.

Today, it is represented in ten African countries.

The company’s focus is on affordable solutions and services for local requirements. These include training programme for tradespeople in Kenya, for example, or auto mechanics in Nigeria.

According to preliminary figures, the company generated sales of some 460 million euros in Africa in 2017. Including the Hytec workforce, Bosch currently employs more than 1 500 associates on the continent.

All four Bosch business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology, are active there. There are two manufacturing sites in South Africa, in Brits and Midrand. Bosch also actively promotes talented young people in sub-Saharan Africa. In 2008, it was one of the initiators of “Afrika kommt!”, an initiative of German industry for junior managers from sub-Saharan Africa.

Bosch Rexroth www.bosch.com www.boschrexroth.com

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September 2018

15

LARGE THICKENERS

Economic Options Finding the optimal design and delivery solution for a large thickener at a remote gold mine in the West African state of Mauritania meant considering a complex range of technical, transportation and assembly options, according to FLSmidth senior account manager, Ricus van Reenen.

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Ricus van Reenen, FLSmidth senior account manager for sub-Sahara Africa region

T

he cost of transporting the components for the 50-metre diameter thickener was a key factor affecting the design, says Ricus. He highlights that transportation of components to remote sites can comprise a substantial portion of costs, and that breakbulk shipping costs are significantly higher than containerised transport.

Welding “Given that the thickener components needed to be shipped by sea as well as road, containers were considered the most economical mode solution,” he says. “This requires that the plate sections be cut and rolled in dimensions that can be packed into containers for shipping to site. The structural support sections like the I-beams will be fabricated to final stage at our facility and just bolted on site, but the plates will need to then be welded by expert welders.”

Concentrate thickener installation

While bolted thickeners are often more economical to construct, as they obviate the need for extensive on-site welding, this option cannot easily be applied to thickeners larger than 50 metres in diameter.

Cost-saving strategies “For these larger designs, the support structure is erected on site followed by the welding together of the plate sections from one end to the other,” he explains. “After the plate sections have been welded to the structure, the welds are sandblasted, primed and applied with a final paint coating over the welded areas.”

Certain cost-saving strategies can still be employed in these situations; for instance, the plates can be painted before shipping with the weld-strips left clean to facilitate on-site welding.

Ricus emphasises the importance of the documented assembly procedure, according to FLSmidth’s global best practice, that is applied when erecting these large thickeners.

Choice of gearbox “When supplying a thickener, part of our engineering deliverables includes an installation methodology for the site contractor to follow, to make sure that they implement each stage correctly,” he says.

“FLSmidth also provides a technical installation expert from the most suitable of our global offices who visits the site at appropriate intervals to advise and inspect.”

High rate thickener installation

Part of our engineering deliverables includes an installation methodology for the site contractor to follow, to make sure that they implement each stage correctly

He further emphasises that the forces demanded within large thickeners makes the choice of gearbox drive much more important.

“Smaller thickeners can usually be designed with planetary gearbox drives – available from a number of OEMs,” he concludes. “With really large drives requiring higher torque, however, we prefer to use our own ring-gear Dorr Oliver drives which can reach much higher torque values than planetary drives. The ring-gear drives are also more able to handle axial and radial loadings on the rakes.”

Terence Osborn, FLSmidth (Pty) ltd, Tel: (010) 210-4820 Email: marinda.kerr@flsmidth.com, www.flsmidth.com

Tailings thickener installation

BULK HANDLING TODAY

September 2018

17

LIFTING

Two crane experts of Konecranes are at GKM for about three months to check all 260 units. From a simple rope hoist to a 300 tonne powerhouse crane, by using the online portal yourKonecranes.com, the experts always have access to all information on their mobile devices.

Looking after 260 cranes and hoists Innovative solution fulfils eco-design requirements, improves reliability, saves energy costs and reduces overall maintenance costs for mining and cement operators.

G

KM power plant’s unit 9 in Germany, which was connected to the grid in 2015, is one of the world’s most efficient coalfired power plants, with a fuel efficiency of 70 percent. For transport, maintenance and lifting tasks, GKM uses 260 crane systems and hoists of various types and manufacturers – an enormous fleet. Reliability of this equipment is crucial. Therefore, for maintenance and check-up purposes, GKM completely relies on Konecranes, one of the world’s leading manufacturers of cranes and hoists.

How is it possible to get a quick, safe and clear overview of such a large fleet of cranes and hoists?

Each of the 260 cranes and hoists, from a simple chain pulley to the 300 tonne powerhouse crane, which the Konecranes installed in the new power plant, requires a yearly safety-related check (UVV) and maintenance.

How is it possible to get a quick, safe and clear overview of such a large fleet of cranes and hoists?

By using the industry leading cloud-based customer portal, yourKonecranes.com, regardless of how many cranes and hoists are in the fleet.

Operational processes

At the beginning of each year, the experts at Konecranes coordinate the timeframes for maintenance and is safety-related checks with GKM. “Complex processes support the supply of energy. For ex-

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September 2018

ample, each year, about 3 million tons of hard coal is required for the operation of the boilers. It needs to be unloaded by the loading bridges, stored and transported to the four power plant units with the conveyor systems at the right time.

“For maintenance and repair of these units, reliable cranes and hoists are crucial”, says Michael Griesheimer, responsible for the maintenance of these facilities at GKM. While planning the service assignments, the operational processes are monitored in detail, and so, an optimal date for maintenance is set. On yourKonecranes.com, GKM can always track the dates. Moreover, the software allows online requests for services.

Maintenance – regardless of type and manufacturer

The cranes and hoists at GKM have different years of construction, manufacturers and histories. This results in individual requirements that need to be considered for the check-up. For maintenance and check-up of all units, Konecranes service technicians spend approximately three months at GKM. With yourKonecranes.com, the crane experts always have mobile access to all information, from technical data to test reports on their smartphone or tablet, regardless of where they are located on the large premises of the plant.

With every check-up, the service technicians update the units’ data on the portal, and GKM can track the status of each maintenance task promptly in the service calendar.

Documentation

Following maintenance work, Konecranes creates a test report for each of the 260 cranes and hoists and advises how to further optimise the units.

Moreover, GKM can access all reports on-line at yourKonecranes.com. With the search function, the units can be arranged by various criteria, like maintenance priority, last actions or newlyrequested services.

High availability of the cranes and hoists is essential for the precisely timed production process at GKM. Therefore, the experts at Konecranes assess the condition of individual units during the check-up.

If the operation of a unit is at risk or if it might fail, quick action is required.

Individual cranes and hoists are assigned to the four power plant units of GKM on yourKonecranes.com.

In this way, the responsible departments receive notifications in a quick and uncomplicated manner, and repair orders can be initiated promptly.

“Complex processes ensure the efficient operation of our four power plant units. For this, we need to have confidence in the reliability of our cranes and hoists. Keeping 260 crane systems and hoists in view is a challenge”, Michael adds. “With the customer portal, we know the condition of each single unit at any time. Konecranes actively supports us, continues to the optimise the portal, and advises us, so that our units are ready for use at any time.” “yourKonecranes.com significantly facilitates the whole process at the Mannheim high-energy power plant. In the United Kingdom, our customers also

use the portal, which facilitates quick and easy access to crane maintenance information, usage data of Truconnect, maintenance information and unit details. Pooled data can be quickly called up, analysed and transmitted, so that sound maintenance decisions are made”, adds Mark Goringe, Konecranes Industrial Service: Area Director, Mid West Europe.

KonecranesDemag UK Limited www.konecranes.co.uk

GKM generates energy for 2.5 million people and for commerce and industry, as well as distant heating for 120,000 households. For this, 260 cranes and hoists are used on the premises of the plant.

Konecranes undertakes the yearly maintenance and safetyrelated check-ups of the units.

BULK HANDLING TODAY

September 2018

19

ASPASA

Mark Hunter, general manager of SACAA (left) and Nico Pienaar, director of Aspasa

Joining

FORCES

In its ongoing effort to reach out to potential users of coal ash products, the South African Coal Ash Association (SACAA) has joined forces with the surface mining industry association, Aspasa.

W

hile the industries derive their products through different means, they share many of the same outlets and in some instances coal ash can be used as a substitute for aggregates in the manufacturing of concrete and construction of roads and other structures.

With its advanced programme in safety, health and environment, as well as long-standing relationships with government and all other industry stakeholders, it makes sense to join a progressive association like Aspasa Furthermore, the machinery used to process, load and transport the two products are similar with similar legislation and challenges. “With its advanced programme in safety, health and environment, as well as long-standing relationships with government and all other industry stakeholders, it makes sense to join a progressive association like Aspasa, which acts with the best interests of its members and the overall industry at heart,� says SACAA general manager, Mark Hunter.

In the surface mining industry, Aspasa, which previously represented only sand and aggregate quarrying companies, has had to diversify to include all types of surface mines to accommodate growing calls for assistance and representation from diverse operations who had not previously enjoyed all the benefits of broad industry representation.

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Promoting ash Aspasa director, Nico Pienaar, says the association wants to play an active role engaging all stakeholders from the ash producers, to current users and resellers, as well as promoting the use of ash broadly to all levels of industry.

250 000 tonnes

of ash from Lethabo Power Station was used for the Katse Dam project

“We welcome members of SACAA and encourage them to make use of our services and engage with us to find ways to promote the safe and responsible use of coal ash,” he concludes.

Aspasa Nico Pienaar Tel: (011) 791 3327, Email: nico@aspasa.co.za www.aspasa.co.za

Finding economical uses

At a recent fact-finding tour of the Matimba and new Medupi power station, SACAA general manager, Mark Hunter, revealed that research is underway to determine the viability of treating the scourge of acid mine drainage throughout the gold mining areas known as the Reef with suitable coal ash.

Certain building products made with ash are also being tested and reviewed for suitability to alleviate housing shortages.

“However, these are not new ideas and we believe that a myriad of other uses exists for this waste product. There are certainly more uses in civil engineering for roads, concrete structures etc, as well as uses in manufacturing, chemical industries, landscaping and other uses.

“All one must do is look at the amazing composition and structure of different types of ash produced in each power station, from fine and potentially valuable fly-ash, to course bottom ash and everything in between.

“We simply need to challenge our technical brains-trust to look for applications in their fields of work or study and to find ways of overcoming challenges to integrate ash into their supply chains. And, for those who think that it is an impossible challenge, it is worth noting that certain countries in developed economies are using as much as 80% of their ash produced,” Mark says.

It is worth noting that South African fly ash and ash products were used to enhance concrete used to build the world’s then tallest building, the Burj Khalifa, as well as improving concrete used to construct the Katse Dam, as well as the superb Maputo Bridge in Mozambique.

SACAA, Mark Hunter, Tel: 083 631 0793, Email: mehunter22@icloud.com, www.coalash.co.za Aspasa, Tel: (011) 791 3327, Email: office@aspasa.co.za

BULK HANDLING TODAY

September 2018

21

MOVING MACHINERY

Spring cable reels One of South Africa’s industry-leading suppliers of electrical and mechanical equipment for moving machinery, has boosted its quality, rugged and reliable cable reeling systems with the introduction of the new SR-Express range from Conductix Wampfler.

P

owermite holds exclusive Southern African distribution rights for Conductix-Wampfler.

“We understand the paramount importance of product quality for customers and end-users because this is fundamental to product reliability which in turn leads to high machine and plant uptime, productivity and profitability,” says Rolf Lung, Managing Director of Powermite, a Hudaco group company.

Supplied with the cable already installed and connected to the slip rings so that it is ready for use to keep downtime to a minimum

“It is therefore our responsibility to supply products of uncompromising quality that will perform reliably over a long lifecycle for lowest total operational and ownership cost. Consequently, we align ourselves only with companies like Conductix-Wampfler, a global designer and manufacturer renowned for its world-class quality, state-of-the-art, customised cable reels for the bulk materials handling industry.”

The new SR-Express SR10-SR60 range is a selection of spring cable reels from Conductix-Wampfler’s global SR range and is a tailored response to customers’ expectations.

Minimum downtime

The range has been engineered to meet the energy and data supply needs of moving machinery that requires energy and data transmission systems including overhead bridge cranes, gantries, mobile tables, aerial ladders and lifts, elevators and elevated work platforms.

The SR-Express is supplied with the cable already installed and connected to the slip rings so that it is ready for use to keep downtime to a minimum. Quality and reliability is part of the DNA of the SR-Express components. From the cables and cable drum to the slip rings, springs and mounting flange, all components are manufactured from the best and most durable materials to ensure operational efficiency over a long lifecycle.

The halogen-free PUR (polyurethane) cables, specifically designed for reeling applications, provide excellent wear resistance and high flexibility. The drum body

and flanks of the cable drum are manufactured from robust zinc-plated steel.

The flank edge has been designed to optimise cable arrangement during winding and to ensure safety for the user. With winding diameters ranging from 170mm to 400mm, the cable drum is fitted with sealed ball bearings and is lubricated for life.

Maintenance

The USR heat-resistant slip rings are part of a new European range and feature a new design that both facilitates and reduces maintenance. The slip rings are located in an ABS-PC techno-polymere housing outside the cable drum for optimal access to connection.

This impact-resistant slip ring housing is protected from dust and moisture ingress and is equipped with captive screws and a breather to prevent condensation.

With an IP65 rating, this range is suitable for both indoor and outdoor applications Arranged in series or parallel, the springs are manufactured from high-performance textured steel and are lubricated with corrosion-resistant grease and individually encapsulated in a cassette. The patented spring cassette ensures safe and easy manipulation including replacement or reversal of winding direction.

Three options

The mounting flange, manufactured from cast aluminium alloy or cast iron, has been specially designed for quick, easy and safe installation of the reel on the spring reel shaft.

Customers and end-users have a choice of three bracket options: fixed bracket, fixed bracket and roller guide arm (available on all models) as well as fixed bracket and roller guide arm and swivel bracket (for SR10 to SR50 models).

With an IP65 rating, this range is suitable for both indoor and outdoor applications, performing optimally in extremely stringent conditions and an ambient temperature range of -20°C up to +60°C for the standard E0 environmental specification and as low as -40°C for the E1 specification.

An E3 option for severe conditions will be introduced at a later stage. The spring cable reels are protected

against dust and water ingress and are able to withstand an impact of 20 joules.

Complete solution

With over 40 years of experience, Powermite is perfectly positioned to offer a complete solution for moving machinery in bulk materials handling applications including cable festoon systems, festoon hardware and accessories such as cable guiding, anchoring and damping devices, junction, roller and connection boxes as well as cable connectors, organisers and clamps.

Motor-driven, level wind and manual reels as well as cables, hoses and accessories for reeling systems complete the turnkey offering from Powermite’s materials handling division.

All products are supported by excellent service and after-sales service delivered by a team of highly-trained, qualified technicians based at Powermite’s countrywide branch network Powermite (a division of Hudaco) Tel: (011) 271-0000 www.powermite.co.za

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September 2018

23

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

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

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

CONVEYING

Gearless Technology An innovative gearless conveyor drive is now available for use on a wider range of conveyor systems. Already proven on larger motors, ABB’s newest drive is designed for medium power range motors (1 to 3 MW per motor) to make this technology economically feasible for a broader range of conveyor systems, including the use on mobile equipment in mining operations. The new solution can be applied for both greenfield and brownfield systems, and significantly decreases the cost threshold for gearless conveyor technology.

F

ewer parts and new motor technology increase the reliability and efficiency of the overall conveyor system. A permanent magnet motor, specifically designed for mining applications, is a core element of this system that

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contributes to its reliability and ability to perform in the most challenging environments.

The gearless conveyor drive system eliminates the gearbox from the drive. This reduces the number of main wear parts, so less maintenance is needed,

and lengthens the lifespan of the equipment. The expected lifespan for the drive train increases by more than 10 years when compared with traditional geared systems, to a projected in-service life of 25 years.

Other advantages include a considerable reduction in the drive system’s footprint, so it can be installed in smaller spaces, carrying less weight and reducing the instrumentation required to operate the system.

The gearless drive design is also more energy efficient, requiring less power, and operates more quietly, thus reducing noise emissions.

Exact benchmarking

In July 2017, the pilot project of this solution was installed in collaboration with Lausitz Energie Bergbau AG (Leag) in the open-pit lignite mine Jänschwalde, located close to Cottbus, Germany.

The new gearless solution was installed on a high

capacity (15.000 t/h) discharge conveyor of a bucket chain excavator in parallel with the existing geared drive. Both drives connect to the same pulley shaft to allow for exact benchmarking. The gearless solution has performed better in regard to dynamic accuracy and overall efficiency than the existing traditional solution.

Running smoothly

Operational data demonstrates the advantages of the gearless solution with fewer components.

A gearless solution is more reliable (with a 50% lower failure rate) and requires less maintenance.

It is meeting eco design and energy performance requirements according to international standards to support mine’s environmental approvals or certification. The new drive also consumes 5% less energy than the other installed drive.

“The interest of Leag in this pilot project mainly lies in the expectations related to higher efficiency, lower wear and hence lower expenses for repairs and maintenance,” says Peter Scholze, Head of Service Open Pit Mines, Leag. “These results were verified from measurements and analytics taken during operations recently. Thanks to the close cooperation between LEAG and ABB, the project could be finalised within a short period of time.

Since commissioning has taken place, the drive has been running smoothly. ”

The gearless solution has performed better in regard to dynamic accuracy and overall efficiency than the existing traditional solution

The operations and maintenance team also found the new system to be easy to learn, understand, and use, without any major difference in operation or handling when compared with the existing systems/ technology.

ABB www.abb.com

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September 2018

27

TRANSFORMING FREIGHT LOGISTICS

TRANSNET FREIGHT RAIL

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

BELTCON 19

Active Winch Take-up System Influence on Conveyor Dynamics

Buchner Oosthuizen

Willem Niemandt

The intention of this paper is to give an indication of the influence of an active winch on a high capacity port loading conveyor’s dynamic problems. Specific focus will be given to the problems experienced with a conventional gravity system and how this was solved by using an active winch system, and the discussion of the starting and stopping trends of the conveyor system.

A

n existing active winch installation will be used as a case study for this paper. The installation was done on an existing port loading facility in Colombia. The existing gravity take-up was replaced with an active winch system to reach the designed plant capacity which was previously limited because of the dynamic problems on the belt, particularly during power loss conditions. The associated installation risks and design philosophies will be discussed in general.

Introduction

The requirement was to design four active winch systems for a port loading facility in Colombia. Dynamic problems were noted on four conveyor systems during the ramp-up and commissioning stages of the project once production reached near design capacity for the system. A dynamic simulation was conducted by a third party on these four conveyor systems and it was concluded that using active winches to stop take-up travel during power loss conditions would minimise dynamic effects on the conveyor systems.

Two of the four conveyors were used for stacking and reclaiming material from the train loadout station onto a stockyard.

The remaining two conveyors were used to transport the reclaimed coal firstly to a buffering silo and then along a jetty to the ship loaders’ boom conveyor.

1. The design tonnage of all four conveyors was 8 000mTPH with a belt width of 2 200mm and conveyor lengths more than 1000m. Production of the complete facility was restricted to 6 000mTPH due to the dynamic effects and adverse forces on the conveyor systems.

All four conveyors had VSD drives installed, and used a 120 second velocity curve to speed up the conveyor system to design velocity in a required time. This start-up time was defined during the initial project.

3. Power Loss Emergency Stopping: The conveyor drifts to a stop uncontrolled.

Using table 1, we can see that the Powered Emergency Stopping time was set shorter than the normal drift time of the conveyor. According to the dynamic analysis, this value had to be increased to 30 seconds in order to reduce the dynamic effects on the conveyor system.

Table 1 summarises the conveyor design data (Ormsbee, 2014).

For the sake of this paper, only CV-004 will be discussed.

This was the system that had the biggest dynamic forces and this was the last system to be tested.

Take-up theory

Conveyor take-ups are required to create adequate take-up tension on the conveyor system to: 1. Transmit mechanical power from drive pulleys to conveyor system in all operating conditions.

2. Limit belt sag between idlers in all operating conditions.

Take-up tension can be created by using the following takeup systems: 1. Manual type take-ups Manual type take-ups are normally used in shorter plant conveyors, with horizontal centres smaller than 50m. This type

Figure 1: CV-001 & CV-002 Belt Diagram

The conveyors use the following stopping procedure: 1. Normal stopping: The conveyor is controlled by the VSD drives to stop in 30 seconds. The VSD drives uses a steady curve to bring the conveyor to a stop.

2. Powered Emergency Stopping: The conveyor is controlled by the VSD drives to stop in 20 seconds. The VSD drives use a steady curve to bring the conveyor to a stop.

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Figure 2: CV-003 Belt Diagram

Figure 3: CV-004 Belt Diagram

BELTCON 19 of take-up will normally have a shorter travel distance which might not allow for surplus requirements. This is the most economical take up system within its allowable parameters.

The tension is manually adjusted by ether tension screws, hydraulic cylinders or even winches.

The take-up tension is created by a take-up mass, usually steel plates or a concrete mass. This in a cost-effective way to create the required take-up tension, with minimal maintenance required.

2. Vertical gravity take-ups

Horizontal gravity take-ups are normally found in conveyors with no headroom to fit a conventional gravity take-up system. The take-up still uses a vertical take-up mass to create the required take-up tension, but the force is then applied to a horizontal carriage through a series of sheave wheels.

Vertical gravity take-ups are normally found in conveyors with adequate headroom close to the head end to house the take-up counterweight as well as the counterweight travel.

3. Horizontal gravity take-ups

4. Active Winch Take-ups

ITEM

CV-001/ CV-002

CV-003

CV-004

Tonnage (MTPH)

8000

8000

8000

Material

Coal

Coal

Coal

Velocity (m/s)

5.2

5.2

5.2

Lift (m)

4

25

9

Length (m)

1425

995

1998

Belt Width (mm)

2200

2200

2200

Belt Class

ST1250

ST1250

ST1250

Starting Time (s)

90

120

60

Where

Stopping Time (s)

25

14.8

25

T1 = Drive Side Tension

Original Take-Up Counterweight Tension

79.9

59.8

69.1

Winch T2 Start-Up Set Point (kN)

85

62

75

Winch T2 Running Set Point (kN)

80

62

70

Winch T2 Power Loss (kN)

194

211

201

Table 1: CV Design Data Belt Type

Permanent Elongation

Plied Fabric

1.5% of belt tape length

Solid Woven Fabric

1.5% of belt tape length

Steelcord

0.05% of belt tape length

Table 2. CMA Permanent Elongation Values

Active winch take-ups are normally used where none of the previous types of take-ups can be used. A winch take-up uses an electric motor to apply the required torque through a reducer (gearbox) to create the required take-up tension.

A winch system can operate in constrained areas, especially in underground mines. Winch take-ups can be versatile, and system tensions can be changed as required during operation.

To transmit mechanical power to the conveyor system theminimum required take-up tension,must be calculated. This can be calculated by using the following equation:

1

T2 = Take-up Tension Ο = Pulley friction factor θ = Pulley wrap angle in radians The take-up tension must also ensure that required sag is maintained. The belt sag must be checked on critical low tension areas along the conveyor system to ensure the belt sag is limited to a maximum of 2%.

The minimum T2 tension is selected based on the highestminimum T2 tension required. Once the minimum required T2 or take-up tension is calculated, the take-up movement is the next critical aspect in take-up design.

Take-up movement is caused due to belt stretch in the conveyor system and consists of the following: 1. Permanent elongation 2. Elastic elongation The permanent elongation is the belt stretch that occurs over long periods of time, whereby the belt will stretch and not return to the previous length. The CMA guideline gives these values as a percentage value of the belt length used on a conveyor system. See table 2.

Figure 4: Simple Stationary Belt Tension Diagram

The elastic elongation of a conveyor system is the amount of belt stretch due to changes in belt tensions in different conveyor belt load cases. Once the load cases change or tension is completely removed from the system, the belt will return to the original belt length. The first principle calculation to calculate the elastic stretch of a belt will be discussed below.

During stationary periods, the belt tension distribution for a simple horizontal belt will be equal along the length of the belt as the take-up or T2 tension, shown in figure 4.

Figure 5: Simple Running Belt Tension Diagram

Once the conveyor starts up, and an effective tension (Te) is applied to the conveyor system through the drive pulleys, the belt will stretch due to the increase in the averaged tension in the system.

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BELTCON 19 This increase in average tension in the conveyor system, will cause the conveyor belt to stretch as predicted by the following formula:

where the brake mechanism will engage and allow the electric motor to be shut down to save energy. Whenever the take-up tension moves out of the dead band, the winch will wake up and adjust the tension accordingly.

During a power loss or emergency stop condition, the winch can be set up to hold the carriage steady during these extreme conditions and therefore reduce dynamic belt movement along the conveyor. Once the conveyor has come to a standstill, the winch will adjust the take-up tension to the start-up tension and shut down until the start-up signal is received from the conveyor.

2

Where: T’ = New Average Belt Tension T = Original Average Belt Tension B = Belt Width μ = Original Belt Length E =modulus of elasticity In order to calculate T’, the average tension in each strand can be calculated and along with the belt strand length, be added up proportionally along the conveyor length.

It is therefore important to design a take-up system that must be able to apply the minimum amount of take-up tension and that must be able to accommodate the maximum required belt stretch.

More complicated take-up systems can be designed if there are additional system constraints, like headroom or takeup length constraints. Multiple lap take-up systems and/or sheave arrangements can be incorporated, but this will not be discussed in this paper.

Equipment description

The active winch in this project consisted of the following items: 1. Electric motor (45 kW) 2. Reducer (Gearbox) 3. Brake mechanism (Fail to safe) 4. Drum complete with rope

During a normal stop situation, the winch can be set-up to either keep a pre-set tension in the take-up system, or it can hold zero movement until the stopping sequence is complete.

Once either one of the above-mentioned sequences is complete, the winch will adjust the tension and shut down until starting signal is received from the conveyor.

The winch is also fitted with a manual local control panel that can be used to release the tension in the take-up system if maintenance is required. It can also be used to manually release stored energy in the event of an over tension trip condition or if the take-up carriage has been wedged on the rails.

During the design phase of the project, the client had the following requirements, and this was then used to design and optimise the winch: 1. To pre-tension the conveyors at start-up 2. To reduce the running T2 tension and keep a constant tension during all running conditions 3. To handle aborted start system tensions 4. To keep a constant tension during controlled stop conditions 5. To keep the carriage stationary during power loss and e-stop conditions

5. Load Cell 6. Electric Panel complete with VVVF The electric motor is controlled by a Variable Voltage Variable Frequency drive (VVVF) inside the electric panel. Once the start-up command is received from the conveyor, the VVVF will hold the electricmotor at zero RPM. The brake mechanism will be given the command to release and the VSD will ramp up the motor torque to keep zero RPM. The load cell will send an electric signal to the electric panel and the VSD will control the motor speed and direction of rotation to adjust the tension to a pre-set value. A pre-set dead band is used to allow the winch to keep the tension in this range.

Whenever the conveyor has reached full speed, a second running take-up tension can be pre-set to allow a reduction in running tension. Once the takeup tension is within the dead band for a pre-set period, the winch will go into sleepmode,

Figure 6: Active Winch Top View

Figure 7: Take-Up System Layout

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BELTCON 19

Figure 8: CV004 E-Stop

These requirements were determined by an external conveyor consultant.

rectified during this stage and could only be rectified during port operation. The end user reported the following problems:

Project challenges

• Excessive counterweight movement during power loss and E-Stop conditions. This also included a power loss test where the counterweight moved up to the mechanical stops of the take-up structure, breaking the steel wire rope before crashing down onto the jetty.

During the project, some major challenges had to be overcome to complete the project successfully.

Original Conveyor System Problems The port loading facility encountered some major problems during the ramp up of the facility during the commissioning stage of the initial construction. These problems could not be

Figure 9: CV004 Start after E-Stop

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• Excessive belt sag and slap during the above-mentioned conditions. As the dynamic waves moved through the

BELTCON 19

Figure 10: CV004 Power Loss 8000 TPH

conveyor system, the belt would sag excessively between the idlers and then slap up, knocking and breaking some idlers and even idler cradles from the structure. This was at its worst close to the tail area where the two dynamic waves would meet.

• Numerous pulley bearing failures on different conveyors because of high dynamic forces in the system.

• Numerous idler and idler frame failures during uncontrolled stoppages.

Design Challenges During the design stage of the active winches, the installation and positioning of the winches was a critical design aspect.

The winches needed to be installed in such a manner to reduce standing time to a minimum for the port loading facility to function as normally as possible. The client restricted the total conveyor shutdown time to two days per conveyor.

The winches also needed to be placed within the areas of the take-up system to keep modifications to existing structures to aminimum. A dynamic simulation was completed on the four most critical conveyors. This showed that the take-up tension would rise from 80 kN running tension to 212 kN during power loss conditions.

The winches had to be designed for this worst-case tension, and all low-tension areas along the conveyor systems had to be checked to ensure the structures would still be adequate for this rise in tension. The winding speed also had to allow for a maximum take-up trolley speed of 0.3m/s during fully loaded starting conditions. This added some challenges in the programming of the PLC system to adjust winding speed of the winch during operation to allow for seamless operation during any starting or operating conditions.

Installation Challenges Once installation started, it was also noted that that there were some discrepancies between the “as built” drawings and what was installed on site. On one of the conveyors, the counterweight hold down bolts were shown as M36 bolts

whereas on the “as built “drawings only M24 bolts were installed. This forced the project team to add additional bracing between the winch base and the existing take-up structure in front of the winch and conveyor trestles behind the winch.

This reduced the turnover force on the base sufficiently for the M24 bolts to be adequate.

Some of the low-tension pulleys had to be changed to handle the increase in tension during aborted start conditions. Most of these pulleys were the take-up pulleys, low tension bend pulleys and in some cases the tail pulleys. In all cases the bearing sizes increased because of an increase in shaft diameter. New pulley stools had to be fabricated for the new plummer blocks. There were no stools installed on the tail pulleys, so the pulley centre height increased by 10-15mm from the existing structure. The return- and carry strand idlers were therefore shimmed to ensure that the beltline was supported as needed and to ensure the small change in belt line would not affect the first few sets of idlers negatively.

Site Optimisation During the commissioning of conveyor take-up systems for CV-001 and 002, some valuable site information was gathered which helped with the optimisation of the CV-004 conveyor take-up system.

Winch Speed: The minimum winch speed gain was modified to ensure the set point was reached in the required time, and to minimise overshooting of the set point and for the winch to re-adjust again. This was especially observed where the winch adjusted during normal running conditions and was continually adjusting due to over or undershooting of the set points.

Winch Reaction Time: The winch reaction time was also adjusted from 2 to 5 seconds to ensure that enough time is given to allow the system to recover once an abnormal reading or situation is picked up. This will keep the winch stable through some oscillating readings.

BULK HANDLING TODAY

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BELTCON 19

Figure 11: CV004 Start After Power Loss

Winch Power Loss Function: This was changed after some very high T2 tension readings were observed during testing. The winch programme was changed to instead of applying the brake immediately, keep zero speed on the carriage and once a certain tension is reached, allow the motor to slip and release some of the tension into the system. This value restricted the T2 peak tension and ensured that take-upmovement was still restricted as previously required.

Post Commissioning Problems After the winches were commissioned, the client had a few questions and some teething problems that we had to help with.

Shortening E-Stop Time: The client wanted to reduce the time for the conveyor system to stop during an E-stop from the current 25 seconds to 15 seconds. Doing so, the client reported much higher forces during this sequence. (Loadcell is limited to 230 kN, and this value was exceeded). The client was requested to revert to the previous stopping time, as this was outside the winch design specification.

Problematic Pressure Switch: The active winch system used a hydraulic power pack to release the fail to safe hydraulic brake. The power pack is equipped with a pressure switch to indicate when the brake release pressure is released. This switch malfunctioned intermittedly and even after it was replaced, still had the same problems.

This unit was fitted to a winch, 220m from the MCC. The on-site electrician inspected the problem and found that due to the length of cable on the installation, the control voltage dropped well below the 24V used on the system. To solve the problem, a new cable was installed in parallel with the current installation, which reduced the resistance in the cable.

Active winch performance

The graphs in this section were gathered during site commissioning and optimisation. These graphs were taken from CV-004 with a full production rate of 8000mTPH. During

testing, the conveyor loads were gradually increased from Empty load until 8000mTPH. During each of the tests, the loading would be set with the plant production software and measured with a calibrated belt scale used to determine material load on the conveyor.

Figure 8 shows the take-up tension during an E-stop situation on the CV004 conveyor system. Once the E-stop is activated, the tension set point is increased and the tension immediately starts to rise and peaks at over 175 kN for more than 5 seconds. This however activates the trip on the winch system and the brake is activated. This causes the VSD torque to drop down to zero, and no movement is possible in the carriage. The dynamics moved through the system and after about 25-30 seconds the conveyor is stationary and the take-up tension has increased from under 75 kN to over 125 kN. Once the conveyor system was inspected for any possible damages, the over tension trip was reset before the conveyor system could be restarted.

Figure 9 shows the start-up tension inside the take-up system with the active winch system. Once the start signal is given, the tension is released from the 140 kNmark to the set point tension. As the set point tension is reached, the drives start up and create slack in the take-up area. The tension drops below the set point value and the winch reacts to increase the tension to prevent drive slip. The winch overshoots on the set point tension and once it releases some of the takeup tension, the system is in motion and the conveyor speed is ramped up. The winch settles down and no major peaks are created. The total carriage movement during this time was about 150-300mm.

Figure 10 shows the take-up tension during a power loss condition at full operating capacity. Once power is lost on the drive system, an immediate tension spike is created spiking up to 215 kN. After this spike, there are three less intensive spikes present in the system before the conveyor system comes to a standstill, after which the winch reacts to release the tension build-up from 130 kN to the required set point value.

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BELTCON 19

Figure 12: Conveyor Belt Loading

The winch does not trip on overload during this period even after higher tension values are registered,mainly due to the short time of the dynamic spikes. The winch remains active and the VSD lets the motor slip in three instances, as shown by the negative VSD speed graph. The carriage movement was negligible and can be excluded.

Once the start command was given, the winch adjusted the take-up tension and then waited for the drives to start.

Again it can be seen that once the drives started, the take-up tension drops down before the winch reacts and increases the take-up tension and then overshoots the set point. Once the winch overshoots the set point, it reduces the tension where after the system is more stable and no further peaks are observed. The approximate carriage movement during this time was 300 – 500mm.

Figure 12 shows the take-up tension and reaction during the loading of the conveyor system. This graph was captured during the testing and optimisation of the active winch system.

The conveyor belt was operating empty and was then loaded at 8000mTPH in order to complete the required tests. As the material was loaded onto the conveyor system at a rapid rate, the belt would stretch and this would cause the tension to drop at a slow rate. Once the tension moves out of the “operating band” area, the winch reacts by increasing the tension which in turn takes up the additional stretch caused by the higher belt tension. This occurance can be seen four times.

Conclusion

Based on the information provided in this paper, it can be said that an active winch system can be used in solving dynamic problems on existing equipment and conveyor systems.

When using the correct design philosophy and principles, existing and new high capacity systems’ dynamic problems can be resolved by using active winch systems to change the take-up tensions in the system as required to ensure safe operation of a conveyor system.

the possibility is available to install an active winch system, and to design a fit for purpose system given small constrained spaces for new equipment.

If dynamic problems are flagged during the design stage of a conveyor system, it is possible to design the system with a cost effective active winch system that can improve the expected dynamic problems, and can be designed to easily be modified if it is found that site conditions are different from the design assumptions.

As with all designs, there are areas of improvement that can be investigated. First, additions to the software that can allow different reaction speeds, in both the winding in and winding out function during different conveyor load cases. This can allow the winch system to react in different ways, depending on what the conveyor system is doing. This however can only be done if sufficient communication can be created between the winch PLC and conveyor programme.

This paper was first presented at the Beltcon Conference in 2017.

Copyright is vested with IMHC. www.beltcon.org.za Buchner Oosthuizen Willem Niemandt Nepean Conveyors South Africa Tel: (011) 708-2854 www.nepeanconveyors.com

If dynamic problems are encountered on existing equipment, BULK HANDLING TODAY

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MARKET FORUM

Addressing material transfer problems Material transfer problems can be addressed easily by considering basic chute specifications, but this necessitates a thorough knowledge of transfer point design as well as the ability to determine best practice for a specific application.

In addition, says Mark Baller, managing director of Weba Chute Systems, it is necessary to be able to custom engineer each design to ensure that it is Each Weba Chute System is custom designed for a specific fit-for-purpose.

Founded on the principle of engineering associated with conventional transfer custom designed chutes, this is exactly chutes, resulting in significant cost what Weba Chute System does. “Nusavings,” adds Mark. merous successful installations of our To date, the company has engineered systems have proved that the correct more than 4 000 transfer chutes, which application of our scientific approach to are operating successfully throughout the dynamics of bulk materials handling the global mining industry. “We consider can completely eliminate the problems

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application

a holistic design that not only focuses on the entry and exit points, but which also incorporates the control of the flow, volume and velocity of the material being transferred at all times,” he concludes.

Weba Chute Systems, Mark Baller Tel: (011) 827-9372, www.webachutes.com

MARKET FORUM

Coal-mine rehabilitation Goscor Earth Moving (GEM) has supplied over R15-million worth of Sany equipment to a construction and rehabilitation company in eMalahleni for a rehabilitation project at the Arnot coal mine in Mpumalanga.

Two SY956H front-end loaders, a SMG200 grader, a SY500H excavator, and a SY335 excavator have been delivered to Ukubhukuda Trading, whose subsidiaries Tipper & Co and E&J Construction have been contracted to carry out the rehabilitation of the mining area.

GEM eMalahleni sales executive, Lee Sampson comments that the initial relationship with Ukubhukuda Trading was forged in March 2017, when it purchased a SYL956H1 front-end loader and a SY335 excavator. The latter is ideal for mining applications due to the use of high-quality wear-resistant plate for added endurance and reliability.

With a maximum digging depth of 6 170mm, and a transport length of 11.1m, the SY335 excavator is ideal for the mining, construction, and planthire sectors.

With a bucket capacity of 2.7m 3 to 3.2m 3 standard and a 4.5m 3 coal bucket, the SYL956H1 front-end loader is ideal for heavy-duty mining operations. The machine’s highly-efficient drive system features a rotary automatic gearbox that boosts travel speed by 10%, and increases towing force by over 6%. The rated load is 5 000kg, the rated power is 162kW, and the maximum lifting force is 172 kN. “As soon as Ukubhukuda Trading commenced with rehabilitation work at Arnot,

they purchased an extra two machines, and we are in the process of delivering a further three SYL956H1 front-end loaders,” Lee concludes.

In addition, E&J Construction purchased a SY500H excavator and an additional SYL956H1 front-end loader in May. Goscor Group, www.goscor.co.za

DRIVING THE CONVEYOR Hyflo Southern Africa's engineering team at the Johannesburg head office facility, has recently completed an 11kW HPU, which has been designed to drive a conveyor system at a mine in Limpopo.

“This HPU, which is capable of supplying a high torque, low speed function for start-up, as well as a low torque, high speed function for normal operation, ensures optimum performance and power efficiency in harsh mining conditions,” says Tinus Vermeulen, project engineer, Hyflo Southern Africa.

“An advanced digital pump control system enables the HPU pump to provide various functions, which are adjustable, to meet exact requirements.”

This robust system is equipped with a Parker PV electro-hydraulic axial pis-

ton pump, which is controlled via an electronic module, located in the local control panel. Other features of the HPU are a strengthened frame, 400 litre tank and hydraulic control manifold, as well as pressure and return line filtration.

Safety features include maintenance indicators, low-level and high temperature cut-outs.

All Hyflo systems are manufactured according to stringent quality and safety standards, as required by customers in diverse industries, including mining and quarrying, manufacturing, agriculture, marine and off-shore services, as well as general engineering.

Hyflo, Tinus Vermeulen, Tel: (011) 386-5800 Email: mpv@hyflo.co.za www.hyflo.co.za

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BULK HANDLING TODAY

September 2018

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MARKET FORUM

New ship loaders A 750t crane from Concord Cranes, a crane hire and specialised transport service company in the Industrial Services Holdings (InServe) stable, was used to install sections of two new ship loaders at Richards Bay, KwaZulu-Natal in April for the largest coal exporter in the world.

Ship loaders are large machines used to load bulk solid materials such as coal, iron ore, bauxite, alumina, fertilisers, phosphates, and sulphur into ships. These loaders are mostly found in ports and jetties from which bulk materials are exported.

Apart from the 750t crane itself, Concord Cranes’ successful involvement in this project was due to the expertise and experience of its operators. Richards Bay Branch Manager, Bella Mollentze comments, “Our operators and support teams

are the heart of our business. You need special people with passion who love what they do.”

Therefore to maintain its high standards of service delivery, Concord Cranes’ operators and support personnel are trained continually and are sufficiently skilled to operate its advanced equipment and technology.

A 750t crane was used to install sections of two new ship loaders at Richards Bay

“It is essential that they are confident with the cranes’ functions and capabilities, especially when dealing with major lifts such as these at Richards Bay,” Bella concludes.

Concord Cranes Herman van Staden Tel: (011) 805-8071 Email: herman@concordcranes.com www.concordcranes.com

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MARKET FORUM

CEO Kim Pratley underneath a 13t bulldozer suspended using Wondafix

A REPE AT PERFORMANCE Pratley celebrates its 70th anniversary, with over 1 000 products in its stable, and 350 global patents.

In 2018 alone, the company has introduced four new products, with at least another three in the pipeline. This is in addition to various advances in its manufacturing and production methodologies. “We are committed to research and development (R&D), and we see our future in our ongoing run of new products.

I certainly also hope to see us establish a successful global presence,” CEO Kim Pratley comments.

The formulation of Pratley Putty in the 1960s not only put the company on the global map, but even on the moon, where the

product was used by NASA on the Ranger Moon Module Project in 1967. Pratley Putty has since become a household name, used to repair and secure everything from swimming pools to the hulls of sunken ships.

The memorable launch of Pratley Wondafix in 1985 saw Kim stand underneath a 13 tonne bulldozer, suspended above his head using a Wondafix adhesive joint.

This death-defying stunt was replicated on Friday 13 July at the Pratley’s Krugersdorp head office as part of its 70th anniversary celebrations.

Pratley Group Tel: (011) 955-2190 www.pratley.com

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MARKET FORUM

Mine development and infrastructure TDS Projects Construction has been awarded the contract for two distinct but integrated projects at Exxaro Matla’s Mine2 and Mine3.

This entails both mine development and infrastructure development.

Lubrication Pinion SKF is offering its Lincoln lubrication pinion LP2 for open gear wheels and gear racks.

Complementing its existing lubrication pinion line, the reliable LP2 features a

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As the lubrication pinion LP2 does not require pressurised air, there is no spray mist to contaminate the environment. Also, higher-viscosity lubricants, such as NLGI grade 2 grease, can be applied. When compared with manual lubrication, use of LP2 pinions ® provides better quality lubrication — safe, reliable & powerfully efficient — and reduces costs, labour and the risk of accidents.

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The modular design enables customers to configure the lubrication pinion to meet specific application requirements. The LP2 is suitable for wind, mining, construction, marine and material handling applications, as well as slewing or pitch bearings.

SKF www.skf.com

TDS will be working alongside Newrak Mining with whom they have entered into a joint venture for this project. Under the terms of the contract, the project will be jointly managed by the two companies. The parties will work together firstly on mining development that will focus on tunnel drilling and blasting to make way for decline and vertical infrastructure construction in Matla’s Mine 2 and Mine 3. TDS will then head up the infrastructure development project.

The scope of work for the mine development phase of the project for Matla 2 and Matla 3 will consist of drilling, blasting, mucking and the hauling of inter-seam material and coal to develop the initial runaround. It will also include development of the roof support, gunniting of walls and roof incline sections and maintaining equipment.

Two declines that will be developed at Matla 3 and two Inclines at Matla 2 will link the current coal seam 4 works with the seam 2 reserve. For the infrastructure development, TDS is providing full turnkey infrastructure development. This includes complete design, procurement, fabrication, installation, construction and commissioning for civils, road inclines, plinths, mechanicals, decline and incline conveyors, EC&I, supply water and waste water extension and electrical reticulation.

"This infrastructure development will advance Exxaro’s coal mining operations at Matla,” says TDS Managing Director, Hennie Coetzee. “We are extremely enthusiastic about the opportunity to work with Newrak on this project and we look forward to establishing a long and successful relationship with Exxaro.” www.tdsprojects.co.za

MARKET FORUM

Thinking for themselves The range of hydraulic breakers with integrated Intelligent Protection System (IPS) technology from mining equipment specialist, Epiroc, delivers efficient and reliable performance over an extended life cycle, presenting customers and endusers with lowest total cost of equipment operation and ownership.

IPS is a fully automated function that enables the breaker to autonomously self-adapt to any working condition with no manual intervention or reaction required. A first of its kind in hydraulic breaker technology, IPS uniquely combines AutoStart and AutoStop in a single function. Previous generation models featured only AutoStart and AutoStop.

Although IPS has been designed to automatically operate within these modes, the user has the option to switch manually between AutoStart and AutoStop, providing an elevated level of control during operation. Alongside the easy, simple mode switching capability, access is also hassle-free.

While previously the StartSelect /manual mode was located within the cylinder and could only be reached through the open-

ing of hydraulic circuit, the IPS is conveniently fitted in the cylinder cover making automated mode switching possible without the need to open the hydraulic circuit.

IPS offers an efficient solution for a variety of applications such as primary and secondary breaking for example that require different set ups. The HB 2000, 2500, 3100 and 3600 models are already available with IPS and the HB 7000 to HB 10 000 hydraulic breakers making their debut towards the end of 2018.

“Significantly decreased costs coupled with increased uptime and productivity, make Epiroc hydraulic breakers with IPS next level in the breaking.”

Epiroc, www.epiroc.com

Larger Facility On the back of continued growth of its several business units in the Mpumalanga area, the Goscor Group of Companies has relocated its Nelspruit branch to a larger facility to better service its expanding customer base.

Effective July 2018, the Goscor Group moved its Nelspruit branch from the previous location at Corner R40 & Wille Street, Riverside, to Unit 3B, 1 Meander Street, Riverside Park. According to Neil Wilson, CEO of the Goscor Group, the growth of the business and the need to accommodate the necessary expansion was the major factor behind the move.

“We have seen substantial growth of several business units within the Goscor Group in the Mpumalanga area. As a result, we needed bigger workshops, as well as machine and parts holding space,” explains Neil.

The new facility also allows the Goscor team to undertake major repairs on some of the larger pieces of equipment. “In addition, we have a larger parts and equipment store which allows us to significantly increase our stockholding as and when required,” he adds.

The Goscor Group is a large capital equipment supply business, representing leading equipment brands across

several sectors through its business units which include Goscor Lift Truck Company (GLTC), Goscor Earthmoving Equipment (GEM), Goscor Cleaning Equipment (GCE), Bobcat South Africa, Goscor Access Solutions, Goscor Power Products and Goscor Compressed Air Systems.

Goscor Group www.goscor.co.za

BULK HANDLING TODAY

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MARKET FORUM

High capacity winch cranes Demag’s compact high capacity winches can handle loads of up to 500t. With its outstanding combination of size and lifting capacity, the HCW creates a full range of solutions for power stations, shipyards and heavy mechanical engineering applications.

By using them as tandem units, their lifting capacity can be increased to 1 000t. HCW open winch units can be configured to meet the customers’ needs thanks to their modular system design, without the need for any additional design or development work.

The load on the crane superstructure can be significantly reduced due to the low hoist unit dead weight. HCW hoist units are equipped with wear-resistant components, ideal for harsh African

environments, and offer good accessibility for service and maintenance. They can also be used to modernise existing crane installations where little space is available.

Demag’s open winch units are ultra-reliable and offer optimum approach dimensions to utilise the existing floor area. Depending on their design, the 4 or 6-wheel crabs ensure uniform distribution of the load on the crane girders.

Many additional options are available according to customer needs, such as single or double hooks, a motor-driven design and a hook position that can be locked at increments of 90°.

Demag, Richard Roughly, Tel: (011) 898-3500 Email: Richard.Roughly@demagcranes.com www.demagcranes.co.za.

Crawler excavator New to HPE Africa’s range of Hyundai Earthmoving Equipment, is the robust R260LC-9S crawler excavator, which is now available on the Southern Africa market.

“Notable features of this series include advanced engine technology for high productivity, fuel efficiency and

low emissions; computer aided power for optimum control of the machine and a high-strength operator cab, with exceptional visibility for greater safety on site,” explains Alex Ackron, managing director of HPE Africa.

which minimises fuel consumption and the auto boom-swing priority function delivers maximum performance. Groundline access to components enables easy maintenance, minimising downtime of the machine.”

“The re-designed hydraulic system ensures fast, smooth and precise control. Advanced hydraulic technologies offer improved pump flow,

Hyundai 9S series excavators are fitted with carefully-selected components, designed for extended service life. Bushings have long-life lubrication intervals of 250 hours; hydraulic filters offer a service life of at least 1 000 hours and hydraulic oil offers 2 000 hours of service. Efficient cooling systems and integrated pre-heated systems extend service intervals and minimise operating costs.

HPE Africa, Tel: (011) 397-4670 Email: lani.vdwatt@hpeafrica.co.za www.hpeafrica.com

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BULK HANDLING TODAY

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SEW-EURODRIVE (PTY) LTD Eurodrive House Cnr. Adcock Ingram & Aerodrome Roads, Aeroton Ext 2 Johannesburg P.O. Box 90004 Bertsham 2013 Tel: +27 11 248 7000 Fax: +27 11 248 7289 www.sew-eurodrive.co.za info@sew.co.za

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