BHT-feb-2011

BULK HANDLING TODAY February 2011 1

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2 BULK HANDLING TODAY February 2011

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BULK HANDLING TODAY February 2011 �

February 2011

ContentsCover Story5 Part of the Process

Power Transmission7 Fabricating the BIG stuff11 Bearings With a Difference

Earthmoving & Plant Hire13 Three-pronged Approach15 Care Saves Money

Crushers, Screens, Chutes & Liners19 Unique Crushing Concept21 Huge Cost Savings

Freight23 Sustainable Approach to Freight in South Africa

Safety Equipment27 Establishing a Health and Safety Bench-mark in Richards Bay

31 Market Forum

Endorsing BodiesCMA (Conveyor Manufacturers Association)

LEEASA (Lifting Equipment Engineering Association of South Africa)

RFA (Road Freight Association)

SAIMechE (SA Institution of Mechanical Engineering)

SAIMH (SA Institute of Materials Handling)

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

Advertising Sales: Surita MarxDTP: Zinobia Docrat and Sean Bacher

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:BMG

Tel: (011) 620-1647 Email:

[email protected]

www.bmgworld.net

� BULK HANDLING TODAY February 2011

CONVEYOR MANUFACTURERS ASSOCIATION

From the Chairman’s Desk

Simon Curry

All members subscribe to the CMA Code of Ethics

CMA Members List as at February 2011

ABB IndustryAfripp ProjectsActomAtlanta ManufacturingBateman Engineered TechnologiesBauerBearings InternationalBelt RecoBMGBonfiglioli Power TransmissionsBosworthBrelko Conveyor ProductsCKIT Conveyor EngineersContinental Crushing & ConveyingConveyor WatchCMG Electric Motors South AfricaCPM EngineeringCPI TechnologiesCT SystemsDavid Brown Gear IndustriesDelras EngineeringDRA Mineral ProjectsDunlop Belting ProductsDymot Engineering CompanyELB Engineering ServicesFacet EngineeringFenner Conveyor Belting (South Africa)Flexible Steel Lacing SAHägglunds Drives South AfricaHansen Transmissions SAHosch - Fördertechnik (SA)Lesa Mining Equipment and Conveyor Belt

M & J EngineeringMartin EngineeringMelco Conveyor EquipmentMoret MiningMS Conveyor Pulleys SANepean ConveyorsOE BearingsOriental Rubber Industries SAOsborn Engineered ProductsPH Projects HoldingsRead Swatman & VoigtRema Tip Top South AfricaRenold CroftsRoymecRSV ENCO ConsultingRula Bulk Materials HandlingSandvik Materials Handling SASchaeffler South AfricaSecrivestSENETSET AgenciesSEW EurodriveShaft EngineeringShaw Almex AfricaSKF South AfricaThyssenKrupp Materials HandlingTransmission ComponentsTransvaal Rubber CompanyUnitek EngineersVeyance Technologies AfricaVoith TurboZest Electric Motors

Companies are expanding with the increase in work, people are on the move upwards to fill the shoes of elders who are retiring, and the CMA

is promoting the excellence of belt conveyors in a myriad of ways.

After the sad message last month that two of our members had had to be expelled for non-payment of subscriptions, I am happy to report that Belt Reco has been re-instated.

Technical mattersOn technical matters, SANS 968, the brand new “home-grown” national standard for solid woven conveyor belting is nearing the prescribed period of publication as a draft South African standard (DSS). SANS 968 will be available from the SABS sales office very shortly.

The idler specification SANS 1313 is not faring as well as it is still caught up in red tape at SABS. Parts 1 and 2 are being kept waiting for Part 3 to go through a second committee draft (CD) stage before publication as a DSS can take place. This whole process has been very protracted indeed, and I look forward to the day when SANS 1313’s publication can finally be announced.

Education projectsCMA education projects are also on the increase where the CMA is the umbrella body acting as custodian of standards being adhered to. Training courses in the standardisation of belt splicing are being considered as well as preliminary discussions taking place on establishing a beltsman training course. The ninth (4-11 April) training course in the design and operation of belt conveyors is now fully booked and a second course is scheduled for September.

Industry is looking forward to Beltcon 16, taking place on 3 and 4 August this year at Birchwood Conference Centre on the East Rand. It is good to note that the papers are coming in for technical peer review; the ex-hibition space is sold out; and there have been requests for registration already! For information on the conference please visit the website www.beltcon.org.za.

Simon Curry

Chairman

Reporting back from a vibrant members’ meeting and stimulated by the interesting interaction between our members that always follow these meetings is heady stuff

indeed. It is humbling and exciting to be a part of the general air of enthusiasm and high anticipation with which things are already happening in 2011.

The idler specification SANS 1313 is still caught up in red tape at SABS


COVER STORY

Now there is a solution for compa-nies experiencing this dilemma. Bearing Man Group (BMG), has just launched eight engineering

hubs throughout South Africa that will not only provide companies with the equipment and spare parts they require, but also with the engineering expertise

to ensure efficient and productive plant operation.

Engineering hubs“As part of our World Class Efficiency programme to partner with custom-ers to become part of their process, we’ve now established eight of a series of engineering hubs across the country,” Gavin Pelser, director of engineered products at BMG, tells “Bulk Handling Today” in an exclusive interview.

“This is a unique concept where, over the past two years, we’ve

systematically amalgamated the different engineering businesses in the company into one engineering division under which these hubs

now operate.

Full range“The services under this division include the supply, installation and repair of a full range of gearboxes and electric motors as well as a whole range of conveyor belting products, from small packaging conveyors right up to mining conveyors,” Gavin adds.

“Not only are these hubs placed at strategic cen-tres around the country, but each hub will have the strategic engineering expertise as well as the critical components that the industry in that area uses regularly.”

Customised to each areaIn order to carry this service off effectively, Gavin’s engineering teams managing the hubs liaised closely with the companies in each area to ensure that adequate stock and the right equipment is on hand to fulfil all the needs specific to the surrounding industries.

Each hub is a new BMG business located in its own premises regardless of whether there is already an existing BMG outlet in the same town. In Nelspruit, for instance, there now is an existing BMG outlet plus the engineering hub which will also service other existing outlets in the surrounding towns.

The commitment“When we changed the company branding we committed not only to the supply of quality components, superior service and technical expertise, but also to become part of the process,” says Gavin. “To do this, it was a logical step to establish the engineering hubs which can take care of absolutely everything for the customer. Therefore each hub has a full team of conveyor specialists who can go out to do splicing, installation and give advice on conveyor systems.

“Each hub will also have a repair and

Part of the ProcessThere is no argument that the dwindling engineering expertise in South Africa is hurting all industries. Com-panies are forking out more for machinery repairs and paying dearly in downtime costs while trying to coun-

ter this lack of expertise with large stockholdings of spares in case something goes wrong.

Gavin Pelser

Servicing a heat exchanger

The services under this division include the supply, installation and repeair of a full range of gearboxes and electricmotors



COVER STORY

new manufacturing facility for gearboxes,” Gavin continues. “This will consist of an area where the gearboxes come in, are washed, stripped and a quote for the repair is worked out before they go to the workshop for repair once the order is placed. This area also houses a manufacturing capability where brand new gearboxes are assembled from components in stock. Typically this stock would reflect the types of gearboxes used in the area. A hub in a mining area will stock different gearbox components from the hub in the heart of the sugar processing industry.

The peopleSimilarly, the technical staff at each hub are ex-perienced in the particular industries of the area. “They are mechanical engineering people who have experience in installations and have a thorough understanding of the customer’s processes,” says Gavin.

“These teams are managed by a REM, a regional engineering manager, who runs the hub as a business unit for each region. Besides the current hubs in Durban, Richards Bay, East London, Port Elizabeth, Cape Town, Kimberley, Johannesburg and Nelspruit, the immediate next three hubs will be set up in Sishen, Rustenburg and Tete in Mozambique.”

On siteApart from assisting customers with problem solving, design and installation, the hubs will be staffed with qualified condition monitoring special-ists. “Then there are the field service teams, the man-in-the-van, who ensure that we remain part of the customer’s process in line with our world class production efficiency programme,” says Gavin.

“These teams are involved in the customer’s process in terms of assessing the plant and suggesting ways and means of making the plant more efficient. Often it’s just a matter of changing out certain components in a system to use less electricity, while improving the customer’s overall productivity.”

Open daysTo introduce the concept to the industry, BMG has been staging open days at all the hubs so that customers can personally witness the extent of the stockholding as well as the engineering capabili-ties now available to them. “The response to the open days has been overwhelming,” Gavin says in conclusion.

“The visitors, running into hundreds at each of the open days, were amazed, not only at the extent of the workshops, but they were also very pleased that we carry stock of the components, or an exact equivalent, which they actually use on their plants.”

BMG Engineered Products, Gavin PelserTel: (011) 620-1647, Email: [email protected]

A gearbox coming off the assembly line at BMG’s new engineering hub in Johannesburg

High frequency welding is just one of the many technologies available at the engineering hubs

The engineering hubs which take care of absolutelyeverything for the customer


POWER TRANSMISSION

A company which specialises in large gear manufacture repair and reverse-engineering is Pylon Gears. To learn more “Bulk Handling Today” visits the company’s headquarters

in Tulisa Park, south of Johannesburg.

“Smaller gears, from 85mm to 3.5 meters, new or repaired, and general machining are done here in Johannesburg while larger gears up to 8.5 metre diameter girth gears are sent to our Heidelberg facility which also has a full fabrication workshop,” explains Justin Botha, sales and marketing. “In terms of refurbishing and repair, we’ll tackle any make and size Gearbox ranging from 250 kW to 9000 kW. Our Thor range of new gearboxes is designed in the same power range, but we’re constantly re-designing and adapting it to specific individual requirements,” he adds.

“Say a client has an obsolete or superseded gearbox and we have to provide a replacement gearbox, we

will custom design our gearbox in terms of size and footprint so that it will fit into place without hav-ing to make changes to the client’s installation,” explains Greg Perry, Chief Engineer at Pylon. “You don’t get spares for many of the older gearboxes which require us to reverse engineer and design parts to refurbish them. We’ll even design and manufacture a whole new one if nothing else fits. In most instances, we end up enhancing the design of the gearbox to improve performance.”

“Our range of gearboxes covers a wide spectrum of applications ranging from light to heavy duty conveyor drives, mixer and aeration plant drives, rotary kiln drives as well as all types of mill drives” explains Greg. “In the lifting industry we cater for cranes, hoists, lifts and winch drives while our solu-tion for mine winder gear has become well-known across the globe.”

The CompanyPylon Gears purchased the business of Vamco Steel & Engineering, giving the company the ideal opportunity to market their services internationally.

Fabricating the BIG stuffLarge machines like draglines, big mobile mining shovels, mills, drilling machines and mine winders all have

huge gears and equally huge gearboxes. To repair, overhaul, refurbish or rebuild gears and drives for these ma-chines therefore requires special engineering expertise, machinery and facilities.

Greg Perry

Justin Botha

Many older gearboxes require us to reverse engineer and design parts to refurbish them


POWER TRANSMISSION

“We’ve become known as the manufacturer of su-perior OEM-alternative replacement parts for rope shovels, draglines and drill rigs in addition to the complete under-carriage solutions we’ve developed over the years.” says Justin. “This includes crawler shoes and pin kits, drive tumblers, take-up idlers, shafts and blocks, propel shafts, pinions and bull gears, as well as lower rollers, pins, bushing and keepers.”

Mine winders“Just recently we refurbished a ASEA Koepe Winder Gearbox weighing over 30 tonnes to a local mining

A gear on the grinding machine Final touches on a gearbox before it goes out A gearbox on the assembly line in Pylon’s workshop

Just recently we refurbished a ASEA Koepe WinderGearbox weighing over 30 tonnes

group,” adds Greg. “One of the particular challenges came from enhancing the design of the Koepe winder gearbox. This is a gearbox that goes into an underground winder sub-station but it can’t be taken down as an assembled unit. It has to be broken down in sections and assembled on site underground. To make final assembly easier, we enhanced the design by fitting eccentric sleeves for all the bearings, allowing trouble-free final adjustments for a perfect contact pattern once the gearbox is re-assembled underground.

“In this case the gearbox is a spare and because we did not have to get involved in the installation, we had to ensure that final assembly would be op-timal in terms of alignment and contact patterns,” Justin adds. “We usually provide the client with a comprehensive installation procedure of a gearbox,

www.riocarb.co.za


Gear cutting is the main business here at Pylon

but in the case of an unusual enhancement like this, we also offer to help out on site to ensure they set it up correctly.”

Quality controlIn manufacturing high precision equipment such as large gearboxes, quality control is always a crucial factor and here, Pylon implements all industrial and on international standards includ-ing AGMA & DIN. We are fully ISO 9001:2000 compliant and have a dedicated inspection de-partment with certified and calibrated measuring equipment,” says Justin. “We’re also guided by a complete comprehensive workshop manual that ensures we live up to our outstanding reputa-tion for quality products recognised locally and internationally.”

In reverse engineering spare parts for gearboxes, one of the biggest challenges is to make them fully interchangeable with other existing parts. To assist the design engineers, Pylon makes use of a CMM (co-ordinate measuring machine) system that feeds measurements directly into design soft-ware programmes. “Especially on mills, you have to make sure that your design fits in with existing gear sets,” explains Greg. “The Stinger is a fully portable 3-dimensional measuring arm used to check the bores in a gearbox housing in terms of alignment and dimensions.”

Digital tracing“It is an absolute necessity for precise reverse en-gineering, literally allowing you to digitally ‘trace’ all the dimensions of a complex part,” Greg adds. “The dimensions are imported into our CAD draw-ings to ensure accurate consistency with existing dimensions.”

On our walk through the workshop, it becomes clear that gear cutting is the main business here, but we also find other sections where general fabrication of parts around the drive is in progress.

This includes footplates, simple base structures and support systems in order for the gearbox to fit into specific unique spaces in various applica-tions. “In most instances, clients have hold points for third party inspection on various products and gearbox repairs and then a test run is performed on each gearbox we’ve worked on,” Greg says in conclusion. “Finally a full test is carried out under no load conditions, usually also witnessed by the client or an independent inspector appointed by the client.”Pylon Gears, Justin Botha, Tel: (011) 613-6117, Email: [email protected]

In reverse engineering spare parts for gearboxes, one of the biggest challenges is to make them fully interchangeable

POWER TRANSMISSION

www.quadrantepp.com


Engineered around you

www.davidbrown.com

David Brown, with 150 years experience, has the engineering expertise and unrivalled customer service to offer bespoke geared solutions specifically for the mining industry.

Global manufacturing locations offering 24/7 service with effective repair and support services for all David Brown products and services.

Solutions tailored for the mining industry:On-site maintenance and inspection

Repairs, overhauls and upgrades

Condition monitoring

Consulting, failure analysis, and strain gaging

Spares

Replacement gearboxes

Products:Girth gears (up to 14m in diameter)

Pinions

Conveyor drives

Mill drives

Thickener drives

Agitator drives

Pump drives

South AfricaDavid Brown Gear Industries12 Birmingham StreetBenoni Industrial1500

Tel : +27 11 748 0000Fax : +27 11 421 2553E-mail : [email protected]: www.davidbrown.com

Quality, reliable solutions for the mining industry

www.davidbrown.com


POWER TRANSMISSION

A slew bearing is a rotational rolling-element bearing that typically supports a very heavy but slow-turning or slow-oscillating load, on either a horizontal, vertical or inclined

platform. A slew bearing can be anything from 300 millimetres to several metres in diameter. It is a cumbersome component to replace and there-fore manufactured, even for OEMs, by specialist manufacturers, not only for precision, but also to obtain a long and lasting life.

Specialised engineeringOne of the world’s leading slew bearing manufacturers is based in Meadowdale near Johannesburg. “Bulk

Bearings With a Difference

Most machines and structures that pivot on a base or require rotation in performing their duties , likestackers, reclaimers, draglines, ship loaders, excavators, cranes, wind turbines, thickeners, clarifiers, theme

park rides, radar equipment and radio telescope dishes, have a slew bearing facilitating the controlled turning, or slewing, of a platform in one form or another.

Handling Today” speaks to one of the directors of Titanus Slew Rings (TSR), Roberto Gaspari. “The business started as a general engineering concern back in 1975, but after doing the first slew bearing in the eighties, the owners soon recognised a niche in the market specifically for precision-made slew bearings and associated components,” he says. “Today the Titanus Slew Ring brand has become known internationally and 50% of our product is exported.”

Although generally called slew bearings, the prod-uct comes in a number of variations and different designs for a broad range of applications. “We’re geared to manufacture, repair or refurbish anything from 500 mm in diameter through to 6.5 metres,” explains Roberto. “Mining is a major industry for us, both on the materials handling side as well as on the processing front.”

Bulk materialshandlingTSR manufactures the slew bearings and slew rings for the large excavators used in the mining industry while stackers, reclaimers and ship loaders all have large slew bearings that have to be replaced or refurbished. Adds Roberto, “We also manufacture the original designs and consequently the spare parts, for most of the OEMs of this bulk material handling equip-ment.”

For mineral processing, all the big thickeners, clarifiers and mills have a slew bear-ing usually driven through a single or multiple pin-ion configuration creating the necessary high torque Specialised induction hardening of main gear

Repair or refurbish anything from 500 mm in diameter through to 6.5 metres

Engineered around you

www.davidbrown.com

David Brown, with 150 years experience, has the engineering expertise and unrivalled customer service to offer bespoke geared solutions specifically for the mining industry.

Global manufacturing locations offering 24/7 service with effective repair and support services for all David Brown products and services.

Solutions tailored for the mining industry:On-site maintenance and inspection

Repairs, overhauls and upgrades

Condition monitoring

Consulting, failure analysis, and strain gaging

Spares

Replacement gearboxes

Products:Girth gears (up to 14m in diameter)

Pinions

Conveyor drives

Mill drives

Thickener drives

Agitator drives

Pump drives

South AfricaDavid Brown Gear Industries12 Birmingham StreetBenoni Industrial1500

Tel : +27 11 748 0000Fax : +27 11 421 2553E-mail : [email protected]: www.davidbrown.com

Quality, reliable solutions for the mining industry


required to process the specific solution. These often have multiple gearboxes and pinions that drive the slew bearing to which the rakes for the mixing/agitating are attached.

In addition to mining, TSR serves many other industry sectors, including the astronomy industry. TSR is proud to have been involved with the supply of the slew bearings for the 7 prototype radio telescopes used in the prestigious Square Kilometre Array (SKA) Project. Another industry well served by TSR is the marine industry in the form of slew bearings for the thrusters which are used to position large ships and highly manoeuvrable tug boats. Marine cranes, both ship mounted and in harbours, all have slew bearing drives while large winches on special ships are used for laying cables or to control seismic probes that scan the seabed.

What is a slew bearing?A slew bearing often resembles a traditional ball bearing with balls or rollers segmented between two rings, however on a much larger scale and capable of withstanding significantly higher loads. “There are many different variations on the design of a slew bearing,” explains Roberto. “The traditional one is a four-point contact bearing in which balls facilitate the rotation of the slew bearing, but you get many other roller combinations such as double roller, triple roller design and combinations of each, all depending on the load and the applica-tion. Effectively the concept is the same as a small traditional bearing, but the rolling elements can go up to diameters of 100 mm.

“In the case of a geared bearing, which forms part of a drive system, the gears are cut either on the

inside or the outside of the slew ring and we usually also manufacture the matching pinions for these,” says Roberto. “The slew bearing is manufactured out of a seamless alloyed steel ring which we source in its raw form from a local supplier in sizes up to four metres in diameter, forged rings larger in diameter are imported from Europe.”

Design “Slew rings/bearings are designed to concurrently handle axial, radial and over-turning moment loads,” Roberto elaborates. “Static load and dynamic life-cycle calculations can be provided to confirm the bearing’s suitability for an application. Our standard slew bearings are fully interchangeable with existing slew bearings and, provided we have a part number, drawing or the old slew bearing available, we can manufacture the equivalent of any slew bearing. We can cost-effectively manufacture quantities as low as just one unit.”

Apart from slew gear manufacturing, the company also offers gear cutting, specialised induction hardening, large diameter CNC machining, large diameter CNC drilling and gear grinding services to the market in general. “We provide both external and internal gear cutting services for all pinions, main gears and girth gear requirements,” says Roberto.

Continuous improvement“We’re planning to move to bigger, specially designed facilities in the near future. For the immediate fu-ture, we’re increasing our machining and induction hardening capacity and will be commissioning a new 6m CNC vertical boring machine with integrated live spindle for CNC drilling. In addition to com-pliment our 2 existing induction hardening plants we will be commissioning a CNC 3 axis induction hardening plant”.

As in all gear manufacturing, the hardening of the gears is one of the most criti-cal factors to ensure a quality product. “We’ve become known as a leader in the supply of specialised induction hardening services,” concludes Roberto. “For many OEMs we’re the first-choice provider of induction hardening, especially complex components. We undertake the hardening of gears, pinions, sprockets, rail wheels, rid-ing rings, sheave wheels and have even done hoist drum rope grooves as you’d find in both the mining and marine industries.”

Contact: Roberto Gaspari, Titanus Slew Rings, Tel: (011) 974-7017, Email: [email protected], www.tsr.co.za

POWER TRANSMISSION

Typical application of large diameter slew bearings, bucket wheel reclaimer

As in all gear manufacturing, the hardening of the gears is one of the most critical factors to ensure a quality product

BULK HANDLING TODAY February 2011 1�

EARTHMOVING & PLANT HIRE

The two companies have a long and success-ful relationship offering financial services to customers in the heavy equipment market through WesBank’s specialised Bell Finance

Division. Therefore, when WesBank identified a need within the public sector, the bank was confident it would suit the business model of its partner, Bell Equipment as well as its new public sector division.

WesBank’s General Manager: Marketing and public sector divisions, Dr George Nyabadza explains that the bank’s public sector division is focused on ser-vicing the public sector and has trained staff who understand and appreciate the complex dynamics of the Public Sector. The Division, headed by Allick Jones, has ten regional heads and the support of WesBank’s extensive countrywide network. Gauteng is the primary hub but the overall focus cuts across all provinces and spheres of government, namely National, Provincial, Local Government, state-owned entities and other organs of the state.

Three-way partnership According to George, the Public Sector is highly legislated and therefore any transaction should

Three-pronged ApproachTo facilitate Government’s campaign to ‘buy local’, a South African original equipment manufacturer and

supplier and the country’s premier ‘wheels bank’, WesBank have created innovative financial service solutions to make heavy equipment more accessible to the public sector.

be handled with cognisance of the impact of the various pieces of legislation involving state tender procurement procedures.

“With our strong partnership with Bell Equipment we are able to assist the various government struc-tures needing earthmoving and material handling equipment in order to meet their service delivery mandates. Bell has the equipment expertise and we have the financial know-how necessary to form a three-way partnership when determining the needs of a customer in the public sector.”

In practiceAllick explains how this partnership works in practice using the example of how an innovative transaction was structured for the Sakhisize Local Municipality in the Eastern Cape. This municipality serves the towns of Cala and Elliott and needed a fleet of earthmoving equipment to maintain the almost 2 000km rural roads within its boundar-ies. Surplus funds obtained through the national government’s Municipal Infrastructure Grant (MIG) were sufficient to buy a grader and an excavator in cash. However, they also needed articulated dump trucks (ADTs), a compaction roller, a water cart, a dozer and a tractor-loader-backhoe (TLB).

Allick says, “By combining the expertise of Bell Equipment and WesBank, we used the municipality’s

allocated monies as a deposit and then structured a financial lease to cover the purchase of the full fleet of items that they required. In doing so we contributed significantly to easing the service delivery burden on this local municipality as we didn’t dip into cash reserves that would have affected cash flow and service delivery.”

Economical and efficientHe explains, “Bell Equipment brings to the mix, its own value proposition in the earthmoving equipment that it manufactures and markets. This is supported by the WesBank value proposition in structuring the finance in such a way that this provides the public sector with products and solutions which are economical and efficient.”

He believes that WesBank has the edge in financing, particularly heavy

(Back left): Terry Gillham (BESSA), Colin Squair (WesBank), Gerard Rokebrand (BESSA), Bok-kie Coertze (BESSA), Bridget Ledwaba (WesBank), Dr George Nyabadza (WesBank), Allick Jones (WesBank); (front left): Bruce Ndlela (BESSA) and Jurie Marais (Bell Finance)

Able to advise customers regarding their equipment needs before tenders are issued

1� BULK HANDLING TODAY February 2011

equipment. Therefore it would be advantageous for Bell Equipment and WesBank to be able to advise customers regarding their equip-ment needs before tenders are issued. In this way the government market would only buy what was really needed according using a financial basis that they can rightly afford.

Buy localThe financial innovations have the buy-in of Bell Equipment Sales South Africa (BESSA) management. BESSA managing director, Bokkie Coertze who says, “As a local manufacturer, we play an important role in the local economy in terms of creating decent jobs for South Africans and uplifting the families we support directly and indirectly. BESSA alone employs 512 people and it is estimated that 45 000 people benefit either directly from employment at Bell Equipment or our local suppliers. Government’s commitment to ‘buy local’ will help to sustain local manufacture, support the existing local job market and help to create future job opportunities.”

“BESSA also has BBBEE Level 4 status, which illustrates our com-mitment to transformation and is of benefit to our customers, who qualify for 100% of their purchases from BESSA as BEE procure-ment. This applies to the purchase of units, parts or service.

Bell Equipment, Tel: (035) 907-9111, Fax: (035) 797 4336, www.bellir.co.za


The Public Sector is highly legislated and therefore any transaction should be handled with cognisance

www.bearings.co.za

www.rema-tiptop.co.za



Even in the tough economic stretch the world has just gone through, where repair-ing equipment rather than

buying new should have been the order of the day, there has been gross neglect in terms of routine maintenance. Although the repair industry welcomes the resulting flood of work, there is the danger that a product can unfairly develop a bad name as a machine that doesn’t last.

Service regularlyCarl Morritt should know as he’s

involved in the highly specialised field of repairing all types of yellow metal machinery. “Bulk Handling Today” visits the workshop of CS Morritt in Kempton

Park, a company that’s been in the business for many years. “Regular routine maintenance could have prevented many of the repairs we encounter on a daily basis,” he says. “Also, there is a tendency to use machine operators who aren’t qualified to operate the machine, never mind taking care of the routine maintenance.

“Unfortunately our industry is riddled with chanc-ers and people often fall into the trap of using inexperienced mechanics who use pirate parts to do repairs, a costly exercise that often damages the machine even more than if the ‘repair’ had not been carried out in the first place,” adds Carl. “Maintenance and repair on earthmoving equipment is not like servicing a car, there’s a lot more to it and mechanics need to have a thorough understanding of hydraulics as well as electricals.”

Exchange systemApart from maintenance and repairs, both in the workshop and as a field service, CS Morritt is also in the business of supplying new, used and refurbished spare parts for heavy machinery. “The

Care Saves MoneyYellow metal equipment is a capital investment generating money for the owner. The longer the equipment

lasts, the bigger the benefit. Yet, many owners of earthmoving equipment fail to maintain their machines on a regular basis, effectively reducing their profits, and sometimes going so far as to run their machines merci-

lessly to destruction

Carl Morritt

The spare parts holding is for JCB earthmoving machinery

There is the danger that a product can unfairly develop a bad name as a machine that doesn’t last


www.rema-tiptop.co.za



majority of equipment suppliers have lost focus by concentrating on new equipment sales rather than the aftermarket,” says Carl. “Over the last two years, however, new equipment sales have dropped dramatically and most companies are now rebuilding instead of buying new.

“This prompted us to pull up our socks and up our game in terms of supplying spare parts as well as servicing machinery in the field,” Carl adds. “We’ll now go out on a regular basis and buy second-hand machines which we break down purely for spare parts. Many parts are good enough to sell second-hand and most other components can be refurbished to a mint condition. We now also have a component exchange system in place where we can exchange a gearbox, axle or any other critical component to keep the client going while we repair or refurbish the component in question.

Ship-shapeCarl’s main new spare parts holding is for JCB earthmoving machinery and Titan ground engaging tools which includes grader blades, cutting edges and bucket teeth. “In terms of services we cover all aspects on a machine by repairing, overhauling or refurbishing hydraulic cylinders, transmissions, engines and axles. The exchange programme has turned out to be a huge success and we intend gearing up to streamline this service to have a machine up and running again within a day. To this end, we’re busy building up various components to ensure there’s enough stock to cover all the popular models our regular clients use.”

CS Morritt’s client base stretches across all industries, from plant hire companies to con-struction companies and the mining industry. “We’re increasingly supplying parts up into Africa and have a growing local client base across the whole country,” Carl says. “For some of our long standing clients we carry out routine maintenance on a service contract basis to ensure that their machines remain ship-shape all the time.

Beware!As far as fly-by-night repair services are con-cerned, Carl has a stern warning for earthmoving equipment owners. “Many young mechanics work in the industry for a couple of months before they get a bakkie and a toolbox to go out on their own,” warns Carl in conclusion. “However, they simply don’t have the experi-ence, or financial backup, to guarantee the work they do and the owner is left with the problem in the end.

“Technicians are extremely scarce but remem-ber, a guy with a toolbox is not necessarily a mechanic, even if he says he is and especially

We’ll now go out on a regular basis and buy second-hand machines which we break down purely for spare parts

Axle refurbishment and repair is a big part of Carl’s business

A bucket refurbished

A hydraulic transmission set ready to be delivered

if his price is very attractive. Use reputable established companies to work on your machinery and make sure replacement parts are the real thing, even if they are second-hand.”

CS Morritt Consulting, Spares and Maintenance, Carl Morritt, Tel: (072) 614-7044, Cell: 082 490 6203, Email: [email protected]


August 3-4 2011, Johannesburg, South Africa

For registration and enquiries, contact Chris Townsend on the following details:

IMHC Organising CommitteeTel: +27 (0)11 888-7163/ +27 (0)11 782-3595Fax: 086 503-4524Email: [email protected]: www.beltcon.org.za

ORGANISED FOR THE INDUSTRY BY THE INDUSTRY

The programme, authors, paper synopses and general details can be accessed on www.beltcon.org.za

International Materials Handling Conference

Winning technology promoting the excellence of belt conveying.

The International Materials Handling Conference and Exhibition , Beltcon, is regarded as the lead-ing international conveyor event and takes place in Johannesburg, South Africa, on August 3-4, 2011.

This conference has been held every two years over the last thirty two years! It has earned a well-deserved reputation as the reference point for information sharing, discussion of new devel-opments in the industry and the latest in design, research and case studies presented by world renowned academics and leaders in the field of belt conveying. Delegates attending the confer-ence are eligible for credits in ECSA’s Continuous Professional Development.

Only papers that contain new and unpublished material and that meet stringent quality standards are presented. These review new technological developments in the bulk solids and materials handling industry, offer fresh insights into the problems and solutions encountered by manufac-turers, suppliers and end-users, spark questions and discussion, and generally stimulate progress in belt conveying.

www.beltcon.org.za


CRUSHERS, SCREENS, CHUTES & LINERS

S imunye Crushing in Boksburg has come up with a solution that not only solves the problem of transporting and erecting crush-ing plants, but also processing plants. It’s a

pre-constructed modular system which fits into a structure the exact same size as a standard container, complete with all the fittings necessary to transport it. In fact, to the untrained eye, it would appear just like a container on the back of a truck.

Containerised“Bulk Handling Today” meets with Mike McNeil, director of Simunye, to talk about this unique concept which has taken off like wild fire in the mining industry. “The entire crushing plant is built into the container frame, pre-wired and tested prior to shipping it to site where it is literally plugged in and started up,” he says. “In this way we can build up an entire mining plant, section by section, such as the primary crusher, secondary crusher and processing plant which are all housed in separate containers but which can be linked to each other to form one complete processing plant.”

“We’ve just completed such a system for one of our first clients in the coal industry,” says direc-tor, André Olivier. “As an agent for McLanahan coal crushers in the USA, this particular project gave us the opportunity to develop a modular system specifically for coal crushing. Just like the other systems we’ve developed over the years for diamond, aggregate, ferro- chrome and other min-

ing applications, each system is customised to a specific requirement.”

Park & OperateThe container, built by Simunye, is a solid steel structure manufactured in the standard six, nine or twelve metres. “It has the same locking pins in position as a cargo container and therefore is simply lifted up onto a standard container transporter and taken to site as a complete working unit,” explains Mike. “Everything in the container; feeder, crusher, conveyors and screens is pre-wired and fully op-erational when it leaves our workshop.”

This principle is used throughout for all the crusher, processing and power supply plants built by Simunye. “It’s only when we have extra long conveyors that need to be stacked to link several units together to make up one large plant, that we have to construct some of the conveyor structures on site,” says Mike. “A large percentage of the plants we build are exported to countries like DRC, Botswana, Abidjan, Ivory Coast and we’ve even done a modular plant for Australia.”

Brainchild“The concept is Mike’s brainchild that came into being during the eight years we’ve been building crusher systems,” says André. “The product is entirely South African except for some types of crushers, like the special coal crusher, which is imported. In some instances we’ve even built our own crusher by reverse engineering a particular type to suit a specific application. For example, Mike used the hammer mill principle to come up with a crusher that produces sand.

“In another instance we took a basic Chinese crusher

Unique CrushingConcept

Designing and building a plant for mining up in Africa has challenges of its own, not only in terms of the plant itself, but also as far as logistics are concerned. Firstly, the plant has to be sent to site, then it has to be erected miles away from civilisation where you’d be lucky to find a hardware store selling nuts and bolts,

never mind the engineering facilities to make you one.

Mike McNeilAndré Olivier

Everything in the container; feeder,crusher, conveyors and screens is pre-wired and fully operational when it leaves our workshop


design and modified it to handle Vanadium at a temperature of 800ºC,” Mike adds. “We changed the lubrication to oil and by fitting a water cooler through which the oil is continuously circulated to all the bearings, we could maintain an even temperature even though the material coming into the crusher was so hot.

“In yet another instance we saved the day for a diamond mining operation where diamonds were being damaged in the crusher,” continues Mike. “We fitted a water flush system that adds the same volume of water as material into the crusher which helps to flush the small diamonds out before they stand a chance of getting damaged.”

How it worksSimunye’s range of modular crusher units has not officially been given a name yet, but it’s more than likely to be called the SimPro range consisting of crusher units, processing units and even a power supply unit constructed to fir into a container as well. “Typically a complete plant put together with a series of containers will consist of a primary crushing unit first,” explains Mike. “From the bin you’ll have a feeder with a by-pass for small mate-rial before bigger lumps go into the jaw crusher. The stream out of the crusher will join the bypass material before going onto a screen prior to going to a secondary crusher.

“A conveyor carries the material to a second con-tainer housing the secondary crusher unit which

will have one or two cone crushers or granulators. The stream out of this unit will go to a screening module that separates the various sizes. From there it goes to a processing module that contains any combination of jigging equipment, spirals and shak-ing tables to finally produce the mineral. A large plant will typically have a fifth container module containing the electrical and control system for the entire plant.”

The current representation of Simunyes’ vibratory equipment stands at about 100 units in Africa. “Our best reference, however, is on our doorstep,” says André. “At Lyttleton Dolomite, just outside Supersport Park in Centurion, there are a total of 13 pieces of our equipment in operation including three 600x1300 vibrating feeders and four 1830 x 4880 double deck vibrating screens. We will gladly accompany anyone interested to this plant to show them the quality of the workmanship and the production achieved by our equipment.”

The futureJudging by the number of installations of this modular system around the world, this clever con-cept is set to grow rapidly, not only because of its mobility, but also because it makes expansion of a plant so much easier and quicker. “Customising each unit for a specific location and application is a bit more work, but in the end we know we’re supplying a system that works for that particular instance,” Mike says in conclusion. “There’s no doubt that the concept will grow even more in the future which is right up our alley, we thrive on the challenges the industry throws our way.”

Simunye Crushing, Mike McNeil or André Olivier Tel (011) 918-5997, Email: [email protected]

The concept is set to grow, not ony because of its mobil-ity, but also because it makes plant expansion easier



The conveyor is fitted with a 1.05 metre wide steel reinforced belt which is fed at a 90° angle by short conveyors from the four crusher

storage bins. The belt, which transports approximately 1 900 tph of primary crushed run of mine ore, is scanned by X-Ray three to four times per annum to determine its condition. An analysis of the severe dam-age experienced on the reinforcing cables indicated that the problem was probably caused by large lumps of ore falling onto the belt from the first or second of the cross conveyors.

ImpressiveIn order to minimise any further damage, a decision was taken by Palabora Mining Company to test a Weba Chute system on the first transfer point in January 2008. The results were so impressive that it was then decided to install another Weba system on the second chute in December 2008, to cater for instances where the first cross conveyor is not operational.

To determine the effectiveness of the Weba transfer points in protecting the belt, the annual average replacement costs for the belts from 2006 to 2008 were calculated at 2009 prices. Then a combination of the cost of belting from the date of installation up to the calculation date with an estimate for the remainder of that year was calculated. The results indicated a substantial saving on belting costs alone.

Main reasonIf one then considers the additional pro-duction gained through less downtime and the direct savings on fewer splices being made; and the cost of other materials and labour, that amount could quite readily be increased by at least a further 50%.

Interestingly, the belt is so much more durable that the deterioration of the splices has now become the main reason for

Huge Cost Savings Two chutes installed on Palabora Mining Company’s 1.3 kilometre long inclined conveyor have saved the

company a substantial amount in belt costs alone.

stoppages, so action is being taken to improve the quality of the splices in future to alleviate this, while saving for the mine mount year on year.

M & J Engineering (Pty) Ltd, MarkBaller, Tel: (011) 827 9372Fax: ( 011) 827 6132, Website: www.weba.co.za

One of the Weba Chutes underground at PMC

The belt is so much more durable that the dete-rioration of the splices has now become the main reason for stoppages


www.engineerplacements.com


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FREIGHT

Sustainable Approach to Freight in South Africa

logistics costs. This can generally be attributed to the large distances between typical origins and destinations and the cost of fuel. South Africa re-quires more transport per unit of commodity than most countries in the world (CSIR. 2008). Almost two thirds of road transport costs are attributable

to fuel expenses and 29% of freight transport cost is exposed to external factors beyond the transport operator’s control (CSIR, 2008).

Externalities affecting freight transport include congestion, accidents and weather. The afford-ability of freight transport is highly exposed and vulnerable to external factors, placing a ques-tion mark behind the freight system’s economic sustainability.

Inter-modalOwnership of infrastructure plays a significant role in the success and growth of the industry. The fact that various infrastructure is privately owned, or owned by Transnet, prohibits cohe-sion, limiting the systemic operational improve-ments that can be achieved. A lack of proper inter-modal facilities between ports, roads and rails, is the main inhibiting factor for growth in containerised traffic.

For instance, Transnet’s responsibility for port planning and management deters private sector investment and has resulted in a situation where several ports are badly in need of further rede-velopment, investment and modernisation, but are limited by the provision of capital under the control of central government. Common transport development plans and policies-and adherence thereto-are required to avoid micromanagement inhibiting growth in the entire system.

Below parSouth Africa is below par when compared with international freight transport best practice. This is due to insufficient equipment, technology and

“Bulk Handling Today” recently attended the Launch of the CSIR’s “Sustainable Transport + Mobility Hand-book.” The section on freight is reproduced here for the benefit of readers.

A lack of proper inter-modal facilities between ports, roads and rails, is the main inhibiting factor for growth in containerised traffic

E conomic sustainabilityFreight transport supports the South African economy, as it constituted more than 8% of South Africa’s gross domestic

product in 2007. Compared with a world average of 39%, transport made up 53% of the country’s


www.afzelia.co.za


facilities. Rail transport equipment (locomotives, wagons, signalling equipment and rail tracks) in general are old and outdated, necessitating much of the nation’s rail rolling stock to need replace-ment soon.

As a result of poor wagon fleet renewal practice, old rail wagons with reduces payloads exist in substantial numbers, limiting the railways’ ability to carry extra tonnage. In addition the rail lines are narrow gauge, which limits their efficient carrying capacity even further. An updated and overhaul of all freight equipment, technology and facilities is needed to improve sustainability.

Environmental sustainabilityIn terms of the non-renewable resources, South African freight transport is highly unsustainable. All roads, water and air freight, as well as about 10% of rail transport, is powered by (non-renewable) fossil fuel. The state of affairs heavily exposed the country to oil supply risks or disruptions, as road transport is by far the dominant mode in the country.

Only pipeline transport and 90% of rail transport is electrified. Though electrified transport allows for the electricity to be generated from renewable resources (such as hydropower or wind), the domi-nant feedstock for electricity generation in South Africa is coal (which is another unsustainable, non-renewable resource).

Substantial damageWith regards to emissions, oil- and coal-powered freight is not ideal. It is, however, beneficial to use electricity as opposed to liquid fuels, because the associated emission can be confined to remote locations and are not necessarily generated at the transport location.

Uneven modal distribution in favour of road trans-port has caused substantial damage to infrastructure in South Africa. The previous Minister of transport, Jeff Radebe, announced in September 2007 that the country faced a R17 billion deficit to road maintenance over the following five years, relating to nearly 15% of the national road network.

There is talk of restricting the size and maximum loads of vehicles in rural roads in an attempt to stop this trend. While this might solve their infrastructure problem temporarily, trucks are at their most efficient when fully loaded. Large vehicles and load com-binations have positive

effects on fuel consump-tion and emissions, but these potential gains will not be attainable should the size restriction come into effect.

Social sustainabilityModal selection is nor-mally based on the type of commodity and its as-sociated transportation requirements. Not all commodities are suitable for transportation on all modes. Factors that could influence the number of potential modes include the mode’s delivery speed, availability, accessibility, inter-modal connections and flexibility, capacity, safety, reliability and cost. This limits the scope of mode selection.

Poor historic monetary policy in South Africa has led to disputes between various transport modes

regarding equity in recovery of infrastructure pro-vision, management, operation and maintenance cost. “The […] situation frequently prejudice South African road transport operators in particular and land freight in general.” (DOT, 1996).

Road over railAdvantages of road freight over rail include: ac-cessibility (many places are only accessible by motor vehicles), competition (resulting improved

Tanya Lane

There is talk of restricting the size and maximum loads of vehicles in rural roads

FREIGHT


service, reliability, operations, equipment and competitive pricing) and no perceived need for cross-subsidisation. It is not surprising that land transportation (road and rail) accounts for more than 90% of total transport, with road enjoying 66% of market share.

Inter-modal interchange facilities (of which there are presently very few in South Africa) can facilitate the use of the most appropriate and environmentally friendly transport for different parts of a journey, for example using rail for long distance and trucks for local travel.

Fatal crashesIn terms of safety, 9.97% of the vehicles involved in fatal crashes in 2004 were trucks per 10 000 vehicles. This is mainly due to the extent at which trucks are used annually (number of vehicles miles travelled). A major contributing factor to the cause of truck related accidents is the age and maintenance levels of trucks. The average age of a truck is 12 years. Improved maintenance and regulations should make these old trucks less accident prone.

Driver fatigue is another major cause of trucking accidents. Shifting some of the road transport to

Trucks have the third highest number of vehicle crashes

FREIGHT

the modes of transport should, therefore, improve road safety in South Africa. South Africa is a country severely afflicted by HIV/Aids. The illness is especially prevalent among truck drivers and the transfer of HIV/Aids and sexually transmitted infections is a growing concern in the transport industry. Truck stops can be an important part of the strategy to protect truck drivers against these and other illnesses and provide information on the risks (www.arrivealive.co.za). Human health is also affected by poor air quality associated with transport emissions. Air quality and emissions standards can combat these effects.

ConclusionSouth African freight is generally not considered sustainable, at present. A move towards modal integration and a more equal modal distribution will go along way to improve system sustainability. Environmentally speaking, stepping away from non-renewable resources and introducing fuel and vehicle emissions standards should be a priority.

The impact of current monopolies on the freight system should be carefully monitored, provoking government action to mitigate negative effects where possible. As with most sustainability initiatives, government has to show strong leadership to elicit buy-in from all stakeholders in the industry.

www.thyssenkrupp-materialshandling.co.za


SAFETY EQUIPMENT

Chairman of the CITC, Franz Schmidt, says that a large number of multinationals oper-ate in the Richards Bay area

and that these companies need to have contractors trained to the same standard as their own permanent employees.

“In the past, many contractors who came onto site had little or no exposure to the industry, as well as the necessary Safety, Health and Environment (SHE) training. A uniform base from which to do generic SHE training was identified by the CITC as being the means by which to alleviate the problems being faced with contractors,” explains Franz.

Having identified a strong need from the various multinationals in the area for a uniform base from which to do generic SHE training, Richards Bay Minerals (RBM) spearheaded a request through the CEO Forum of the Zululand Chamber of Com-merce and Industry (ZCCI) for a dedicated training facility.

Franz says that the CITC was founded to mandate this request by establishing this training facility and overseeing the ongoing activities thereafter.

The Richards Bay National Ports Authority, Mondi Kraft, Richards Bay Minerals, BHP Bayside Alu-minium, BHP Hillside Aluminium, Bell Equipment, Richards Bay Coal Terminals and Ticor SA (now Exxaro KZN Sands) were all founding members of the CITC. Each participating member is required to

Establishing a Health and Safety Benchmark

in Richards Bay

Since its establishment as a health and safety (H&S) advisory body in Richards Bay in 2002, the Centralised Induction Training Committee (CITC) has managed to set industry benchmarks with

regards to managing the process and standard of H&S training of contractor workers.

Andre at the Riski Diski launch

Left To Right: Andre Arendse, Lizette Kruger, Sian Thurtell and Norman Hartman

The means by which to alleviate the problems being faced with contractors


Diarise!

nominate representa-tives to speak on be-half of their company on the CITC steering committee.

“It was decided that CITC members’ con-tractors should be in-ducted on a bi-annual basis at a centralised training centre,” ex-plains Richards Bay Minerals CITC rep-resentative, Hendrik McCarthy.

“KBC was identified as being the best-suited candidate to start up a project of this nature and as a result was successful in obtaining the tender. Since then, the contract has come up for tender every three years – with KBC successfully retaining the contract on each occasion,” says Franz.

With the guidance of the CITC, KBC set up a centralised con-tractor induction training centre that addresses generic safety training to: effectively eliminate a full day of training for any contractor who has already received this generic training; reduce duplication of training; and to set minimum standards for all SHE training required by all CITC members.

With regards to training material, CITC members indicated the

KBC Health and Safety Managing Director Graham Emmett

Effectively eliminate a full day of training for any contractor that has already received this generic training

SAFETY EQUIPMENT

Health and Safety inspires people to change their mindsets around safety issues in the workplace

www.lmi-academy.co.za

www.silvera.co.za


content and scope of the material to be covered, which KBC developed in line with these requirements.

The following courses are presented at the centralised training facility as a minimum safety requirement for employment at CITC members sites: Industrial Surface Level 1 (for employees not in supervisory/ management roles); Administrators Course Level 1 (for admin staff who will not access site); Supervisors Level 2; and Legal Liability (for employers, managers and people responsible for health and safety on site).

The CITC’s partnership with KBC is enabling fair and consistent access to affordable quality SHE training to ensure the Health and Safety of all contractors and other employees.

Quality Control Training modules are reviewed and updated at a regular basis to comply with changes in legislation. In addition, KBC is au-dited six times a year by the CITC member companies, thus ensuring a high standard with regards services and products supplied by KBC.

“The audits check a number of items in terms of service provision, but also comprise CITC member company specific issues. In this process continual improvement in safety training is managed. The CITC then provides KBC with feedback on training statistics, adequacy of training materials and trainers, and specific safety related issues,” says KBC Business Unit Leader for Richards Bay Barbara Moscicki.

KBC Health and Safety, Lizette Kruger, Tel: (011) 675 3722 Email: [email protected]

Running the huge risk of being held liable forinjuries

SAFETY EQUIPMENT

Richards Bay

www.transmission.co.za

�0 BULK HANDLING TODAY February 2011 Advanced Materials Today September 2007 39

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

www.animalsindistress.org.za

BULK HANDLING TODAY February 2011 �1

Market Forum

A major force in material handling FLSmidth recently acquired the majority ownership of Roymec (Pty) Limited, located north of Johannesburg, South Africa. Since its establishment in 1979, Roymec has supplied min-ing infrastructure including bulk material handling solutions. Its products include plant and overland conveyors, waste spreader systems, stockyard systems, run-of-mine tips, rail load-out stations, crushing and screening, as well as mate-rial handling services.

FLSmidth Roymec will be integrated into FLSmidth’s present South African organisation increasing the total workforce to around 400 people. This enhanced local setup will provide a strong basis for handling the growing activities in the region with resources-related investment expected to increase in the coming years.

“FLSmidth Roymec is now in the enviable position where we have access to a global range of equipment and technical capabilities to complement our local project execution ability, while retaining our B-BBEE credentials. This underlines our one source strategy and permits us to further strengthen our position as a leading regional bulk materials handling solutions provider,” managing director Peter Lohrmann comments.

FLSmidth Roymec, [email protected], Tel: (011) 210-4000, Fax: (011) 210-4050

Helps with expansionBateman Engineered Technologies (BET) Specialised Handling Division is supplying a further five Bateman Redler chain conveyors and elevators to Willowton Oil and Cake Mills’ Isando factory, building on a 40-year business relationship. “The order for the extra five machines brings the total op-erating equipment in that plant to 74,” says Peter Cheshire of Bateman’s Specialised Handling Division.

Willowton Oils Johannesburg based oil extraction plant (be-ing one of three in the country) known as Isando Foods, is one of South Africa’s biggest producers of cooking oil from sunflower seeds. This particular order covers the handling of sunflower husk from the decorticating machines to the storage area or directly to burn in the boilers, any husks superfluous to Isando’s needs are transported off site for sale as cheap fuel or poultry bedding. The additional equipment comprises Bateman Redler chain conveyors and elevators to convey the sunflower husks at rates of between 7 and 10 t/hour.

Bateman Redler Bucket Elevators are commonly used in the brewing and food industries as their robust design enables slow running for minimum wear and product degradation, and they offer high capacities exceeding 1 000 t/h.

Bateman Redler En-masse Conveyors convey particulate solids cleanly, gently and economically by inducing the material to move like a liquid through dust-tight casings. This action ensures minimal product degradation, while the dust tight casings protect the conveyed material and the environment from mutual contamination.

Bateman Engineered Technologies, Peter Cheshire, Tel: (011) 201.2300, Email: [email protected]

Conveyors in operation from previous installations at Isando Foods

Most advancedClyde Bergemann Africa successfully concluded a contract with Eskom for fly ash handling at Eskom’s Kusile power station. The power station is currently being built by Eskom near Delmas in Mpumalanga.

The order is worth around R350 million and Clyde Bergemann Africa will be responsible for the design; supply; construc-tion and commissioning of the fly ash handling system. This includes the removal of fly ash from the bag houses to the storage silos and thereafter conditioning of fly ash onto overland conveyor belts.

Advanced Materials Today September 2007 39

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�2 BULK HANDLING TODAY February 2011

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BULK HANDLING TODAY February 2011 ��

Market Forum

In October 2009, the company was awarded the contract for the same scope of work at Eskom’s Medupi Power Sta-tion, and the work is progressing on schedule. The holding company in Germany (Clyde Bergemann Power Group) was awarded the contract to supply Sootblowers for Medupi and Kusile through Hitachi, who are responsible for building the boilers.

Early in November, the African company was also contracted to do the complete design, supply and commissioning of a new Dust Handling Plant for Units 4 – 6 at Matla Power Station. The value of this contract is around $13.9 million (R95 million)

After Medupi, Kusile Power Station is the most advanced coal-fired plant project in Eskom. When completed, the power station will have six boilers each powering an 800 MW turbine, producing 4800 MW of power, thus making it one of the biggest coal-fired power stations in the world when fully commissioned.

“This great success in South Africa confirms our market strategy to be close to local customers with a global organisation and excellent products and technologies. Booking these projects un-derpins a business devel-opment where, after some market restraints, we see stronger bookings kicking in now worldwide.” states Franz Bartels, President & CEO of Clyde Bergemann Power Group.

Clyde Bergemann Africa (Pty) Ltd, Jeremy Kirsch, Tel: (011) 704-0580, Fax: (011) 704-0597, Email: [email protected]

Idler aligner A new conveyor idler aligner featuring a safe and effective method to manually fine tune OEM-style self-adjusting idlers has been introduced by Martin Engineering. The Martin Idler Aligner ensures precise adjust-ment, using a handle and comb for course modification, with slots for finer tuning. Proper align-ment is an extremely important factor in a conveyor system, as a misaligned belt can cause uneven wear, belt / structure damage and material spillage.

The aligner bracket mounts to most manufacturers’ self-align-ing idlers, allowing for broad application. To improve safety, the design eliminates the need to

tie off idlers to the surrounding structure, and the locking bar features a hole for padlock placement to restrict access and handle movement. The slotted comb on the new idler provides a range of incremental adjustment settings (±7.5°) to ensure consistent performance. The handle can also be allowed to float freely on top of the locking bar to provide course adjustments of ±2.5°.

The Martin Idler Aligner installs quickly and easily — a one-person job requiring no measuring, cutting or heavy lifting — allowing workers to safely and conveniently make manual adjustments to fine tune the idler from outside of the stringer. The new design is also available in stainless steel construction.

Martin Engineering USA, Rick Felde, Email: [email protected], Web site: www.martin-eng.com

�� BULK HANDLING TODAY February 2011

Market ForumSlow and sluggishToday’s Cat machines are faster, more powerful, and easier to operate thanks to technological advancements in their hydraulic designs. But maximizing this performance depends on strict contamination control, which is why customers are making Caterpillar’s CHS (or Custom Hydraulic Service) part of their overall maintenance programme.

“In essence, CHS enables customer to maintain peak hydraulic system performance and catch problems be-fore they turn into costly repairs,” explains Paul Ver-wey, a group products specialist at Barloworld Equ i p -ment. “In fact, long before contaminants cause component failure, they slowly reduce system efficiency, which has a tremendous impact on machine productivity.” (Barloworld Equipment is the Caterpillar dealer in southern Africa.)

Consider this: controlled studies have shown that without a monitoring mechanism in place, hydraulic efficiency can fall off by as much as 20% before being detected by even the best operators,” Paul continues. “Efficiency losses of

Caterpillar’s Custom Hy-draulic Service ensures that machines perform at their optimum levels.

this magnitude can equate to a day of lost production each week. They also cause machines to burn more fuel and shorten component life.”

CHS inspections should be performed twice a year or every 1 000 hours. The inspection service is comprehensive and

typically entails a range of performance tests. The latter include hydraulic cylinder drift, and hydraulic

system cycle times and pressures.

Barloworld Equipment, Paul Verwey, Tel: (011) 929-0000, E-mail: [email protected]

www.rsa.voithturbo.com


Market ForumAwareness campaign In the last two decades, counterfeiting in general has grown substantially globally. While there has been much reporting about consumers being taken advantage of by counterfeits in music, film, home electronics and designer clothing, a far greater risk lies in industrial counterfeiting of items such as tires, seals and bearings. Many of these products are safety-critical and fake versions may pose a real threat.

To raise the awareness about this the World Bearing As-sociation (WBA) has launched a campaign to inform about potential safety hazards arising from counterfeit bearings.

“Our initiative is aimed at sensitising the public on the dangers associated with counterfeits,” says James W. Griffith, WBA president. “The WBA is thus intensifying its anti-counterfeit-ing initiatives – that means information for customers on the one hand and consistent prosecution of offenders through the competent authorities on the other.”

“The fight against counterfeiting is not only about protecting the SKF brand but also about protecting our customers and the public from a potentially serious safety risk. Customers are being cheated into paying for a genuine product but are supplied with a fake alternative. Being a part of the World Bearing Association campaign is a way to further reinforce our commitment to fight this illegal activ-ity,” says Tom Johnstone, SKF President and CEO.

Counterfeiting violates trademarks. Be-cause counterfeits look like and are marketed like genuine branded prod-ucts, it usually takes a trained expert to identify them.

SKF South Africa (Pty) Ltd, Samantha Joubert, Tel: (011) 821-3500, Fax: (011) 821-3501, Email: [email protected], Web: www.skf.co.za

New coal stockyardThyssenKrupp Materials Handling (TKMH) secured the tender to supply coal handling equipment to feed the new 4 800 MW Medupi Power Station built by Eskom Holdings Ltd. in Lephalale, Limpopo province.

The tender calls for the supply of two off luffing slewing stackers and two off bi-directional drum reclaimers, each with a 43.5m rail width, to handle the coal stockpiles with respective handling capacities of 4000 tonnes /hr and 3 400 tonnes /hr.

According to TKMH marketing manager, Willie Agenbag, these two drum reclaimers will be the largest to be manufactured and supplied by TKMH in South Africa. He adds that older generation TAS 43.5m rail large drum reclaimers have been operating successfully at a coal plant in Kazahkstan for many years.

Fuel injection servicesFuel injection services are becoming ever more specialised as technology develops to higher levels of sophistication to comply with stringent new emission legislation. Increasingly Original Equipment Manufacturers (OEMs) turn to special-ists such as Reef Fuel Injection Services to enable them to comply.

“It is not only the OEMs who are upping their trade with us,” Warren Hauser, workshop manager at Reef Fuel Injec-tion Services, says. “We are seeing significant growth in our traditional markets as well – the transportation, construction and mining sectors, and in fact, all companies with large fleets – because of the level of specialisation required. At Reef, we not only have the advanced equipment necessary to meet rigorous demands, but above all, the highly skilled and qualified personnel, the streamlined processes and ef-ficiencies that guarantee exceptional customer service.”

The Bosch 815 test bench at RFIS

Market ForumReef Fuel Injection Services is one of the limited number of Bosch-appointed EDC (electronic diesel control) service centres in South Africa, and also boasts Denso, Delphi and Standyne accreditation for fuel injection components. “These accreditations bear testimony to the fact that we possess the necessary skills, expertise and technological prowess to satisfy customers fully,” Hauser points out. As one of the best equipped service and repair facilities in the country, the company has an established reputation as a Cat specialist. All test equipment is checked and maintained to SABS 0166 and ISO 9002 standards.

Reef’s rapid collection and delivery service further speeds up the process. Hauser believes that it is this extraordinary efficiency and attention to specific customer needs which sets Reef Fuel Injection Services apart in the market.

Reef Fuel Injection Services, Warren Hauser, Tel: (011) 873 2354


with a generator and compressor as well as having containers to carry hundreds of litres of lubricating oil. Gerhard says that the used oil is also stored in the unit for transporting back to the dealership’s bulk used oil store as part of its environmental initiatives.

“Today customers require not only flexible servicing hours – including weekends and nights – but also the option of having servicing done on site, hence the acquisition of the mobile unit,” he adds.

“This mobile service unit is critical to providing the required levels of service to the fleet of 10 Hino 700 Series trucks now operating from Blinkwater Mills’ facility in Nelspruit.”

Hino Division, Ignatius Muthien, Tel: (011) 809-2064/2255, Fax: (011) 809-9064, Email: [email protected]

Market ForumTKMH will supply all relevant stockyard conveyors and transfer houses, hoppers and feeders and will also be responsible for associated civil works. Willie points out that all the equip-ment will be locally designed by TKMH and manufacture will also be done locally.

“The coal stockyard demands a turnkey offering,” explains Willie “and we are responsible for an end-to-end service including design, supply, commissioning and hand over”.

ThyssenKrupp Materials Handling, Willie Agenbag, Tel: (011) 236-1000, Email: [email protected], Web: www.thys-senkrupp-materialshandling.co.za

Flexible servicing options “Providing flexible servicing options is now a critical com-ponent in ensuring customer satisfaction – particularly with operators of extra-heavy duty trucks,” says the dealer principal of Hino Middelburg, Gerhard Kotze, which is why a large mobile servicing support vehicle has been built for the dealership.

The well-equipped unit, based on a long-wheelbase Hino 300 Series 611 chassis-cab, was constructed by Maximus Bodies in Alrode, who previously built a similar type of unit for Hino Honeydew. A custom-built trailer will be hitched to the Hino to carry service parts. The mobile unit is equipped

Market Forum

www.skf.co.za


Moving the earth Tlhago Boswa, which primarily focuses on major earth-moving projects for mining operations in the North West province, purchased a Hyundai HL770 wheel loader from HPE Africa in November to complement its existing range of Hyundai HL780 and HL760 wheel loaders, which were purchased from HPE Africa earlier in the year.

Director Alan McGill points out that Tlhago Boswa places a high emphasis on quick turnaround times when choosing suppliers, and that the level of service received from HPE Africa - the sole distributor of Hyundai earthmoving equip-ment in Southern Africa - has exceeded all expectations.

Positive feedback Melco Conveyor Equipment South Africa has sold and installed 72 motorised pulleys into various South African industries since introducing the motorized pulleys two years ago.

“There has been positive feedback from all of our clients, which is evidence of the benefits being gained from the product.

Motorized Pulleys save space because they are compact, have low noise levels and save energy. Being lighter and concentrically mounted, the support structure required is leaner” says Melco motorized pulley product manager Julian Steinmann.

Some examples include:

Project engineering house, TWP, which installed a 500H – 1200 RL – 18.5kW motorised pulley for use at the Black Rock manganese mine and Roymec which installed a 630H - 1700 RL – 37kW motorised pulley for coal-mining giant Anglo Coal. If the motorised pulley had not been installed, the conveyor gantry would have had to be considerably upgraded to be able to carry external drive components cantilevered

Market Forum

“After selecting HPE Africa, I have been happy with the excellent standard of service that has been delivered,” ex-plains Alan. “HPE Africa’s sales staff are always on-hand to offer support and advice, which is important to us. What’s more, the delivery time of the machinery has been quick and hassle-free.”

Tlhago Boswa also purchased two Hyundai R305LC-7 excavators – with a powerful operating weight of 29,4 tons and a bucket capacity of 2 m3- from HPE Africa in July and October2010 respectively.

HPE Africa , Kirsty Denholm, Tel: (011) 397 4670, Fax: (011) 307 4683, Email: [email protected] , Web: www.hpeafrica.co.za

on the side. The case demonstrates the advantage of the entire drive being concentrically loaded on the conveyor gantry” states Julian.

Melco Conveyor Equipment (Pty) Ltd, Julian Steinmann, Tel: (011) 825 3520, Email: [email protected]

Market Forum


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Source of prideHansen Transmissions South Africa has secured an order from Sishen Kumba Iron Ore for the supply of large conveyor drives for overland conveyors as well as for conveyors feeding bedding and blending plant, at Sishen.

This order comprises three ‘R’ and three ‘L’ drive units car-rying an approximately value of R9.5 million. The ‘R’ size units, QHRR3 CTN 31.5:1, with a 2660kW AGMA rating, have a special installed 720kW motor and the 1370kW AGMA rated ‘L’ size units, QHRL3 CTN 25:1, are supplied with a special installed motor of 600kW.”

According to Clive Dicks, Hansen Transmissions Sales Man-ager, the three 600kW drives for the overland conveyors are interchangeable between all 13 conveyor positions with only a slight difference between the belt lengths and tonnage per hour. “The three 720kW drives are on the conveyor which has a horizontal belt length of 504m, and which feeds the bedding and blending plant where it moves product at a rate of 8000t/h,” explains Clive and adds, “Although we supplied a standard Hansen gearbox, some on site modifications were necessary in order to accommodate the upgrade.

“Repeat orders are always a particular source of pride and is regarded as proof positive of our customers’ faith and confidence in not only our superior product range, but also in our exemplary service support and customer relations management,” comments Clive.

Hansen Transmissions SA, Fritz Fourie, Tel: (011) 397-2495, Fax: (011) 397 2585, Email: [email protected], Web: www.hansen.co.za

Thirty years and still going strongRio-Carb is celebrating its 30th anniversary this year, a mile-stone that Rio-Carb founder and director, Martin Maine is very proud to have achieved.

“The biggest challenge over the past 30 years has been changing the traditional mindsets in the mining industry towards abrasion control and resistance. Chromium Carbide has amazing properties in terms of abrasion applications, and over the years our clients have seen the benefits time and time again,” he explains.

A major driving force behind the company’s continued suc-cess is Rio-Carb’s MaxCS™ process, which ensures maximum carbide saturation - the key to long wear life. By using the latest technology and digital controls, Rio-Carb is now able to accurately monitor and add the exact amount of Chromium Alloys to the welding area. The selection of raw materials and the precise use of essential additives also assists the forming of these compacted Carbides. This has resulted in MaxCS ™- Maximum Carbide Saturation - which assures clients the longest life of all Chromium Carbide Wear-Plates.

‘Innovate, Trust and Service’ has been Rio-Carb’s motto over the years, and it is what drives the company today. “Progressive thinking and Innovation is at the heart of every-thing that we do. At the end of the day, we don’t just offer products, but long-term solutions that allow our clients to ‘Fit and Forget’,” concludes Maine.

Rio-Carb. Tel: 011 908 1014, Email: [email protected], Web: www.riocarb.co.za

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�0 BULK HANDLING TODAY February 2011

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BHT-feb-2011