BHT: Aug 2010

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BULK HANDLING TODAY August 2010 1

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Bulk Handling Today

Transcript of BHT: Aug 2010

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August 2010

ContentsCover Story5 Powerful Production Truck

Project Management7 Control, Control, Control11 Managing Mine Development

Mining17 Cut Your Costs23 Sound Engineering Saves the Day

Crushers27 Size Counts ...31 New Crushers for Local Market

34 Market Forum

Endorsing BodiesCMA (Conveyor Manufacturers Association)

HCASA (Hydraulic Conveying Association of SA)

LEEASA (Lifting Equipment Engineering Association of South Africa)

RFA (Road Freight Association)

SAIMechE (SA Institution of Mechanical Engineering)

SAIMH (SA Institute of Materials Handling)

Proprietor and Publisher:PROMECH PUBLISHINGTel: (011) 781-1401Fax: (011) 781-1403E-mail:[email protected] Website: www.promech.co.zaManaging Editor: Susan CustersJoint Editor: Andrew Lanham

Advertising Sales: Surita MarxDTP: Zinobia Docrat and Sanette Lehanie

Printed by:Typo Colour PrintingTel: (011) 402-3468

Our e-mail address is [email protected]

Visit our website on www.promech.co.za

The monthly circulation is 4 016

CopyrightAll rights reserved. No editorial matter published in “Bulk Han-dling Today” may be reproduced in any form or language without written permission of the publish-ers. 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.

Featured on the cover:

Scania

Tel: (011) 661 9600www.scania.co.za

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CONVEYOR MANUFACTURERS ASSOCIATION

Simon Curry

Belt conveyors are probably the most efficient means of transporting bulk materials. However, they are considered

dangerous due to the sheer size of the installation, which prevents clear and unimpeded visibility down the length of the system.

Conveyors can be one of the most hazardous mine or plant equipment

From the Chairman’s DeskSafety. This word conjures up so many images, and we in the conveyor industry are particularly sensitive to it. So much so, that a Safety around Belt Conveyors Guideline was generated even before the current legislation

came into effect!

installations if safety regulations are not strictly followed or if the conveyors are not properly main-tained.

The South African Mines Health and Safety Act (Act 4 or 1996 Section 21) states that the onus is on the supplier to provide the correct conveyor design, taking into consideration the risk to the health and safety of operating personnel. These same conditions are further extended to cover the installation of the conveying system as a whole.

SymposiumThe Conveyor Manufacturers Association has organised a Safety Symposium to bring together stakeholders from the Department of Mineral Re-sources and end users like Anglo American and Sasol. The focus of the event, whilst exploring all aspects of conveyor safety, will be the promotion of safety during the design of conveyor systems, with input from all stake holders.

The CMA initiated Safety Symposium will be held in downtown Johannesburg on Tuesday 31 August. For more details, please contact the Secretariat on telephone 011 888-7163 or by email to [email protected].

Simon CurryCMA Chairman

The onus is on the supplier to provide the correct conveyor design

ABB IndustryAfripp ProjectsActomAtlanta Manufacturing Bateman Engineered TechnologiesBauer a Division of Hudaco TransmissionBMG (Bearing Man Group)Bearings InternationalBelt Reco RSA Bonfiglioli Power Transmissions Bosworth A Division of Hudaco Trading Brelko Conveyor ProductsCKIT Conveyor Engineers Continental Crushing & Conveying

All members subscribe to the CMA Code of EthicsCMA Members List as at August 2010

Conveyor WatchCMG Electric Motors SACPI TechnologiesCPM EngineeringCT SystemsDavid Brown Gear Industries Delras EngineeringDRA Mineral ProjectsDunlop Belting ProductsDymot Engineering Company ELB Engineering ServicesFacet EngineeringFenner Conveyor Belting SAFlexible Steel Lacing SAHansen Transmissions SA Hosch - Fördertechnik

Lesa Mining and Conveyor Belt EquipmentM & J Engineering Martin EngineeringMelco Conveyor Equipment Moret MiningMS Conveyor Pulleys SANepean ConveyorsOE BearingsOsborn Engineered Products SAPH Projects HoldingsRead Swatman & VoigtRema Tip Top SARenold CroftsRoymecRSV ENCO Consulting

Sandvik Materials Handling SA Schaeffler South AfricaSecrivest SENETSET AgenciesSEW EurodriveShaft EngineeringShaw Almex AfricaSiemens Southern AfricaSKF SAThyssenKrupp Materials HandlingTransmission ComponentsTransvaal Rubber CompanyUnitek EngineersVeyance Technologies AfricaVoith Turbo Zest Electric Motors

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COVER STORY

Development and extensive testing of the new platform 16.4-litre V8 engine took five years and has lifted the R-Series newcomer into the ranks of a

super-truck.

Its output is almost 50% up on the power delivery of the V8 model sold up to now by Scania in SA, which is 500 horsepower. A limited number of 580 horsepower models have been sold here too.

Powerful Production Truck

Scania set a new benchmark when it launched a 730 horsepower variant as the latest, range-topping addition to its R-Series product line-up. The latest generation V8 engine has taken over Volvo’s place from the mantle

as the most powerful standard production truck in the world.

PowerPower output is one thing, but when talking about trucks, it is all about the other kind of torque, which is measured in Newton metres. Here, the new 730 hp Scania breaks through the 3 000 Nm barrier. The new engine, with high pressure injection into common rails, hits a new high in torque delivery at 3 500 Nm between 1 000 and 1 350 r/min.

This is a big jump from the output figures pertaining to the world’s previous most powerful truck, the Volvo FH 16 700, which was launched at the beginning of last year and pumps out 700 hp and 3 150 Nm

Engine power outputs are now offered at 500, 560, 620 and 730 hp

Award winner“Scania has delivered a ‘state-of-the-art’ truck that sets new standards in terms of fuel economy, driveability and overall efficiency,” says International truck of the year jury chairman, Gianenrico Griffini, when he presented the coveted award for 2010 to Scania at its R&D centre in Södertälje, (Scania previously won the award in 2005).

The new Scania R-Series model, which was launched in Sweden in September last year, came out top, in a contest where it faced tough opposition from Volvo, MAN and Mitsubishi Fuso, with a jury of 22 commercial vehicle journalists giving input in a competition that has been running since 1977.

The main criterion is that the winning truck model should be the one making the strongest contribution towards making road transport more efficient. The R-Series was a clear cut winner by 106 points.

In addition, the Scania R 480 model won the comparative 1000 Point Test organised by the German commercial vehicle trade press by a wide margin.

Meanwhile, Scania is very upbeat about its sales in 2010. Global orders were up 166% from the crisis levels of 2009 and the company says it is expecting firmer demand in the coming months. Orders in Western Europe rose 204% year-on-year for the first quarter of 2010.

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COVER STORY

All engines and electronics are developed, tested and optimised in-house

from its 16-litre straight six engine.

TransmissionThe fully automated 12-speed Scania Opticruise transmission with single disc clutch and range splitter gearbox features an efficient retarder, and a powerful exhaust brake.

A new shift strategy is designed to maintain the truck’s speed when going uphill without a fuel penalty, while the gear changing pattern adapts to driving style, load and topography.

In conjunction with the launch of the engines, Scania’s V8 truck range has been given a unique identity and bold appearance that reflects the strong position these models enjoy in the marketplace.

Five engine power outputs are now offered, the 500, 560, 620 and 730 hp in Euro IV and V specification and 500 and 580 hp in Euro III.

In-house designAll these engines, including all the electronics, are developed, tested and optimised in-house at Scania and ensure a perfect match with the rest of the drive train components that are also in-house designs.

Scania’s V8 heritage dates back more than 40 years to 1969 when the first generation V8 was born and almost 250 000 of these power units have been produced since then. It had a capacity of 14-litres and developed 350 hp and 1 245 Nm of torque, less than half the performance of the latest V8 derivative.

Scania, Tel: (011) 661 9600, www.scania.co.za

4 - 8 OCTOBER 2010MTN Expo Centre at Nasrec, South Africa

M I N I N G – I N D U S T R I A L – C O N S T R U C T I O N – P O W E R G E N E R A T I O N –

For further information contact Specialised ExhibitionsTel: +27 (0) 11 835 1565

Fax: +27 (0) 11 496-1363or email [email protected]

or [email protected]

T r a n s p o r t f o r t h e M i n i n g I n d u s t r y

INCORPORATING

SK

ET

CH

3187/1

07/1

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PRE-REGISTER ATwww.electramining.co.zaEntrance without a ticket, or a busi-

ness card, or pre-registration is subject to a R20 entrance fee.

Electra Mining Africa 2010Diarise now!

See 1000’s of products, 100’s of exhibitors

4-8 October 2010, MTN Expo Centre, Nasrec

Register for your free ticket at www.electramining.co.za

FORTHCOMING ATTRACTIONFORTHCOMING ATTRACTION

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PROJECT MANAGEMENT

A company that has firmly established itself as specialists in this engineering and project management field is DRA Mineral Projects. To learn more about the challenges “Bulk

Handling Today” speaks to Wray Carvelas, director at DRA Mineral Projects.

Culture“Over the years we have built up a project manage-ment ethos and culture unique to DRA,” he says. “For us, the key to effective project execution is Engineering Excellence first and foremost. This is something DRA pride themselves on. With respect to the art of Project Management the three Cs; control, control and control are key to successful delivery of any project.

In order to deliver a project within the technical, budget, schedule and safety objectives, complete control of all aspects of the project is essential and to do this the necessary toolkits are essential. Naturally people assume these tools are fancy

Control, Control, Control Of all types of projects, there probably isn’t one to beat the complexity of integrating quite so many different engineering disciplines in order to build a mine on a bare piece of land

usually out in the sticks somewhere remote.

computer-based systems, but the tools needn’t always be that sophisticated.

“Of course, sophisticated tools have their rightful place to control functions at the top tier such as Gantt chart planning, quality control, cost control, risk management and procurement management, but it is very important to have physical hands-on control at the second tier,” explains Wray. “Simple checklists and ‘chase schedules’ are necessary and effective in controlling the hands-on objectives, making sure that all aspects of the project are on

schedule and to the right standard.

Our way“We have a saying in the company called ‘doing things the DRA way’ because we’ve learnt through experience that there is only one way of doing a project properly,” says Wray. “This constitutes having the right focus on the technical aspects and the right control over schedule, quality and safety. The DRA way is different from how others do it, but we’re proud of it and strive to retain this unique hands-on culture we’ve built up over the past 26 years which has resulted in our becoming one of the most success-ful project houses on the continent today.

The three Cs; control, control and control are key tosuccessful delivery of any project

Wray Carvelas, director at DRA Mineral Projects

The Pilansberg Platinum mine during construction

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Our project teams are in control of all aspects of the project, ensuring it’s success

DRA’s project at the Tati nickle processing plant

PROJECT MANAGEMENT

“We like to think that our project managers think about what they’re doing and don’t solely rely on sophisticated software packages to tell them what’s going on,” adds Wray. Our engineers and project managers have a pride and passion for what they do. That is our key. Our project teams are in control of all aspects of the project, ensuring it’s success. Our staff goes the extra mile taking full responsibility and accountability for their decisions and actions. “The fact that 99% of our projects are finished within budget and on schedule is posi-tive proof that we’re doing things the right way.”

Blue chipOutsourcing projects to specialist engineering houses is a growing trend as mining companies simply no longer have the necessary skills in-house. “Not only have projects grown in number and size, but our clientele has also changed over the years,” says Wray. The blue-chip companies have differ-ent requirements in that you simply won’t get the job if you don’t have the right control systems in place. Naturally, sophisticated systems are vital, but ultimately project management requires a good

engineer who can think on his or her feet and make good practical decisions.”

Wray is responsible for all the project managers in the company, so we asked whether he chooses professional project managers or rather searches for a good engineer to manage a project. “Tradition-ally we’ve always looked for a good engineer,” he replies. “Over the years all of our project managers have been engineers who have come up through the ranks. So, we firstly look at that and then look at the management exposure and experience.”.

Good people“Today I am responsible for all projects in execution phase. To make my job easier I simply appoint good people, the best that the industry has to offer,” he says with a chuckle. “But, it’s not a perfect world, there are project managers you need to mentor more than others. The managers all submit fortnightly and monthly reports on the state of health of the various projects. I also visit their project sites as often as I can and from that I get a good idea of the health of the project. This determines how much time I need to spend with each job.

“However, we have a policy that the project man-agers are completely responsible and accountable for their projects,” Wray says. “This is one of the

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reasons we’re so successful be-cause it gives them a sense of ownership of the project. I don’t interfere too much but I certainly want the information for assurance that everything is under control. The reports and visits provide me with a constant birds-eye view of all the projects in execution.”

SafetyThe projects DRA hand le are all mining-related projects undertaken by in-house mechanical, structural and process engi-neering specialists who are managed by the project managers. “Our work covers all mineral projects, right from conceptual design, through to detailed design, erection commissioning and ramp up. Es-sentially from concept to handover and ramp up,” explains Wray. “The only time we outsource skills is when we need very specialised services or skills, but we always remain responsible for the work.

In DRA one of the most important aspects and one of our key success stories is our unique approach to safety management, says Wray in conclusion, “We call it People-Based Safety, and it is an ap-proach to safety that encourages every single person on a project to care for everyone else on the project, because if everyone does that, we will achieve our targets of Zero Harm. People-Based Safety embraces a concept called ‘actively caring for people’ and it is an approach that is bearing fruit in our company.

In summary I would like to conclude on paying tribute to the DRA WAY ,in saying that with the right direction, dedication, commitment and calibre of people, virtually anything can be achieved, even against all odds. Our track record and success stories bears testimony to the DRA WAY and we are proud to have project teams that have rede-fined the meaning of dedication, hard work and determination.”

Wray Carvelas, DRA Mineral Projects, Tel: (011) 202-8787, Email: [email protected]

The Khumani Iron mine

Unique approach to safety management is vital

PROJECT MANAGEMENT

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PROJECT MANAGEMENT

P roject management companies, who take on such work, require a broad engineering skills base in order to cover the wide range of disciplines that constitutes modern cost-

effective mining operations. “Bulk Handling Today” visits such a company, Agere Project Management, to speak to director, Johan Odendaal.

“Basically, three associate companies operate under one umbrella to execute a project as a whole,” he

Managing Mine Development

In the past, most mining houses did it all themselves, as they say. They were pretty much totally self-suf-ficient with plenty of in-house divisions. Over the last ten years, after the unbundling of the mining houses, outsourcing has become the trend. This gave rise to specialist engineering companies being established to

handle various mining aspects on a project basis.

explains. “Minxcon is a mining consulting company, Agere Project Management handles projects, and Minesoft develops and supports various software solutions for mining management.

All-encompassingAgere established itself as a project management company specialising in the management and op-timisation of projects within the mining industry, all the way from exploration to mining, metallurgy, infrastructure and associated activities. “Our skills portfolio includes exploration services such as project valuation, exploration target generation, exploration method identification, exploration

Small mines are often the starting point for bigger developments

Company specialising in the management andoptimisation of projects within the mining industry

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PROJECT MANAGEMENT

programme management, geological services and quality compliance,” says Johan.

“In addition our metallurgical services encompass plant optimisation, benchmarking, cost analysis and feasibility studies.”

Scope“This means that we’re now ideally placed to liter-ally take a project from a Greenfields, concept or idea, through to exploration, into pre-feasibility, and onto feasibility,” says Johan. “The next natural step is to take the project through to design, engineer-ing and then EPCM. “On the materials handling side, we’re currently in the process of gearing up to handle the EPCM (Engineering, Procurement, Construction Management),” Johan adds.

“Although this is a long term strategy in terms of expanding the company, we have access to the necessary engineering specialists right now who are pulled in to manage such projects under the Agere umbrella until such time as we’ve built up the capacity to take it on in-house.”

ExplorationAgere works in close association with Minxcon, a well-established exploration and mining consulting company, providing them with a strong skills net-work. “Our cutting-edge technology, vast industry

expertise and technical know-how ensure that we can always meet market needs in terms of modern mining requirements,” says Uwe Engel-mann, explora-tion director.

“Our services under the explo-ration umbrella include project data compilation such as GIS and Datamine. We do project potential valuation, exploration target generation and also cover the exploration method identification, geological field mapping through to generating drilling and exploration programmes and managing the exploration project. This includes core logging and sampling as well as auditing, compliance evaluation and the sign-off on QA/QC processes and procedures.”

MetallurgyOn the metallurgical side, the services offered include plant optimisation and trouble-shooting. “Regardless of the mineral, all the samples from the ore body have to be evaluated in order to confirm

Johan Odendaal of Agere Project Management

Exploration work in the field

Providing a total solution to mining companies

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whether the metal can be extracted eco-nomically before exploration commences and the mine is developed,” explains Dario Clemente, metallurgy director at Agere.

“Our findings and conclusions then flow back into the project in terms of what it will cost to mine the mineral cost-effectively,” adds Dario. Here metal accounting, benchmarking, process auditing and technical evaluation is the order of the day. In addition, a full-cost analysis and optimisation schedule is prepared, an operating and management system is provided, training takes place and the metallurgy is fine-tuned. Explains Dario, “We review and assess the security systems in full pre-feasibility and feasibility study reports. Apart from projects that are in development, we also provide these metal-lurgical services to operating mines.”

ToolsThe project management tools used by Agere’s engineers are based on best prac-tice requirements generally accepted in the mining industry worldwide. “Apart from in-house software developed by Minesoft, we also make use of project management tools such as MS Project and spreadsheets to produce the necessary Gantt chart sched-ules to keep track of project development progress,” explains Uwe.

“Our fully-integrated and relational database is integrated with all the software packages, aimed at providing a total solution to min-ing companies. The database also helps for compliance purposes to ensure that codes are adhered to throughout the processes we use to execute the project.”

Five pillarsAgere Project Management works closely with Minxcon. “Minxcon is well positioned to assist mining and exploration companies in meeting their Mining Charter obligations and has the infrastructure to undertake projects from the target definition stage right through to mine clo-sure,” says Johan.

“They combine a core and non-core team based on the five pillars of mining, viz, geology, mining engineering, metallurgy, socio-economic develop-ment and mineral economics.”

Mining Engineering“The Mining Engineering Division of Minxcon has a team of mining engineers with a wide variety of skills and experience in underground mining, open pit mining, project management, mine management and life of mine planning,”Johan explains. “This team of professionals also undertakes capital and operating cost estimations through to pre-feasibility and final feasibility studies.”

With future plans including EPCM project manage-ment capabilities Agere is set to make its mark in the mining industry as a skills intensive mining engineering company. “If you want your project to be managed in the most cost effective way, we’ve got the skills in-house,” Johan says in conclusion.

“What sets us apart from most is the fact that we have broad base of expertise, not only in exploration and metallurgy, but in all engineering aspects that go hand in hand with developing and establishing the entire mining operation.”

Johan Odendaal, Agere Project Management, Tel: (011) 958-2899, Email: [email protected]

Drilling work is the core of exploration work

If you want your project to be managed in the most cost effective way, we’ve got the skills in-house

PROJECT MANAGEMENT

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This growth trend is fast continuing for Electra Mining Africa 2010, tak-ing place at the MTN Expo Centre, Nasrec, from 4-8 October, with strong

market support and space selling fast.

Veda Koekemoer, Exhibition Manager for Electra Mining Africa says, “The market is showing a definite positive trend and the demand for space has increased consider-ably, with most of the space either sold or on option.

It’s been a very encouraging start to the Elec-tra Mining 2010 year and we are certainly looking forward to a bumper show.”

“On the back of the economic downturn, we are seeing a steadily increasing number of exhibitors confirming participation at the show,” she says.

International interestAlso, very encouraging is the increase in international interest in the show, with many more countries participating than in 2006 and 2008. Countries include Botswana, Croatia, Italy, China, Belgium, Brazil, Austria and France.

The Australian Trade Commission in South Africa has confirmed an Australian Pavilion, and reserve options are also in place for French, Italian and Canadian Pavilions.

“We’ve also had enquiries from a number of countries who are interested in arranging ‘Inward Buying Missions’ to the show.

This is very positive for Electra Mining Africa 2010 as this certainly proves the exhibition’s credibility and value to the International Market,” says Veda.

Many new innovations will be showcased, including energy efficiencies and environmen-tally friendly products, as well as products in line with the mining industry’s goals on health and safety.

http://www.electramining.co.za

StrongSupport

Electra Mining Africa experienced its big-gest show in 2008 with more than 41 000 visitors and 700 local and international ex-

hibitors.

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COMPANYBateman Engineered Technologies LtdBearings International (Pty) LtdBrelko Conveyor Products (Pty) LtdCKIT Conveyor Engineers (Pty) LtdCPM EngineeringCT Systems ccConveyor Watch (Pty) LtdDavid Brown Gear lndustries (Pty) LtdDeebar Mining & Industrial SuppliesEast Rand Engineering ServicesELB Engineering Services (Pty) LtdEngicon Systems (Pty) LtdFacet Engineering ccGoba Consulting EngineersGroup Line Projects (Pty) LtdHagglunds Drives SA (Pty) LtdHansen Transmissions SA (Pty) LtdlllustechKetapele Flexible Manufacturing ccMacsteelVRNMartin EngineeringMelco Conveyor EquipmentMorris Material Handling SA (Pty) LtdOsborn Engineered Products(Pty)LtdP D Engineering Services ccPDNA M&r (PTY) LTDQuadrant PHSRenold Crofts (Pty) LtdSandvik Materials Handling AfricaScrew Conveyors & Material HandlingSenetSecrivest (Pty) LtdSEW EurodriveShatterprufe a Div. of PG Group Pty LtdSpar Western CapeSuper Dock SystemsUnitek EngineeringZest Electric Motors (Pty) Ltd

REPRESENTATIVEMr R PieterseMr F PienaarMr P EllisMr P StaplesMr Doug FennerMr A.SingerMr A SurteesMr D WhitfordMr D SoekoeMr Jan DreyerDr S J MeijersMr Dave MorganMr C.D. FairweatherMr A GriffithsMr D KellyMr M GullickMr C E DicksMr Rick Du ToitMr O L LeburuMr Ross WylieMr J HicklingMr Derek CohenMr Mike LongoMs C FallowsMr Kevin ThomasMr Devan GovenderMr H PretoriusMr N PeraMr A PainMr M OveryMr H ThiartMs Ann DixMr U RoosMr Q Van MeyrenMr S EngelbrechtMr C Van ZylMr Bruce WilsonMr David Claassen

A reminder that our Annual Golf Day

will be on 14th October, 2010 (please diarise

the date) Invitations will be sent out shortly but

anybody wanting to play can contact Graham

Downing (082 3725150) or

email [email protected]

SAIMH NEWS

Diarise!

Engineer PlacementsProfessional opportunitiesOur job board continues to display a wide variety of excellent job positions that you can review and apply for on- line. Keep your credentials on our secure and confidential database, update them at any time.We keep in touch with you.www.engineerplacements.com

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This coal transport research was based on a hybrid research strategy. The first stage comprised a phenomenological based, in-ductive approach to evaluating the literature

available on different coal transport technologies, but moreover to conduct primary evaluative research into the subject. The second positivist based, deductive approach included primary research, based on the outcome of the first stage, aimed at fully evaluating, understanding and quantifying the characteristics, capacities, costs and socio-economic impacts of each transport mode.

Due to the research being based on this hybrid strategy, it required a multi-method data gather-ing approach, which included focused desktop research and more than 15 general interviews with various senior managers from a number of different organizations within the coal and trans-port industries. Based on the initial information garnered, selected technology modal specialists were targeted for in-depth interviews, further data gathering, cross referencing and validation. In total, 16 specialist interviews and targeted discussions were completed.

Cut Your Costs A case study was undertaken by Crick-may and Associates (Pty) Ltd on behalf of Coaltech on different bulk materials

systems. Sixteen different systems were extensively researched. Coaltech com-missioned an independent coal trans-

port investigation to identify alternative transport modes and technologies, with the aim of determining which technolo-

gies are best suited for specific coal transport requirements. These transport requirements may vary according to the

lead distance, terrain, throughput re-quirements and geographical location, to

name but a few factors.

CompletedDifferent transport options are generally classified into modes, based on the infrastructure that is required to enable such transport. Similar guide-lines have been used during this coal transport investigation and the 18 identified transport modes were grouped as indicated in Table 1.

Eleven of these identified transport options are already being used commercially and are applicable under South African conditions, while a further three options need further evaluation and testing before

a definitive answer can be provided.

To accurately com-pare transport modes against each other, it was imperative that these technologies be evaluated using the same criteria. To achieve this objective, the evaluation criteria were structured according to the physical system characteristics, the socio-economic im-pacts of each system, its local applicability and any further research requirements that were uncovered.

Cost comparisonsThe cost comparisons, based on the transport unit cost, at various lead distances ranging from 1 to 1 000 kilometers, based on three distinct

Transport Mode In Commercial Use Feasible in SARoad Based Transport OptionsCurrent Road Transport Yes YesQuantum 1 Road Transport Yes YesPBS Vehicles Yes YesRoadtrains Yes YesRail Based Transport OptionsGeneral Freight Rail Transport Yes YesHeavy Haul Rail Transport Yes YesMagnetic Leviation System Not for Freight NoPipeline and Tube Based Transport OptionsCoal Log Pipelines No To Be ValidatedSlurry Pipelines Yes To Be ValidatedTube Freight Transportation System Not for Bulk Materials NoContinuous Articulated Rail in a Tube (CARIAT) No To Be ValidatedConveyor and Cable Transport OptionsOverland Conveyor Systems Yes YesAerial Ropeway Systems Yes YesRope Conveyor Systems Yes YesCombination Transport OptionsRail-Veyor System Yes YesBimodal Transport Options Yes YesOther Transport OptionsWater Based Transport Options Yes NoAir Transport Options Yes No

Table 1: Available Transport Modes

MINING

Eleven of these identified transport options are already being used commercially

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rand

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081691_Bulk Handling.indd 3 2010/07/27 2:49 PM

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freight volume scenarios of 1, 5 and 50 Million Tonnes per Annum (MTPA), respectively are sum-marised and the transport options are ranked in order of economic competitiveness in Table 2.

The individual transport modes were ranked per lead distance segment for each of the three volume scenarios and then averaged per distance grouping, which resulted in the overall ranking indicated in Table 2. From Table 2 it is possible to ascertain which transport mode, based on cost only, is the most competitive option at a given lead distance and for a specified product throughput.

It should be noted that six transport options, which are applicable to the Medium lead distance applications, were omitted from Table 2 for the Short lead distance applications below 10 km, as these rail and pipeline type options are simply not competitive at such short distances. Similarly, four transport options were also omitted from the Long lead distance applications above 100 km, as conveyor type technologies are not practically suited to such long distances.

Every single scenarioThe outcome of the research broadly conformed

Short (<10 KM)Scenario A

1 MTPA Rank Scenario B5 MTPA Rank Scenario C

50 MTPA Rank

Rail-Veyor 1 Rail-Veyor 1 Conveyor 1Roadtrain (180 t) 2 Aerial Ropeway 2 Pipe Conveyor 2Roadtrain (105 t) 3 Conveyor 3 Rail-Veyor 3PBS Vehicles (48 t) 4 Pipe Conveyor 4 Rope Conveyor 4Aerial Ropeway 5 Roadtrain (180 t) 5 Aerial Ropeway 5Quantum 1 Road (38 t) 6 Roadtrain (105 t) 6 Roadtrain (180 t) 6Conveyor 7 PBS Vehicles (48 t) 7 Roadtrain (105 t) 7Current Road (31 t) 8 Quantum 1 Road (38 t) 8 PBS Vehicles (48 t) 8Pipe Conveyor 9 Current Road (31 t) 9 Quantum 1 Road (38 t) 9Rope Conveyor 10 Rope Conveyor 10 Current Road (31 t) 10

Intermediate (10 KM – 100KM)Scenario A

1 MTPA Rank Scenario B5 MTPA Rank Scenario C

50 MTPA Rank

Heavy Haul Rail (Current Rates) 1 Rail-Veyor 1 Conveyor 1PBS Vehicles (48 t) 2 Heavy Haul Rail (Current Rates) 2 Pipe Conveyor 2Quantum 1 Road (38 t) 3 Roadtrain (180 t) 3 Rail-Veyor 3GFB Rail (Current Rates) 4 Conveyor 4 Rope Conveyor 4Roadtrain (180 t) 5 Coal Log Pipeline 5 Coal Log Pipeline 5Roadtrain (105 t) 6 Roadtrain (105 t) 6 Roadtrain (180 t) 6Current Road (31 t) 7 PBS Vehicles (48 t) 7 Heavy Haul Rail (Current Rates) 7Coal Log Pipeline 8 Aerial Ropeway 8 Roadtrain (105 t) 8Rail-Veyor 9 GFB Rail (Current Rates) 9 Heavy Haul Rail (Private) 9Conveyor 10 Pipe Conveyor 10 PBS Vehicles (48 t) 10Aerial Ropeway 11 Quantum 1 Road (38 t) 11 GFB Rail (Current Rates) 11Pipe Conveyor 12 Slurry Pipeline 12 GFB Rail (Private) 12Slurry Pipeline 13 Current Road (31 t) 13 Quantum 1 Road (38 t) 13GFB Rail (Private) 14 Heavy Haul Rail (Private) 14 Slurry Pipeline 14Heavy Haul Rail (Private) 15 GFB Rail (Private) 15 Current Road (31 t) 15Rope Conveyor 16 Rope Conveyor 16 Aerial Ropeway 16

Long (100 KM – 1,000KM)Scenario A

1 MTPA Rank Scenario B5 MTPA Rank Scenario C

50 MTPA Rank

Heavy Haul Rail (Current Rates) 1 Heavy Haul Rail (Current Rates) 1 Coal Log Pipeline 1GFB Rail (Current Rates) 2 Coal Log Pipeline 2 Rail-Veyor 2Coal Log Pipeline 3 Slurry Pipeline 3 Heavy Haul Rail (Current Rates) 3PBS Vehicles (48 t) 4 GFB Rail (Current Rates) 4 Slurry Pipeline 4Quantum 1 Road (38 t) 5 Rail-Veyor 5 Heavy Haul Rail (Private) 5Roadtrain (180 t) 6 Roadtrain (180 t) 6 GFB Rail (Current Rates) 6Current Road (31 t) 7 PBS Vehicles (48 t) 7 GFB Rail (Private) 7Slurry Pipeline 8 Roadtrain (105 t) 8 Roadtrain (180 t) 8Roadtrain (105 t) 9 Quantum 1 Road (38 t) 9 Roadtrain (105 t) 9Rail-Veyor 10 Current Road (31 t) 10 PBS Vehicles (48 t) 10GFB Rail (Private) 11 GFB Rail (Private) 11 Quantum 1 Road (38 t) 11Heavy Haul Rail (Private) 12 Heavy Haul Rail (Private) 12 Current Road (31 t) 12

Table 2: Summary of Feasible Transport Options per Scenario

MINING

0816

37A

Daim

ler B

rand

The Mercedes-Benz Axor. The all round answer when duty calls.The Mercedes-Benz Axor is a flawless, all-rounder that will do any company proud; for years to come. All thanks to its robust design and long service intervals. But it’s over medium-distance haulages or heavy-duty short radius carrying distances that the Axor comes into its own. With unsurpassed

technology scattered generously throughout its design, it’s the drivers who’ll benefit most. Let’s also not forget the nationwide support network on 24-hour standby. For more information contact your Mercedes-Benz Commercial Vehicle dealer, telephone 0800 133 355 or visit www.mercedes-benz.co.za/trucks

081691_Bulk Handling.indd 3 2010/07/27 2:49 PM

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20 BULK HANDLING TODAY August 2010

to expectations, where conveyor type technologies are suitable across shorter lead distances, with the flexibility and scalability of road transport ensuring

that it remains an option in most applications. The different versions of rail transport further indicated that it is very competitive at intermediate to long

lead distances, while the pipeline based technologies also seemed to be an option at mid-volume and long lead distance applications.

The most surprising outcome of this re-search, however, is the comprehensively competitive possibilities of the Rail-Veyor System, which proved to be the only technology that was competitive under every single scenario. However, the selection of a specific transport mode is not a simple economic calculation, but rather a complex decision based on various influencing factors including the availability of infrastructures, individual system characteristics, system integration possibilities and various socio-economic implications.

Individual routeThe main conclusion from this research is therefore that no single transport technol-ogy exists that could cost effectively satisfy all the divergent transport requirements, across all distances, at different volumes and across all types of terrain. The opti-mum coal distribution solution lies in the effective combination of all the available transport options into an integrated and well managed network, where individual technologies are applied on merit. This approach allows for the safest and most cost effective transport application for each

MINING

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BULK HANDLING TODAY August 2010 21

The most surprising outcome of this re-search, however, is the comprehensively competitive possibilities of the Rail-Veyor System

individual route, with the lowest socio-economic impact, while protecting and enhancing the avail-able transport infrastructure.

Next logical stepThe research was conducted at a very high level and intentionally kept as generic as possible. The results are valuable and adequate for guiding se-lected transport and distribution related decisions,

in cases where the lead distance, basic geogra-phy and product volumes are known. However, a logical next step in this field of research would be to investigate the integrative and cooperative approaches that could be followed to improve distribution productivity, efficiency, reliability and cost effectiveness of the coal supply chain at an industry level.

The introduction of an industry wide-supply chain network optimisation initiative and the establish-ment of coal hubs are two possible options to achieve this level of cooperation, which warrants further investigation.

Why not consider using Rail-Veyor to move your bulk material? This cost effective and safe method of transporting material can be designed to your exact requirements.

Rail-Veyor has a number of features over other conventional modes of transport that are currently used.

For further information on the Deebar Rail-Veyor system, please contact: Desmond Soekoe on 082 654-2598 or Johan van Vollenhoven on 082 326-1657.

MINING

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22 BULK HANDLING TODAY August 2010

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BULK HANDLING TODAY August 2010 2�

MINING

Northam Platinum Mine commissioned an original equipment circular stacker/ reclaimer from ThyssenKrupp Materi-als Handling (TKMH) in 1991. During

2009 problems with the slew bearings on the stacker became evident and TKMH was requested to conduct an onsite inspection of the equipment with specific reference to the condition of the slew bearings.

Fixing the problem“Bulk Handling Today” speaks to the engineers involved in this project. “Post inspection, our sup-port staff and Northam Mine Management entered into discussions and deliberations around the refurbishment project in order to finalise various issues including final scope of work as well as a feasible schedule for the execution of the work,” says Dietmar Pratz, the TKMH Product Support Engineer who was appointed as the responsible project manager.

Sound Engineering Saves the Day

The ingenuity of experienced engineers

saved the day for a mine when they

developed a problem with a stacker

reclaimer system. Being able to fix the

problem on site and within record time

shows that OEMs simply know how to

engineer around the practical problems

encountered on site work.

“When the circular stacker was originally installed and commissioned, we recommended that critical spares, such as slew bearings with a long delivery lead time, be kept in stock to reduce downtime to a minimum while limiting the high cost of alternative interim materials handling options,” he adds. “With replacement bearings in stock, we could therefore start construction work early in January 2010.”

The circular stacker weighs in at 168 tonnes and the two slew bearings with diameters of 1.70m and 2.00m at 300kg and 650kg respectively.

Special jacking trestles“Before our construction team could proceed with the removal of the slew bearings, we had to engineer and manufacture special jacking trestles to jack and support the machine centre column”, explains Dietmar. “The jacking process is crucial as the slightest imbalance can cause the machine to topple over. Accurate load calculations and pressure readings on the calibrated jacks were essential to ensure even lifting, after which, the slew bearings were rigged out onto the special steel support frames we constructed.”

With the slew bearings removed, structural damage and corrosion fatigue on the boom structure as well as the centre column became evident which is to be expected after nearly two decades of trouble-free service. While critical repairs were recommended for the centre column in situ, TKMH engineers suggested that the boom structure be transported to a workshop for a more in-depth evaluation and possible repairs under controlled conditions.

More damageSandblasting revealed the full extent of the dam-age to the boom structure and it was agreed that repair was not a viable option. “It was decided to manufacture a complete new boom while repair work to the centre column would continue on site,” says Dietmar.

“Based on price and commitment to the shortest delivery time, the mine gave consent and the order for the new boom was finalised and manufactur-ing went ahead. With the original design drawings available from our archives, the boom construction

Limiting the high cost of alternative interim materials handling options,

Sybrand Visagie of ThyssenKrupp Materials Handling

MININGMINING

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2� BULK HANDLING TODAY August 2010

MINING

was completed in accordance with our specifica-tions and was delivered to site after release by our quality control department.”

Record time“This was done within a record time of ten weeks, two weeks ahead of schedule” adds product support manager, Sybrand Visagie. “The entire Northam Platinum Concentration Plant engineering team, fitters, boilermakers, electricians and technicians together with engineering supervisor, Willie Ste-vens leading them, committed many long hours

Structural damage and corrosion fatigue on the boom structure as well as the centre column became evident

The special jacking trestles to jack and support the machine centre column

Before

of dedication, skill and experience to the safe and successful conclusion of the project.”

According to Willie, Len Slippers’ Noordwes En-gineering, responsible for most of the hydraulic systems, also played a major role in a massive team effort that required diverse skills and total commitment to complete the project within the required timeframe despite very wet and extremely unpleasant weather conditions.

Fine example“This project is a fine example of a giant and very

After the repair work

After

As new, a fine example of a very successful team effort

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BULK HANDLING TODAY August 2010 2�

successful team effort that required professional-ism, commitment and cooperation to ensure that the project could be finalised without incident and according to schedule,” comments Sybrand.

“TKMH’s engineering expertise, long hours and commitment to delivering quality products and services, made it possible for us to bring this refurbishing project to its safe and incident-free final conclusion,” adds Willie.

Discussing the merits of an OEM, Sybrand says, “The original supplier and specifically international organisations, have up-to-date product knowledge, experience over a wide front and can offer fit-for-purpose parts and components without having to reinvent the wheel which are all benefits that an independent service company cannot offer.”

RisksIt is TKMH’s policy to undertake work on its own original equipment installations but the company

The new bearing fitted and all refurbishing completed in a record time

does work on other installations pro-vided the client obtains consent from other OEM’s and can provide the original design considerations as well as detailed design drawings. On a cautionary note, Sybrand says that embarking on large refurbishment projects without ac-cess to the original design documents etc, increases the end user’s risk in many ways espe-cially in terms of safety as well as equipment reliabil-ity which can be compromised.

In conclusion, he highlights the ex-pansion over time of product sup-port service by TKMH, a division of ThyssenKrupp PDNA Engineer-ing which include: maintenance audits followed by main-

tenance reports; the execution of maintenance tasks and refurbishment projects; technical sup-port in respect of analysing and engineering out of repetitive failures backed by global experience; improvement projects against global benchmarking; and full time on-site support with emphasis on the training of operating and maintenance staff as well as the development of best practice maintenance procedures.

Sybrand Visagie, ThyssenKrupp Materials Handling Prod-uct Support Manager, Tel: (011) 236-1000/1235. Email: [email protected], Website: www.thys-senkrupp-materialshandling.co.za

The jacking process is crucial as the slightest imbalance can cause the machine to topple over

The special jacking trestles to jack and support the machine centre column

MINING

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2� BULK HANDLING TODAY August 2010

WEARCOAT PC

The latest technology in modern Pipe Lining

WEARCOAT TP

Application to Pipe bends, Slurry lines, Pump casing, Cyclones, Conveyor pulleys, Chutes, Hoppers, Launders and Feeder boxes etc….

WEARCOAT PO

Application to Agitator blades, Bucket elevators, Coal feeders, Cyclones, Launders, Ducting fans, Distribution tank, Fan casing, Feeder boxes, Flotation cells, Hoppers, Impellers, Pipes and Pipe bends.

WEARBACK HI

This backing material is a modified epoxy resin system formulated as a superior backing compound for crusher liners. When cured it provides a high compressive strength support for all types of wear liners.

WEARBACK STD

This product formulated for the use in all type of Cone crushers, Grinding mills, Primary, Gyratory crushers and any other Heavy machinery that requires backing material

WEARCON IMPACT GRID

The IMPACT GRID is a ceramic impact protection procedure comprising of Mentis Grating mild steel Recta Grid filled with 30mm cylindrical ceramic tiles and supported with WEARCOAT TP

Head Office & Manufacturing Facility: WEARCON (Pty) Ltd 16 Industria Road Vorsterskroon Nigel GAUTENG Tel: +27 11 814 2983 Fax: +27 11 814 2984 E-mail: [email protected] Website: www.wearcon.co.za

10kg or

20kg Kits

10kg or

20kg Kits

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CRUSHERS

VSI crushers are well-suited to providing specific shapes and sizes as a paving product and secondly, cubical stone prod-ucts are better for all types of concrete

because they achieve higher strengths and savings in cement content. What’s more, VSIs have a lower purchase price, lower installation cost and operat-ing costs can come in the same as for traditional compression equipment such as cone crushers, even in hard abrasive rock processing especially when specifications are critical.

The principle of VSIVSI’s predominantly utilise velocity rather than surface force to break rock which means that the breaking force is applied evenly both across the surface of the rock as well as through the mass of the rock. Rock, regardless of size, has natural fissures throughout its structure and as it is flung by a VSI rotor against a rock bed, it fractures and breaks along these fissures.

Final particle size can therefore be controlled by

Size Counts…The requirements for aggregate shape and size, especially for asphalt applications, have become more stringent which has increased the popularity of VSI (vertical shaft impact) crush-

ers in this industry.

the velocity and volume at which the rock is thrown against the rock bed. This results in a consistent cubicle shape such as that required by modern highway asphalt applications.

Improved design“Bulk Handling To-day” visits South African VSI manufacturer, OreCrusher in Benoni to speak to managing director, Harry Collins, about the VSI range of crushers they make. “Although the company is only six years old, I have been in the crushing industry for over 30 years,” he says. “South African rock is very different from anywhere else in the world, necessitating a home-grown crusher like the Ore Master we now build.

“Over the years we’ve made improvements to the VSI design to suit the particular conditions of South African rock,” he adds. “Originally we mainly catered for the export market with general improvements but as local demand grew, we introduced ‘customised’ South African features because the type of materials here are vastly different from what they’re crushing overseas where the VSI design originated.

Unique hard rock“From our involvement in crushing manganese ore, chrome ore and diamond bearing rock, we’ve learnt that these materials are much more difficult to crush than the general rock found overseas,” says Harry. “Apart from making changes to improve crush-ing performance, we’ve also made the machines more user-friendly and optimised power consump-tion, resulting in a product way ahead of its time in this country. As a result, we’ve gone from strength to strength in both the aggregate and the mining industries.”

In principle, OreCrusher’s Ore Mater VSI works the

Rotors of different sizes in stock

Harry Collins, managing director of OreCrusher

South African rock is very different from anywhere else in the world

WEARCOAT PC

The latest technology in modern Pipe Lining

WEARCOAT TP

Application to Pipe bends, Slurry lines, Pump casing, Cyclones, Conveyor pulleys, Chutes, Hoppers, Launders and Feeder boxes etc….

WEARCOAT PO

Application to Agitator blades, Bucket elevators, Coal feeders, Cyclones, Launders, Ducting fans, Distribution tank, Fan casing, Feeder boxes, Flotation cells, Hoppers, Impellers, Pipes and Pipe bends.

WEARBACK HI

This backing material is a modified epoxy resin system formulated as a superior backing compound for crusher liners. When cured it provides a high compressive strength support for all types of wear liners.

WEARBACK STD

This product formulated for the use in all type of Cone crushers, Grinding mills, Primary, Gyratory crushers and any other Heavy machinery that requires backing material

WEARCON IMPACT GRID

The IMPACT GRID is a ceramic impact protection procedure comprising of Mentis Grating mild steel Recta Grid filled with 30mm cylindrical ceramic tiles and supported with WEARCOAT TP

Head Office & Manufacturing Facility: WEARCON (Pty) Ltd 16 Industria Road Vorsterskroon Nigel GAUTENG Tel: +27 11 814 2983 Fax: +27 11 814 2984 E-mail: [email protected] Website: www.wearcon.co.za

10kg or

20kg Kits

10kg or

20kg Kits

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2� BULK HANDLING TODAY August 2010

same as its competitors but subtle refinements have put the design a step ahead of the rest. “If required, for example, we can set the machine to produce a lot more fines and achieve higher reduction ratios,” Harry explains. “Our rotor design, which has the

main function of flinging the rock out of the rotor, allows us a reduction of 25% in required horse power. This translates to 25% more throughput for the same power rating.

Best tonnage rate“In addition, the roller design is such that we’re getting double the life between wear-part changes,” adds Harry. “These improvements, together with the fact that the machines are manufactured right here in South Africa, has contributed to our hav-ing around 70% market share in the aggregate industry.

“Despite tough competition against less expeensive crushers available to the local market, many of our machines are running at 70% less per tonne over the long run than most VSI installations,” says Harry. “Our success, however, has been with the bigger companies where they’re now increasingly considering lifecycle costs. They appreciate that durability is an investment as opposed to being an alternative option.”

Diamond industryAs the OEM, the OreCrusher can be customised for applications that are out of the ordinary. “It all depends on the application, but if it’s a very wet and sticky material like manganese, for example, A VSI taking shape in the factory

CRUSHERS

Running at 70% less per tonne over the long run than most VSI installations

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BULK HANDLING TODAY August 2010 2�

At the heart of a VSI is the rotor, being balanced here in Ore-Crusher’s factory

breaking the crystal,” Harry adds. “This used to be done with ball mills but they tended to damage the crystal as well. The flexibility of our design allows us to refine the adjustment to such an extent that it leaves the majority of the crystals in their complete form. Crushing rock is not just a matter of breaking big bits down to smaller bits, we have to know what the customer wants to do with the end product, what grading he wants to achieve and we then set the machine up accordingly.”

Caring for a VSIThe VSI crusher is generally known to be temperamental, but it’s reliable when taken care of properly. “We’re not here only to sell a cost-effective machine that is proven to save end-users money, our main objective is to provide back-up and service to our customers,” Harry says in

conclusion. “Apart from training operators, we have also developed a lubrication system for our machines to assist customers in this often- neglected aspect of running and maintaining crushing machines.”

Harry Collins, OreCrusher SA, Tel: (011) 420-1145, Email: [email protected], Website: www.orecrusher.co.za

CRUSHERS

we can make modifications to the machine to cater for this tendency,” explains Harry. “Crushing in the diamond industry is unique in that you want to liber-ate the diamond from the rock without breaking or damaging the diamond. Here it’s simply a matter of setting up the machine to do just that.

“In other situations, clients may want the ore to be crushed down to its crystalline size as opposed to

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�0 BULK HANDLING TODAY August 2010 Advanced Materials Today September 2007 39

AMT Sept 07 zin.indd 39 2007/09/11 10:28:49 AM

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CRUSHERS

Surprisingly, many customers in the market for crushing equipment don’t know or fol-low this maxim when they set out to buy new plant. Complementing their full range

New Crushers for Local Market

Crushing a rock mechanically for a specific purpose is not as easy as throwing big rocks in one end and get-ting smaller stones out the other side. Crushing rock is a scientific process where, depending on the composi-tion of the rock, you may use any one of several crushing technologies available to arrive at a certain shape

and size of smaller stone with the least amount of wasted material at the end.

of crushers, Wirtgen South Africa is now offering the South African market a professional service, based on worldwide experience of the crushing industry, which assists customers in choosing the

Wirtgen’s managing director, Heinrich SchulenburgDave Newman, product specialist, crushing and screening

A mobile crusher plant

Advanced Materials Today September 2007 39

AMT Sept 07 zin.indd 39 2007/09/11 10:28:49 AM

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�2 BULK HANDLING TODAY August 2010

CRUSHERS

right crushing equipment to achieve optimum end results cost effectively.

Before you buy…“Bulk Handling Today” speaks to Wirtgen’s managing director, Heinrich Schulenburg, at the company’s headquarters in Sebenza near Johannesburg. “We regularly get people who call up and ask for a crusher that is able to produce a certain tonnage per hour, but that’s not how you approach crushing,” he says. “The most important aspect to consider, long before purchasing a crusher, is the type of material you’re putting in and what the needs are

in terms of the output material. It could be shape or size, or both, depending on what the material will be used for.

“If, for example, you’re building roads you have specific size ranges and even different shapes for specific road coverings,” adds Heinrich. “Similarly, mining has its own requirements to arrive at spe-cific ore sizes as far as input and output sizes are concerned while the end-user, who may be making concrete, for example, has his or her own require-ments for different concrete mixes.”

Raw material characteristics“Choosing the right type of crusher, or combination

The most important aspect to consider, long before purchasing a crusher, is the type of material you’re putting in

A Kleemann crusher plant

of crushers, not only depends on what the customer wants do with the material as a final product, but also on the nature of the raw feed material,” adds Dave Newman, product specialist, crushing and screening, as he joins Heinrich. “Is it hard rock, is it abrasive or is it soft rock? All this has to be taken onto account. You wouldn’t use certain crushers for really hard rock, for example. Or, you might have to use a jaw crusher in combination with a cone crusher to achieve a specific require-ment. We match the crushing plant with what the customer has at source and with the end use of the final product.

“The crux is to use the right equipment to achieve the right size cost-effectively,” explains Dave. “It’s not a matter of sitting down and choosing a crusher from a catalogue. Considerable time is allocated to gather the information from the client, determine what type and combination of crushing technique, be it mobile, fixed or both, will give a specific end result. Each plant is meticulously customised to suit the requirement of each customer in a given situation. The rock on the north face of an open pit or quarry, for instance, could be very different from the rock on the south face in the same location.”

The rangeWirtgen’s range of crushers is made by Kleemann in dedicated crusher manufacturing factories in Germany and is well known for its top quality, the latest technology in machine control and some

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unique features. “We have four other product ranges in road building equipment and asphalt processing, but the Kleemann crushers are fairly new to South Africa and we’re systematically introducing them to the market now,” says Dave. “It’s a sophisticated design aimed at the professional market where precise results are important for the operator.

“The diverse range of crushers covers capacities from 210 to 1500 tonnes per hour and is available in mobile, portable or stationary configurations including screening and conveying systems,” adds Dave. “Crusher types cover the whole gamut, from jaw crushing to cone crushing, impact crushing as well as vertical shaft impact crushers in secondary, primary and tertiary crushing configurations.”

Special featuresThe Wirtgen crusher range has several unusual features. “Say you’re working out in the sticks and something goes wrong, you simply pop a sim-card into the control unit and dial up Kleemann in Europe and they can remotely diagnose what has gone wrong on your machine and advise what steps will fix it,” explains Heinrich. “If a part or circuitry is needed, they immediately notify the nearest supplier and delivery procedures are set in motion right away. This is absolutely necessary for today’s crusher machines which use a lot of electronics.”

“Kleemann was the first crusher manufacturer to introduce a pre-screening feature,” adds Dave. “This system, quite large in terms of surface area,

Each plant is meticulously customised to suit the requirement of each customer in a given situation

Crushers covers capacities from 210 to 1500 tonnes per hour and is available in mobile, portable or stationary configurations

removes the fines from the feed material going into the crusher which dramatically reduces wear on the wear plates. This in turn increases the throughput capacity because you’re taking the fines out of the feed which allows more of the plus-size to be fed into the flow of material.

Technology driven“The Kleemann company is technology driven so they’re continually coming up with new innova-tions to maintain their position as one of the top crusher manufacturers in the world,” Heinrich says in conclusion. “From Wirtgen’s side we aim to maintain this status in South Africa by having all the necessary spare and wear parts in stock at all times but a crusher is only as good as its operator. Therefore, we have an extensive training programme in place for customer operators.

“I’d like to challenge anyone out there to compare costs per tonne,” says Dave. “The Kleemann crushers use fuel efficient engines, unique screening features and they simply don’t break down which, unques-tionably, brings down the costs considerably.”

Heinrich Schulenburg, Wirtgen South Africa, Tel: (011) 452-1836, Email: [email protected], or Dave New-man, (011) 452-4886, E-mail: [email protected], Website: www.wirtgen.co.za

CRUSHERS

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Market ForumSampling theoryDeveloped by Multotec in collaboration with Dr D Francois-Bongarcon, the True-Belt Sampler’s design is based on existing go-belt technology, offers sampling theory compliance and ensures a truly representative sample.

Rolf Steinhaus, director of Multotec Process Equipment, says the upgraded design used for the True-Belt Sampler is based on an in-depth analysis of any bias triggered mechanisms.

The True-Belt Sampler design complies with international sampling standards and is suitable for conveyor belt widths from 450 mm to 2 400 mm. “In this further improved cross belt design, the material is sampled only after it has been removed from the belt in a manner that gives every fragment orginally on the belt the same probability of ultimte selection into the sample.”

It can be installed on horizontal or inclined conveyor belts with an angle of up to 18° and is designed to suit various troughing idlers. It is a direct drive unit with a geared brake motor and a dedicated brake controller panel and adjustable timer. Where applications dictate, a long and durable stainless steel or manganese steel sampler plough will be used.

Multotec Group, Bernadette Wilson, Tel: (011) 923 6193, Email: [email protected], www.multotec.com

Weighing silosSA Automation has completed the installation of a weigh-ing scale for a fibreglass silo at the Honeydew premises of Paintcor, for storing bulk emulsion. The main contractor, Cape-based Chaswill Process Technology, carried out the project for material supplier Servochem, to enable daily monitoring of material consumption.

The weighing system with indicator verifies the amount of material delivered and records how much is used on a daily basis. The rectangular platform supporting the fi-breglass hopper measures 2,5m x 2,5m. Three load cells are installed under the platform on base plates, fixed with chemical anchors. The platform is configured so that test weights can be applied up to 8 tonnes to check calibration up to 16 tonnes.

The SABS approved weighbridge indicator supplied is de-signed for high precision weighing applications. The Dux unit features a ratio-metric measurement technique and built-in transducer supply and the microcontroller-based analogue to digital conversion method, combined with automatic drift compensation, ensures a high accuracy and stability.

SA Automation Systems, Bill Krause, Tel: (011) 699 7900, Fax: (011) 699 7901

A diagram of the True Belt Sampler

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Market ForumLifetime warranty Control Instruments Automotive has announced a lifetime warranty on its range of Warn winches.

With every winch sold from the 1st July 2010, a WARN service and warranty booklet is provided that will capture the installer’s details as well as the service history of the winch.

“The most popular winch has a pulling capacity of 4 000 kg, with a remote control and cable as a standard feature. It is one of the fastest, under-load line retrieval winches on the market,” Leonard Chester, Warn product manager at Control Instruments Automotive says.

Other winches in the range include the Premium series that consist of winches in the range of 2 720kg, 3 630kg, 3 760kg, 4 000kg and 5 448kg.

The company also offers smaller winches that are ideal for small businesses. This particular range is available with a pulling capacity ranging from 772kg to 2 134kg.

Control Instruments Automotive, Leonard Chester, Tel: (011) 627-2500

Breeding the unethicalThe poor state of roads and unreasonable demands from some contractors means some operators have to set unre-alistic deadlines and poor maintenance precedents. Add to this, the fact that drivers can be forced to work through the night, are pushed to exceed the speed limit and often, turn

to alcohol, drugs and prostitutes. This behaviour, coupled with poorly maintained fleets, results in higher incidence of accidents.

To cope with this, some insurance com-panies have responded to the unethical behaviour with strict, complicated and wordy policies in place that make it easier for them to repudiate claims and make it difficult for operators to understand and meet their policy obligations.

Heavy Commercial Vehicle Underwrit-ers (HCV) tries to be different. With the industry positioning of “caring for trucks and truckers,” HCV aims to assist op-erators who are dedicated to improving their operations and behaviours. True to his brand’s positioning, MD Chris Barry introduced free driver training initiatives for policyholders’ drivers.

In addition, the underwriter collaborates with like-minded brands to educate police in identifying un-roadworthy vehicles. HCV has also simplified its policy wording to ensure that policyholders know what is expected of them. And the product range is specially designed to address the needs of trucks and truckers.

www.hcv.co.za

Resistant surfacesWearcon is a developer and manufacturer of several wear and corrosion resistant epoxy ceramic products, especially designed to offer maximum abrasion protection.

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�� BULK HANDLING TODAY August 2010

Market Forum

Losing productivity due to lagging?Conveyor belt slippage, poor traction, poor wear properties, inadequate water shedding and resultant high running costs and lower productivity are the nightmares which plague operators of conveyors.

Multotec’s Direct Bonded Ceramic Pulley Lagging has become the accepted solution for mining and industrial operations as a response to these recurring problems.

“Multotec’s locally manufactured studded ceramic pulley lagging is particularly effective in aggressive conditions, even on bucket elevators or where material is inevitably trapped between the pulley shell and the conveyor belt,” Faan Viljoen, technical director of Multotec Wear Linings, says.

“Ceramics have a longer life compared with traditional rubber pulley lagging where material is removed from both the rubber lagging and the rubber belt bottom cover when belt slippage occurs. A further benefit of direct bonded ceramic lagging is a significant extension of the useful pulley life.”

Traction is improved considerably, even under wet and slip-pery conditions. The insignificant ceramic wear rates will improve plant availability and reduce pulley and conveyor belt maintenance costs.

“While it is true that the ceramic material is slightly more costly than conventional rubber lagging, this is more than compensated for by its extended lifecycle of at least 20:1 compared to the usual expected life of rubber pulley lagging. This ultimately impacts very positively on the bottom line,” concludes Faan.

Multotec Group, Bernadette Wilson, Tel: (011) 923 6193, Email: [email protected], www.multotec.com

These modified epoxy ceramic linings contain sapphire hard alumina ceramic beads, which provide an abrasion resistant surface, designed to withstand the mining and industrial industry’s requirements. The surfaces are designed to con-trol wear, corrosion, abrasion and at the same time provide protection. According to the company, these linings would be best suited in water lines, slurry lines, sewer casings, feeder boxes, ducting fans, cyclones, hoppers, valve bodies and high-impact surfaces.

Wearcon also deals in the latest pipelining technology and is the inventor of the new ceramic diamond pulley lagging.

The company believes in the philosophy that in today’s competitive environment, companies in all industries must strive to get the best return on investment on all equipment used.

Wearcon has 15 years experience in the development and manufacturing sector and so, is committed to manufacturing and supplying high-quality products.

http://www.wearcon.co.za/

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BULK HANDLING TODAY August 2010 ��

Market Forum

A lengthy conveyerIn December 2009, a team from Zest and WEG successfully commissioned the longest VSD-driven conveyor in Africa for Anglo Thermal at the Zibulo Coal Mine near Witbank. The conveyor transports coal from Zibulo mine to the Phola coal processing plant.

“The conveyor system reduces the environmental impact while saving energy,” Chris Watkins, sales manager for drives and automation at Zest Electric Mo-tors, says.

The 16 km length of the conveyor belt and its 1750 tph carrying capacity presented numerous chal-lenges which the WEG design was able to resolve successfully.

“Due to the torque output from the 560 kW motor, it was extremely important to control torque lev-els and load-sharing between the different motors accurately,” says Chris.

The system has been operating smoothly and efficiently and will produce significant benefits over months and years to come,

The head end of the overland conveyor operated by four 560kW WEG VSD driven motors

furthermore, the new system will also reduce the operation’s carbon footprint and reduce dust.

Zest Electric Motors, Chris Chryssoulis, Tel: (011) 723 6000, Fax: (011) 723 6001, www.zest.co.za

Safe liftingDynasafe load limiting devices from Becker Engineering ensure that overhead cranes and lifting devices are operated safely within their working limits.

“Current legislation requires that overhead cranes must be fitted with a load limiting device,” says Charlotte Megannon, product manager, Becker Engineering. “The Dynasafe load limiter range, for intelligent monitoring and load limiting of lifting systems, consists of the Dynasafe Universal load limiter HF

32 series, which is a device that ensures overhead cranes and lifting devices are operated safely within their working load limits.

“These units, which are manufactured in accordance with CE specifications, connect directly into the UP function of

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�� BULK HANDLING TODAY August 2010

overhead cranes and hoists which have a dead-end wire rope,” she says.

A trip point provides a signal that the user may employ when he needs to limit loads in lifting systems, limit speed as a function of the load on traversing, or to limit the effort applied for pulling. This unit has a trip point power of 220 Vac/5A.

The operating principle is based on the use of microswitches which may be wired directly into the UP function of the lifting system. An ‘all-or-nothing’ signal detects movement within the elastic limits of specially treated steel, under the effect of an increasing load.

Because this unit may be set to automatically cut off at an exact point in an over-load situation, readings are consistently accurate. The HF series has no wearing parts, which extends the life of these machines and cable fatigue is eliminated because there is no steep angulation of the rope to the switch. As an added safety feature, the HF unit switch is based on a positive contact principle. The position of the adjustable pin sets the capacity range (between 250 kg and six tonnes) and the central universal fixing bracket is adapted to suit wire rope from 5mm - 26mm.

The effort applied through the wire rope deforms the body of the load cell, and, depending on the position of the adjust-able pin that sets the capacity range, gives a difference in the relative positions of the two sections. This results in a dependably precise reading.

The two units in this range - the HF 32/1 and HF 32/2 - have an IP40 index protection rating which means that dust and water cannot affect the performance of these machines.

Becker Engineering, Charlotte Megannon, Tel: (011) 617 6300, Email: [email protected], www.za.becker-mining.com

Market Forum

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The Dynasafe Universal load limiter HF 32 series ensures overhead cranes are operated safely

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Website: www.scaw.co.za

Haggie® Steel Wire Rope Products:• Double drum winder ropes• Koepe / Friction winder ropes• Shaft sinking ropes• Mine hoist ropes• Scraper and haulage ropes• Dragline and hoist- and drag-ropes• Face shovel ropes

Chain Products:• Round link welded chain and chain fittings in

grades 3 to grade 8 to national and international standards.

Cast Products:• Mantles and bowl liners• Mill liners• Rope sockets• Track shoes• Dragline parts• Ground engaging tools (GET)

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

The Scaw Metals Group (Scaw) is an international group, manufacturing a diverse range of steel products. Its principaloperations are located in South Africa, South America, Canada and Australia. Smaller operations are in Namibia, Zimbabweand Zambia. Scaw’s Specialist products manufactured for the shaft mining and surface mining industries include:

Haggie® Steel Wire Rope: Tel: +27 11 620-0000 • Fax:+27 11 620-0009

Chain Products: Tel: +27 16 428-6000 • Fax:+27 16 428-1212 / 1089

Eclipse East Foundry: Tel: +27 11 747-5000 • Fax:+27 11 421-4943

Cast Products: Tel: +27 11 749-3600 (GET) • Tel: +27 11 842-9303 (Other)

Fax:+27 11 421-8032 (GET) • Fax:+27 11 842-9710 (Other)

Scaw has produced these products for the mining industry since 1921 and is atechnological leader in this field and manufactures to national and internationalstandards.

Scaw provides a full range of customer support services. A team of qualifiedengineers with extensive experience in all aspects of steel wire ropes, chain andcast products are available to advise on the selection, handling, installation andmaintenance of products as well as provide on-site inspection of products andequipment.

Scaw supplies globally and also offers nationwide distribution in South Africathrough its strategically located branches throughout the country.

Fabf

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Gra

phic

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(011

) 622

-991

7

SCAW MINING/ECLIPSE ADVERT 27/2/09 10:24 Page 1

Page 39: BHT: Aug 2010

BULK HANDLING TODAY August 2010 ��Website: www.scaw.co.za

Haggie® Steel Wire Rope Products:• Double drum winder ropes• Koepe / Friction winder ropes• Shaft sinking ropes• Mine hoist ropes• Scraper and haulage ropes• Dragline and hoist- and drag-ropes• Face shovel ropes

Chain Products:• Round link welded chain and chain fittings in

grades 3 to grade 8 to national and international standards.

Cast Products:• Mantles and bowl liners• Mill liners• Rope sockets• Track shoes• Dragline parts• Ground engaging tools (GET)

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

The Scaw Metals Group (Scaw) is an international group, manufacturing a diverse range of steel products. Its principaloperations are located in South Africa, South America, Canada and Australia. Smaller operations are in Namibia, Zimbabweand Zambia. Scaw’s Specialist products manufactured for the shaft mining and surface mining industries include:

Haggie® Steel Wire Rope: Tel: +27 11 620-0000 • Fax:+27 11 620-0009

Chain Products: Tel: +27 16 428-6000 • Fax:+27 16 428-1212 / 1089

Eclipse East Foundry: Tel: +27 11 747-5000 • Fax:+27 11 421-4943

Cast Products: Tel: +27 11 749-3600 (GET) • Tel: +27 11 842-9303 (Other)

Fax:+27 11 421-8032 (GET) • Fax:+27 11 842-9710 (Other)

Scaw has produced these products for the mining industry since 1921 and is atechnological leader in this field and manufactures to national and internationalstandards.

Scaw provides a full range of customer support services. A team of qualifiedengineers with extensive experience in all aspects of steel wire ropes, chain andcast products are available to advise on the selection, handling, installation andmaintenance of products as well as provide on-site inspection of products andequipment.

Scaw supplies globally and also offers nationwide distribution in South Africathrough its strategically located branches throughout the country.

Fabf

orm

Gra

phic

s cc

(011

) 622

-991

7

SCAW MINING/ECLIPSE ADVERT 27/2/09 10:24 Page 1

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�0 BULK HANDLING TODAY August 2010

67678 Multotec A4 Industry Ad 6/17/10 8:52 AM Page 1

Composite

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