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From the Chairman’s Desk 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.
C
ompanies are expanding with the Technical matters
increase in work, people are on the On technical matters, SANS 968, the brand new
move upwards to fill the shoes of “home-grown” national standard for solid woven
elders who are retiring, and the CMA conveyor belting is nearing the prescribed period
is promoting the excellence of belt conveyors of publication as a draft South African standard
in a myriad of ways. (DSS). SANS 968 will be available from the SABS
After the sad message last month that two sales office very shortly.
of our members had had to be expelled for The idler specification SANS 1313 is
non-payment of subscriptions, I am happy to
Simon Curry report that Belt Reco has been re-instated.
still caught up in red tape at SABS
N
ow there is a solution for compa- Full range
nies experiencing this dilemma. “The services under this division include the supply,
Bearing Man Group (BMG), has installation and repair of a full range of gearboxes
just launched eight engineering and electric motors as well as a whole range of
hubs throughout South Africa that will conveyor belting products, from small packaging
not only provide companies with the conveyors right up to mining conveyors,” Gavin
equipment and spare parts they require, adds.
but also with the engineering expertise
to ensure efficient and productive plant
operation. The services under this division include
the supply, installation and repeair of a
Engineering hubs full range of gearboxes and electric
“As part of our World Class Efficiency
programme to partner with custom- motors
ers to become part of their process,
we’ve now established eight of a “Not only are these hubs placed at strategic cen-
series of engineering hubs across tres around the country, but each hub will have
the country,” Gavin Pelser, director the strategic engineering expertise as well as the
of engineered products at BMG, critical components that the industry in that area
tells “Bulk Handling Today” in uses regularly.”
an exclusive interview.
Customised to each area
“This is a unique concept where, In order to carry this service off effectively, Gavin’s
over the past two years, we’ve engineering teams managing the hubs liaised closely
systematically amalgamated the with the companies in each area to ensure that
different engineering businesses in adequate stock and the right equipment is on hand
the company into one engineering to fulfil all the needs specific to the surrounding
division under which these hubs industries.
now operate.
Gavin Pelser 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.
Justin Botha
Greg Perry
A
company which specialises in large gear will custom design our gearbox in terms of size and
manufacture repair and reverse-engineering footprint so that it will fit into place without hav-
is Pylon Gears. To learn more “Bulk Handling ing to make changes to the client’s installation,”
Today” visits the company’s headquarters explains Greg Perry, Chief Engineer at Pylon. “You
in Tulisa Park, south of Johannesburg. don’t get spares for many of the older gearboxes
which require us to reverse engineer and design
Many older gearboxes require us to reverse engineer and parts to refurbish them. We’ll even design and
design parts to refurbish them manufacture a whole new one if nothing else fits.
In most instances, we end up enhancing the design
“Smaller gears, from 85mm to 3.5 meters, new or
of the gearbox to improve performance.”
repaired, and general machining are done here in
Johannesburg while larger gears up to 8.5 metre “Our range of gearboxes covers a wide spectrum
diameter girth gears are sent to our Heidelberg of applications ranging from light to heavy duty
facility which also has a full fabrication workshop,” conveyor drives, mixer and aeration plant drives,
explains Justin Botha, sales and marketing. “In terms rotary kiln drives as well as all types of mill drives”
of refurbishing and repair, we’ll tackle any make explains Greg. “In the lifting industry we cater for
and size Gearbox ranging from 250 kW to 9000 cranes, hoists, lifts and winch drives while our solu-
kW. Our Thor range of new gearboxes is designed tion for mine winder gear has become well-known
in the same power range, but we’re constantly across the globe.”
re-designing and adapting it to specific individual
The Company
requirements,” he adds.
Pylon Gears purchased the business of Vamco
“Say a client has an obsolete or superseded gearbox Steel & Engineering, giving the company the ideal
and we have to provide a replacement gearbox, we opportunity to market their services internationally.
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
“We’ve become known as the manufacturer of su- group,” adds Greg. “One of the particular challenges
perior OEM-alternative replacement parts for rope came from enhancing the design of the Koepe
shovels, draglines and drill rigs in addition to the winder gearbox. This is a gearbox that goes into
complete under-carriage solutions we’ve developed an underground winder sub-station but it can’t
over the years.” says Justin. “This includes crawler be taken down as an assembled unit. It has to be
shoes and pin kits, drive tumblers, take-up idlers, broken down in sections and assembled on site
shafts and blocks, propel shafts, pinions and bull underground. To make final assembly easier, we
gears, as well as lower rollers, pins, bushing and enhanced the design by fitting eccentric sleeves
keepers.” for all the bearings, allowing trouble-free final
adjustments for a perfect contact pattern once the
Just recently we refurbished a ASEA Koepe Winder gearbox is re-assembled underground.
Gearbox weighing over 30 tonnes
“In this case the gearbox is a spare and because
we did not have to get involved in the installation,
Mine winders we had to ensure that final assembly would be op-
“Just recently we refurbished a ASEA Koepe Winder timal in terms of alignment and contact patterns,”
Gearbox weighing over 30 tonnes to a local mining Justin adds. “We usually provide the client with a
comprehensive installation procedure of a gearbox,
www.davidbrown.com
David Brown, with 150 years experience, has the engineering expertise and Solutions tailored for the mining industry:
unrivalled customer service to offer bespoke geared solutions specifically for the rOn-site maintenance and inspection
mining industry. rRepairs, overhauls and upgrades
Global manufacturing locations offering 24/7 service with effective repair and rCondition monitoring
support services for all David Brown products and services. rConsulting, failure analysis, and strain gaging
rSpares
South Africa rReplacement gearboxes
David Brown Gear Industries
Products:
12 Birmingham Street
Benoni Industrial
rGirth gears (up to 14m in diameter)
1500
rPinions
rConveyor drives
Tel : +27 11 748 0000 rMill drives
Fax : +27 11 421 2553 rThickener drives
E-mail : salesSA@davidbrown.com rAgitator drives
website: www.davidbrown.com rPump drives
Bearings With
a Difference
Most machines and structures that pivot on a base or require rotation in performing their duties , like
stackers, 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.
A
slew bearing is a rotational rolling-element Handling Today” speaks to one of the directors of
bearing that typically supports a very heavy Titanus Slew Rings (TSR), Roberto Gaspari. “The
but slow-turning or slow-oscillating load, business started as a general engineering concern
on either a horizontal, vertical or inclined back in 1975, but after doing the first slew bearing
platform. A slew bearing can be anything from in the eighties, the owners soon recognised a niche
300 millimetres to several metres in diameter. It in the market specifically for precision-made slew
is a cumbersome component to replace and there- bearings and associated components,” he says.
fore manufactured, even for OEMs, by specialist “Today the Titanus Slew Ring brand has become
manufacturers, not only for precision, but also to known internationally and 50% of our product is
obtain a long and lasting life. exported.”
Although generally called slew bearings, the prod-
Repair or refurbish anything from 500 mm in diameter uct comes in a number of variations and different
through to 6.5 metres 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,”
Specialised engineering explains Roberto. “Mining is a major industry for
One of the world’s leading slew bearing manufacturers us, both on the materials handling side as well as
is based in Meadowdale near Johannesburg. “Bulk on the processing front.”
Bulk materials
handling
TSR 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
Specialised induction hardening of main gear the necessary high torque
required to process the specific solution. These inside or the outside of the slew ring and we usually
often have multiple gearboxes and pinions that also manufacture the matching pinions for these,”
drive the slew bearing to which the rakes for the says Roberto. “The slew bearing is manufactured
mixing/agitating are attached. out of a seamless alloyed steel ring which we source
In addition to mining, TSR serves many other industry in its raw form from a local supplier in sizes up
sectors, including the astronomy industry. TSR is to four metres in diameter, forged rings larger in
proud to have been involved with the supply of the diameter are imported from Europe.”
slew bearings for the 7 prototype radio telescopes Design
used in the prestigious Square Kilometre Array “Slew rings/bearings are designed to concurrently
(SKA) Project. Another industry well served by TSR handle axial, radial and over-turning moment loads,”
is the marine industry in the form of slew bearings Roberto elaborates. “Static load and dynamic life-
for the thrusters which are used to position large cycle calculations can be provided to confirm the
ships and highly manoeuvrable tug boats. Marine bearing’s suitability for an application. Our standard
cranes, both ship mounted and in harbours, all slew bearings are fully interchangeable with existing
have slew bearing drives while large winches on slew bearings and, provided we have a part number,
special ships are used for laying cables or to control drawing or the old slew bearing available, we can
seismic probes that scan the seabed. manufacture the equivalent of any slew bearing.
We can cost-effectively manufacture quantities as
As in all gear manufacturing, the hardening of the gears low as just one unit.”
is one of the most critical factors to ensure a quality
Apart from slew gear manufacturing, the company
product
also offers gear cutting, specialised induction
hardening, large diameter CNC machining, large
What is a slew bearing? diameter CNC drilling and gear grinding services to
A slew bearing often resembles a traditional ball
the market in general. “We provide both external
bearing with balls or rollers segmented between two
and internal gear cutting services for all pinions,
rings, however on a much larger scale and capable
main gears and girth gear requirements,” says
of withstanding significantly higher loads. “There
Roberto.
are many different variations on the design of a
slew bearing,” explains Roberto. “The traditional Continuous improvement
one is a four-point contact bearing in which balls “We’re planning to move to bigger, specially designed
facilitate the rotation of the slew bearing, but you facilities in the near future. For the immediate fu-
get many other roller combinations such as double ture, we’re increasing our machining and induction
roller, triple roller design and combinations of hardening capacity and will be commissioning a new
each, all depending on the load and the applica- 6m CNC vertical boring machine with integrated
tion. Effectively the concept is the same as a small live spindle for CNC drilling. In addition to com-
traditional bearing, but the rolling elements can go pliment our 2 existing induction hardening plants
up to diameters of 100 mm. we will be commissioning a CNC 3 axis induction
hardening plant”.
“In the case of a geared bearing, which forms part
of a drive system, the gears are cut either on the 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: sales@tsr.co.za, www.tsr.
co.za
Typical application of large diameter slew bearings, bucket wheel reclaimer
Three-pronged Approach
To 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.
T
he two companies have a long and success- be handled with cognisance of the impact of the
ful relationship offering financial services to various pieces of legislation involving state tender
customers in the heavy equipment market procurement procedures.
through WesBank’s specialised Bell Finance
“With our strong partnership with Bell Equipment
Division. Therefore, when WesBank identified
we are able to assist the various government struc-
a need within the public sector, the bank was
tures needing earthmoving and material handling
confident it would suit the business model of its
equipment in order to meet their service delivery
partner, Bell Equipment as well as its new public
mandates. Bell has the equipment expertise and
sector division.
we have the financial know-how necessary to form
Able to advise customers regarding their equipment a three-way partnership when determining the
needs before tenders are issued needs of a customer in the public sector.”
In practice
WesBank’s General Manager: Marketing and public Allick explains how this partnership works in
sector divisions, Dr George Nyabadza explains that practice using the example of how an innovative
the bank’s public sector division is focused on ser- transaction was structured for the Sakhisize Local
vicing the public sector and has trained staff who Municipality in the Eastern Cape. This municipality
understand and appreciate the complex dynamics serves the towns of Cala and Elliott and needed
of the Public Sector. The Division, headed by Allick a fleet of earthmoving equipment to maintain the
Jones, has ten regional heads and the support of almost 2 000km rural roads within its boundar-
WesBank’s extensive countrywide network. Gauteng ies. Surplus funds obtained through the national
is the primary hub but the overall focus cuts across government’s Municipal Infrastructure Grant (MIG)
all provinces and spheres of government, namely were sufficient to buy a grader and an excavator in
National, Provincial, Local Government, state-owned cash. However, they also needed articulated dump
entities and other organs of the state. trucks (ADTs), a compaction roller, a water cart, a
dozer and a tractor-loader-backhoe (TLB).
Three-way partnership
Allick says, “By combining the expertise of Bell
According to George, the Public Sector is highly
Equipment and WesBank, we used the municipality’s
legislated and therefore any transaction should
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 efficient
He 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.”
(Back left): Terry Gillham (BESSA), Colin Squair (WesBank), Gerard Rokebrand (BESSA), Bok- He believes that WesBank has the
kie Coertze (BESSA), Bridget Ledwaba (WesBank), Dr George Nyabadza (WesBank), Allick
edge in financing, particularly heavy
Jones (WesBank); (front left): Bruce Ndlela (BESSA) and Jurie Marais (Bell Finance)
Buy local
The 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
E
ven in the tough economic Park, a company that’s been in the business for
stretch the world has just many years. “Regular routine maintenance could
gone through, where repair- have prevented many of the repairs we encounter
ing equipment rather than on a daily basis,” he says. “Also, there is a tendency
buying new should have been the to use machine operators who aren’t qualified to
order of the day, there has been operate the machine, never mind taking care of
gross neglect in terms of routine the routine maintenance.
maintenance. Although the repair “Unfortunately our industry is riddled with chanc-
industry welcomes the resulting ers and people often fall into the trap of using
flood of work, there is the danger inexperienced mechanics who use pirate parts to
that a product can unfairly develop do repairs, a costly exercise that often damages
a bad name as a machine that the machine even more than if the ‘repair’ had
doesn’t last. not been carried out in the first place,” adds Carl.
Service regularly “Maintenance and repair on earthmoving equipment
Carl Morritt should know as he’s is not like servicing a car, there’s a lot more to it and
Carl Morritt mechanics need to have a thorough understanding
involved in the highly specialised field of repairing
all types of yellow metal machinery. “Bulk Handling of hydraulics as well as electricals.”
Today” visits the workshop of CS Morritt in Kempton Exchange system
Apart from maintenance and repairs, both in the
There is the danger that a product can unfairly develop a workshop and as a field service, CS Morritt is
bad name as a machine that doesn’t last also in the business of supplying new, used and
refurbished spare parts for heavy machinery. “The
Ship-shape
Carl’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 A hydraulic transmission set ready to be delivered
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- A bucket refurbished
cerned, Carl has a stern warning for earthmoving
equipment owners. “Many young mechanics if his price is very attractive. Use reputable established
work in the industry for a couple of months companies to work on your machinery and make sure
before they get a bakkie and a toolbox to go replacement parts are the real thing, even if they are
out on their own,” warns Carl in conclusion. second-hand.”
“However, they simply don’t have the experi-
ence, or financial backup, to guarantee the We’ll now go out on a regular basis and buy second-hand
work they do and the owner is left with the machines which we break down purely for spare parts
problem in the end.
“Technicians are extremely scarce but remem- CS Morritt Consulting, Spares and Maintenance, Carl Morritt,
ber, a guy with a toolbox is not necessarily a Tel: (072) 614-7044, Cell: 082 490 6203, Email: csmorritt@
mechanic, even if he says he is and especially gmail.com
Winning technology promoting the excellence of The programme, authors, paper synopses and
belt conveying. general details can be accessed on www.beltcon.
The International Materials Handling Conference org.za
and Exhibition , Beltcon, is regarded as the lead-
ing international conveyor event and takes place
in Johannesburg, South Africa, on August 3-4,
For registration and enquiries, contact Chris
2011.
Townsend on the following details:
This conference has been held every two years
over the last thirty two years! It has earned a IMHC Organising Committee
well-deserved reputation as the reference point Tel: +27 (0)11 888-7163/
for information sharing, discussion of new devel- +27 (0)11 782-3595
opments in the industry and the latest in design, Fax: 086 503-4524
research and case studies presented by world Email: ctr@beltcon.org.za
renowned academics and leaders in the field of Web: www.beltcon.org.za
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.
Unique Crushing
Concept
André Olivier Mike McNeil
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.
S
imunye Crushing in Boksburg has come ing applications, each system is customised to a
up with a solution that not only solves the specific requirement.”
problem of transporting and erecting crush- Park & Operate
ing plants, but also processing plants. It’s a The container, built by Simunye, is a solid steel
pre-constructed modular system which fits into a structure manufactured in the standard six, nine
structure the exact same size as a standard container, or twelve metres. “It has the same locking pins in
complete with all the fittings necessary to transport position as a cargo container and therefore is simply
it. In fact, to the untrained eye, it would appear lifted up onto a standard container transporter and
just like a container on the back of a truck. taken to site as a complete working unit,” explains
Mike. “Everything in the container; feeder, crusher,
Everything in the container; feeder,crusher, conveyors conveyors and screens is pre-wired and fully op-
and screens is pre-wired and fully operational when it erational when it leaves our workshop.”
leaves our workshop This principle is used throughout for all the
crusher, processing and power supply plants built
Containerised
by Simunye. “It’s only when we have extra long
“Bulk Handling Today” meets with Mike McNeil,
conveyors that need to be stacked to link several
director of Simunye, to talk about this unique
units together to make up one large plant, that we
concept which has taken off like wild fire in the
have to construct some of the conveyor structures
mining industry. “The entire crushing plant is built
on site,” says Mike. “A large percentage of the
into the container frame, pre-wired and tested prior
plants we build are exported to countries like DRC,
to shipping it to site where it is literally plugged
Botswana, Abidjan, Ivory Coast and we’ve even
in and started up,” he says. “In this way we can
done a modular plant for Australia.”
build up an entire mining plant, section by section,
such as the primary crusher, secondary crusher and Brainchild
processing plant which are all housed in separate “The concept is Mike’s brainchild that came into
containers but which can be linked to each other being during the eight years we’ve been building
to form one complete processing plant.” crusher systems,” says André. “The product is
“We’ve just completed such a system for one of entirely South African except for some types of
our first clients in the coal industry,” says direc- crushers, like the special coal crusher, which is
tor, André Olivier. “As an agent for McLanahan imported. In some instances we’ve even built our
coal crushers in the USA, this particular project own crusher by reverse engineering a particular
gave us the opportunity to develop a modular type to suit a specific application. For example,
system specifically for coal crushing. Just like the Mike used the hammer mill principle to come up
other systems we’ve developed over the years for with a crusher that produces sand.
diamond, aggregate, ferro- chrome and other min- “In another instance we took a basic Chinese crusher
design and modified it to handle Vanadium at a will have one or two cone crushers or granulators.
temperature of 800ºC,” Mike adds. “We changed The stream out of this unit will go to a screening
the lubrication to oil and by fitting a water cooler module that separates the various sizes. From there
through which the oil is continuously circulated it goes to a processing module that contains any
to all the bearings, we could maintain an even combination of jigging equipment, spirals and shak-
temperature even though the material coming into ing tables to finally produce the mineral. A large
the crusher was so hot. plant will typically have a fifth container module
“In yet another instance we saved the day for a containing the electrical and control system for
diamond mining operation where diamonds were the entire plant.”
being damaged in the crusher,” continues Mike. The current representation of Simunyes’ vibratory
“We fitted a water flush system that adds the same equipment stands at about 100 units in Africa.
volume of water as material into the crusher which “Our best reference, however, is on our doorstep,”
helps to flush the small diamonds out before they says André. “At Lyttleton Dolomite, just outside
stand a chance of getting damaged.” Supersport Park in Centurion, there are a total of
13 pieces of our equipment in operation including
The concept is set to grow, not ony because of its mobil- three 600x1300 vibrating feeders and four 1830
ity, but also because it makes plant expansion easier x 4880 double deck vibrating screens. We will
gladly accompany anyone interested to this plant
to show them the quality of the workmanship and
How it works the production achieved by our equipment.”
Simunye’s range of modular crusher units has not
The future
officially been given a name yet, but it’s more than
Judging by the number of installations of this
likely to be called the SimPro range consisting of
modular system around the world, this clever con-
crusher units, processing units and even a power
cept is set to grow rapidly, not only because of its
supply unit constructed to fir into a container as
mobility, but also because it makes expansion of
well. “Typically a complete plant put together with
a plant so much easier and quicker. “Customising
a series of containers will consist of a primary
each unit for a specific location and application
crushing unit first,” explains Mike. “From the bin
is a bit more work, but in the end we know we’re
you’ll have a feeder with a by-pass for small mate-
supplying a system that works for that particular
rial before bigger lumps go into the jaw crusher.
instance,” Mike says in conclusion. “There’s no
The stream out of the crusher will join the bypass
doubt that the concept will grow even more in the
material before going onto a screen prior to going
future which is right up our alley, we thrive on the
to a secondary crusher.
challenges the industry throws our way.”
“A conveyor carries the material to a second con- Simunye Crushing, Mike McNeil or André Olivier
tainer housing the secondary crusher unit which Tel (011) 918-5997, Email: mikem@simunyec.co.za
T
he conveyor is fitted with a 1.05 stoppages, so action is being taken to improve the quality
metre wide steel reinforced belt of the splices in future to alleviate this, while saving for the
which is fed at a 90° angle by short mine mount year on year.
conveyors from the four crusher
M & J Engineering (Pty) Ltd, MarkBaller, Tel: (011) 827 9372
storage bins. The belt, which transports
Fax: ( 011) 827 6132, Website: www.weba.co.za
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.
CONEXPO-CON/AGG 2011
is co-located with:
Sustainable Approach to
Freight in South Africa
“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.
E
conomic sustainability logistics costs. This can generally be attributed to
Freight transport supports the South the large distances between typical origins and
African economy, as it constituted more destinations and the cost of fuel. South Africa re-
than 8% of South Africa’s gross domestic quires more transport per unit of commodity than
product in 2007. Compared with a world average most countries in the world (CSIR. 2008). Almost
of 39%, transport made up 53% of the country’s 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-modal
Ownership 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 par
South Africa is below par when compared with
international freight transport best practice. This
is due to insufficient equipment, technology and
service, reliability, operations, equipment and the modes of transport should, therefore, improve
competitive pricing) and no perceived need for road safety in South Africa. South Africa is a
cross-subsidisation. It is not surprising that land country severely afflicted by HIV/Aids. The illness
transportation (road and rail) accounts for more is especially prevalent among truck drivers and
than 90% of total transport, with road enjoying the transfer of HIV/Aids and sexually transmitted
66% of market share. infections is a growing concern in the transport
Inter-modal interchange facilities (of which there industry. Truck stops can be an important part of
are presently very few in South Africa) can facilitate the strategy to protect truck drivers against these
the use of the most appropriate and environmentally and other illnesses and provide information on
friendly transport for different parts of a journey, the risks (www.arrivealive.co.za). Human health
for example using rail for long distance and trucks is also affected by poor air quality associated with
for local travel. transport emissions. Air quality and emissions
standards can combat these effects.
Trucks have the third highest number of vehicle crashes Conclusion
South African freight is generally not considered
Fatal crashes sustainable, at present. A move towards modal
In terms of safety, 9.97% of the vehicles involved integration and a more equal modal distribution
in fatal crashes in 2004 were trucks per 10 000 will go along way to improve system sustainability.
vehicles. This is mainly due to the extent at which Environmentally speaking, stepping away from
trucks are used annually (number of vehicles miles non-renewable resources and introducing fuel and
travelled). A major contributing factor to the cause of vehicle emissions standards should be a priority.
truck related accidents is the age and maintenance
levels of trucks. The average age of a truck is 12 The impact of current monopolies on the freight
years. Improved maintenance and regulations should system should be carefully monitored, provoking
make these old trucks less accident prone. government action to mitigate negative effects where
possible. As with most sustainability initiatives,
Driver fatigue is another major cause of trucking government has to show strong leadership to elicit
accidents. Shifting some of the road transport to buy-in from all stakeholders in the industry.
Establishing a Health
and Safety Benchmark
in Richards Bay
C
hairman 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 Left To Right: Andre Arendse, Lizette Kruger, Sian Thurtell and
with contractors,” explains Franz. Norman Hartman
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
KBC Health and Safety Managing Director
as being the best- Graham Emmett
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.
Effectively eliminate a full day of training for any
contractor that has already received this generic
training
Richards Bay
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:
Lizette@kbcsa.co.za
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NAME : ______________________________________________________________________________________________
30 BULK HANDLING TODAY February 2011 Advanced Materials Today September 2007 39
Market Forum
Helps with expansion Bateman Redler En-masse Conveyors convey particulate solids
Bateman Engineered Technologies (BET) Specialised Handling cleanly, gently and economically by inducing the material
Division is supplying a further five Bateman Redler chain to move like a liquid through dust-tight casings. This action
conveyors and elevators to Willowton Oil and Cake Mills’ ensures minimal product degradation, while the dust tight
Isando factory, building on a 40-year business relationship. casings protect the conveyed material and the environment
“The order for the extra five machines brings the total op- from mutual contamination.
erating equipment in that plant to 74,” says Peter Cheshire Bateman Engineered Technologies, Peter Cheshire, Tel: (011) 201.2300,
of Bateman’s Specialised Handling Division. Email: sales@bateman-bet.com
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 A major force in material handling
to Isando’s needs are transported off site for sale as cheap FLSmidth recently acquired the majority ownership of Roymec
fuel or poultry bedding. The additional equipment comprises (Pty) Limited, located north of Johannesburg, South Africa.
Bateman Redler chain conveyors and elevators to convey the Since its establishment in 1979, Roymec has supplied min-
sunflower husks at rates of between 7 and 10 t/hour. ing infrastructure including bulk material handling solutions.
Bateman Redler Bucket Elevators are commonly used in the Its products include plant and overland conveyors, waste
brewing and food industries as their robust design enables spreader systems, stockyard systems, run-of-mine tips, rail
slow running for minimum wear and product degradation, load-out stations, crushing and screening, as well as mate-
and they offer high capacities exceeding 1 000 t/h. 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, peterlohrmann@flsmidth.com, Tel: (011) 210-4000,
Fax: (011) 210-4050
Most advanced
Clyde 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
Conveyors in operation from previous installations at Isando Foods overland conveyor belts.
Supply
beyond the call of duty to
enhance the environment in which
they operate.
Awards
those in 2010, enjoyed a wonderful
response from the supply chain
community and everything is on track to
make the 2011 event one of the
industry’s most prestigious accolades.
The well-equipped unit, based on a long-wheelbase Hino “This mobile service unit is critical to providing the required
300 Series 611 chassis-cab, was constructed by Maximus levels of service to the fleet of 10 Hino 700 Series trucks
Bodies in Alrode, who previously built a similar type of unit now operating from Blinkwater Mills’ facility in Nelspruit.”
for Hino Honeydew. A custom-built trailer will be hitched to Hino Division, Ignatius Muthien, Tel: (011) 809-2064/2255, Fax:
the Hino to carry service parts. The mobile unit is equipped (011) 809-9064, Email: imuthien@hino.co.za
Moving the earth “After selecting HPE Africa, I have been happy with the
Tlhago Boswa, which primarily focuses on major earth- excellent standard of service that has been delivered,” ex-
moving projects for mining operations in the North West plains Alan. “HPE Africa’s sales staff are always on-hand to
province, purchased a Hyundai HL770 wheel loader from offer support and advice, which is important to us. What’s
HPE Africa in November to complement its existing range more, the delivery time of the machinery has been quick
of Hyundai HL780 and HL760 wheel loaders, which were and hassle-free.”
purchased from HPE Africa earlier in the year. Tlhago Boswa also purchased two Hyundai R305LC-7
Director Alan McGill points out that Tlhago Boswa places excavators – with a powerful operating weight of 29,4 tons
a high emphasis on quick turnaround times when choosing and a bucket capacity of 2 m3- from HPE Africa in July
suppliers, and that the level of service received from HPE and October2010 respectively.
Africa - the sole distributor of Hyundai earthmoving equip- HPE Africa , Kirsty Denholm, Tel: (011) 397 4670, Fax: (011) 307
ment in Southern Africa - has exceeded all expectations. 4683, Email: kirsty@hpeafrica.co.za , Web: www.hpeafrica.co.za
Positive feedback
Melco Conveyor Equipment South Africa has sold and installed on the side. The case demonstrates the advantage of the
72 motorised pulleys into various South African industries entire drive being concentrically loaded on the conveyor
since introducing the motorized pulleys two years ago. gantry” states Julian.
“There has been positive feedback from all of our clients, Melco Conveyor Equipment (Pty) Ltd, Julian Steinmann, Tel: (011)
which is evidence of the benefits being gained from the 825 3520, Email: julians@melco.co.za
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
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