Bulk Handling Today Jan/Feb 2018

BULK

HANDLING

BULK HANDLING TODAY

T O D A Y

January/February 2018

1

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

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH

T O D A Y

Jan/Feb 2018

INTRICATE LIFTING OPERATIONS OVERVIEW OF CRUSHING INDUSTRY BULK HANDLING TODAY

January/February 2018

1

Copyright

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

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

The monthly circulation is 3 673

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Advertising Sales: Linda Patricio DTP: Anne Rotteglia and Tish Strydom 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

January/February 2018

3

The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

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

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

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

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

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

BULK HANDLING TODAY

January/February 2018

5

6

BULK HANDLING TODAY

January/February 2018

BULK HANDLING TODAY

January/February 2018

7

FLSmidth SA

Kwatani

Osborn Engineered Products SA

Total Number of Employees

738

± 160

250

Employees with tertiary qualifications Number of years operating in SA

70% 20 +

75% 42

98

ISO Accredited

Yes

Yes

Subsidiary of Overseas Principal

Private

Yes

Yes

Yes Public / Subsidiary of Overseas Principal Yes

8

3

-

Name of company

Ownership CAD/FEA and/or CAM facilities BEE rating Type of crushers handled ▪ Jaw

ü

ü

▪ Cone

ü

ü

▪ Mineral sizers

ü

▪ Gyratory

ü

ü

▪ Impact Crushers

ü

— Horizontal Shaft

ü

— Vertical Shaft

ü

— Hammer mill Primary area of expertise: ▪ Design ▪ Manufacture/assembly ▪ Import ▪ Export ▪ Installation and commissioning ▪ Turnkey Contract to supply and install ancillary items such as: ▪ Structures ▪ Screens ▪ Chutes and feeders ▪ Pit civils and front-ends ▪ Grizzly screens ▪ Cyclones ▪ Separators ▪ Liners

ü ü ü ü ü ü ü

ü ü ü ü

ü ü ü

ü ü

ü

ü

ü ü ü ü ü ü ü

ü ü

ü ü ü ü ü ü ü -

ü ü ü ü ü ü ü R80 m -

-

R50 m +

-

1 500 tons

7 000 tons

-

-

30% of orders

-

Yes

Yes

Yes

Service support: ▪ Manufacture and delivery to site ▪ Assembly on site ▪ Commissioning ▪ On-site supervision ▪ Personnel training ▪ On-site annual shutdown service ▪ Maintenance contracts Total value of last two contracts Number of projects completed in 2016 Value of largest contract completed in past 5 years Size of largest contract in terms of tons conveyed per hour Number of export orders over past 5 years Professional affiliations

8

BULK HANDLING TODAY

January/February 2018

ü ü ü ü

-

Pilot Crushtec

Sandvik Mining & Rock Technology

Weir Minerals

Wirtgen SA

Total Number of Employees

117

1600

1250

64

Employees with tertiary qualifications Number of years operating in SA

27

80% 25

107

30

ISO Accredited

Yes

Yes

Yes

Yes

Private

Subsidiary of Overseas Principal

Subsidiary of Overseas Principal

Subsidiary of Overseas Principal

-

Yes -

Yes -

6

Name of company

Ownership CAD/FEA and/or CAM facilities BEE rating Type of crushers handled ▪ Jaw

ü

ü

ü

ü

▪ Cone

ü

ü

ü

ü

▪ Mineral sizers

ü

▪ Gyratory

ü

▪ Impact Crushers

ü

ü

ü

ü

— Horizontal Shaft

ü

ü

ü

ü

— Vertical Shaft — Hammer mill Primary area of expertise: ▪ Design ▪ Manufacture/assembly ▪ Import ▪ Export ▪ Installation and commissioning ▪ Turnkey Contract to supply and install ancillary items such as: ▪ Structures ▪ Screens ▪ Chutes and feeders ▪ Pit civils and front-ends ▪ Grizzly screens ▪ Cyclones ▪ Separators ▪ Liners

ü

ü ü

ü

ü ü ü ü ü ü

ü ü ü ü ü ü

ü ü ü ü ü ü

ü ü ü

ü ü ü

ü

ü ü ü ü ü

ü

ü ü ü ü ü

ü ü ü ü ü ü

ü ü ü ü

ü

ü ü ü ü

ü

ü -

ü ü ü ü ü ü ü R 30 m -

ü ü ü ü ü ü ü R24.5 m -

ü ü ü ü ü ü ü -

-

R 300 m

R45 m

-

-

1 000 tons

400 tons

-

-

-

-

-

IQSA

Yes

SAIMM, SACPS, IQSA

-

Service support: ▪ Manufacture and delivery to site ▪ Assembly on site ▪ Commissioning ▪ On-site supervision ▪ Personnel training ▪ On-site annual shutdown service ▪ Maintenance contracts Total value of last two contracts Number of projects completed in 2016 Value of largest contract completed in past 5 years Size of largest contract in terms of tons conveyed per hour Number of export orders over past 5 years Professional affiliations

BULK HANDLING TODAY

January/February 2018

9

Mobile Bulk Material Handling Solutions ELB Equipment, the Sub-Sahara Africa distributor of a complete range of Telestack Radial Telescopic Conveyors is dedicated to offering the most cost-efficient and effective way of stockpiling material on the market.

In today’s competitive environment, you need high quality equipment accompanied by an outstanding support network. Our sales and aftermarket teams are trained to provide customers with outstanding stockpiling solutions accompanied by product warranty and 24/7 technical support and parts service.

Contact us to see how you can increase your stockpile capacity by up to 30% Distribution and Product Support by:

BUILT TO LAST

Website: www.elbequipment.co.za

nt.com

ELB EQUIPMENT - HEAD OFFICE:

14 Atlas Road, Anderbolt, Boksburg • Tel: +27 (0)11 306 0700• Fax: +27(0)918 7208 • e-mail: Elb@elbquip.co.za

BRANCHES & DEALERS – SOUTH AFRICA:

BRITS: +27 (0)12 250 1565 • CAPE TOWN: +27 (0)21 933 2383 • DURBAN: +27 (0)31 464 6522 • EAST LONDON: +27 (0)31 464 6522 • GEORGE: +27 (0)21 933 2383 • KIMBERLEY: +27 (0)53 841 0040 • MIDDELBURG: +27 (0)13 246 2312 • POLOKWANE: +27 (0)11 306 0700

SUBSIDIARY: ELB EAST AFRICA: NAIROBI, KENYA: +254 (0)20 807 0728

DEALERS – SOUTHERN AFRICA:

BOTSWANA: +267 (0)390 9972 • LESOTHO: +266 (0)28 313 926 • MOZAMBIQUE: +268 (0)76 022 8488 • NAMIBIA: +26 (0)46 123 4052 • SWAZILAND: +268 (0)518 5348 / 518 5602 • ZAMBIA: +26 (0)21 221 0642 • ZIMBABWE: +263 (0)77 236 2596

BULK HANDLING TODAY

January/February 2018

11

14

BULK HANDLING TODAY

January/February 2018

16

BULK HANDLING TODAY

January/February 2018

BULK HANDLING TODAY

January/February 2018

17

Andries Wiid

Figure 1. Aerial photograph of the Majuba Power Station

20

BULK HANDLING TODAY

January/February 2018

Bruno Marrai

Figure 2. The vertical crack in the silo with coal running from the crack, followed by the horizontal cracks

Figure 3. The collapsed silo with the bottom part below the 28 m level remaining in situ

BULK HANDLING TODAY

January/February 2018

21

SILO No.

SURFACE

BY MEANS

RESULTS

10

Internal

By naked-eye from the silo roof with flood lights.

Some larger cracks visible; smaller ones not visible due to poor visibility. Coal build-up present and visible.

External

Naked-eye while walking up stairs leading to the roof slab.

Extensive cracks of various sizes.

Internal

Skyriders – abseiling from roof slab.

Extensive cracks visible, large and small, and coal build-up present.

External

Binoculars from ground level.

Cracks not visible due to dark grey color of the silo.

Naked-eye while walking up stairs leading to roof slab.

Extensive horizontal and vertical cracks present. Visible from approximately level 35.0m upwards.

30

Table 1. Findings of visual observations on silos 10 and 30

Figure 8. Typical tensile failure of rebar

Figure 5. Plan view on silo 20 indicating the location of the coal build-up as well as the location of the origin of the fracture that resulted in the failure of the silo

Figure 6. Part of the cylinder wall

Figure 9. Coal build-up inside silo 30

Figure 7. Concrete wall sections and reinforcement steel

22

BULK HANDLING TODAY

January/February 2018

Figure 10. Coal build-up on silo 10 Plan View on Opening

Side View Figure 11. General arrangement of the 10 000 tonne silos

End View

BULK HANDLING TODAY

January/February 2018

23

Figure 12. Comparison of the flow functions of coal property analysis information for Eskom coal pre-1995 *MC Moisture Content by mass, FFt Flow Function for time consolidation, FF0 Flow Function for instantaneous condition

Figure 13. Comparison of the flow functions of coal property analysis information for the current coal in comparison to the original coal Key 1. Mass flow 2. Funnel flow 3. All solids in motion 4. Flowing 5. Flow channel boundary 6. Stationary 7. Effective transmission 8. Effective hopper

Figure 14. Typical flow conditions

BULK HANDLING TODAY

January/February 2018

25

Figure 15. Distributions of initial wall pressures in the container during filling

Wall pressure in the cylinder

Theoretical position of the switch pressure at the intersection Figure 16. Distribution of wall pressure in hopper with surcharge during flow

Actual distribution of the switch pressure

Figure 17. Spreading of mass flow peak into cylinder section

Figure 18. Funnel flow hopper – flow channel intersecting cylinder wall

26

BULK HANDLING TODAY

January/February 2018

Figure 19. Wall load for the original coal base on the ACI 313 standard

Figure 20. Wall load for the current coal based on the ACI 313-91standard

BULK HANDLING TODAY

January/February 2018

27

Figure 21. Wall load for the original coal based on AS 3774-1996

Figure 22. Wall load for the current coal based on the AS3774-1996 – excluding eccentricity

28

BULK HANDLING TODAY

January/February 2018

Figure 23. Wall load for the current coal based on the AS 3774-1996 – eccentricity included

Figure 24. Switch pressure along build-up development based on the AS 3774-1996

BULK HANDLING TODAY

January/February 2018

29

Figure 25. Comparison of the symmetric loads for the AS 3774-1996 and the ACI 313-91

Figure 26. Wall load above the transition for eccentric discharge while filling coal at the same time

30

BULK HANDLING TODAY

January/February 2018

Figure 27. FEM (finite element modelling) presentation of simultaneous filling and discharge under eccentric condition

Figure 28. As a result of the stagnant coal in the silo, a switch pressure develops at the convergence point of the flow channel to the vertical wall.

BULK HANDLING TODAY

January/February 2018

31

Piecing together your success.

12415/E

We understand that you’ve been building your career piece by piece, and that all those hours, projects and plans allow you to live the lifestyle you deserve.

Partner with PPS, and let us help you ensure your success is more than the sum of its parts.

Proud sponsor of the SAICE Young Engineer of the Year.

Visit pps.co.za to find out more about our financial solutions for graduate professionals.

PPS is an authorised Financial Services Provider.

Figure 29. Extract from the Jenike and Johanson investigation

Figure 30. Extract from the Jenike and Johanson investigation

BULK HANDLING TODAY

January/February 2018

33

Figure 31. Extract from the Jenike and Johanson investigation

Figure 32. Comparison of the derived wall loads along the long side of the hopper opening for symmetric flow condition

34

BULK HANDLING TODAY

January/February 2018

Figure 33. Comparison of the derived wall loads along the long side of the hopper opening for eccentric flow condition at the far side to the opening under operation

imagine … all parts, one supplier TVH PARTS SOUTH AFRICA (PTY) LTD • HEAD OFFICE JOHANNESBURG sales.southafrica@tvh.com www.tvh.com • T +27 11 281 2700

BULK HANDLING TODAY

January/February 2018

35

www.flsmidth.com • +27 (0)10 210 4000

36

BULK HANDLING TODAY

January/February 2018

ABSOLUTE MATERIAL FLOW CONTROL

CHUTE SYSTEMS & SOLUTIONS • Optimum material flow • Up to 80% decrease in material degradation

• Reduced dust and noise levels • Virtually maintenance free

• Greatly reduced spillage • Significant reduction in belt damage

Tel: +27 (0) 11 827-9372 email: info@webachutes.com

www.webachutes.com

BULK HANDLING TODAY

January/February 2018

37

38

BULK HANDLING TODAY

January/February 2018

Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine well-appointed and equipped business suites.

Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages.

Secure parking, business centre, fibre optic broadband AV, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

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

FEEL THE EARTH MOVE ...

TAKRAF Africa is a key supplier of equipment and systems for surface mining and bulk handling solutions.

From excavation and comminution, environmental control, conveying and stockyards, through to loading and unloading, we have the systems and expertise.

Including spares and support with locally based in-house maintenance teams, specialised technicians and engineers.

A Level 2 B-BBEE Company. 125% spend recognition.

TAKRAF Africa

96 Loper Avenue, Aeroport, Spartan, Kempton Park, 1619, South Africa T: +27 11 201 2300 takraf.afr@tenova.com

www.takraf.com