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Page 1: BHT: Jul 2010

BULK HANDLING TODAY July 2010 1

Page 2: BHT: Jul 2010

2 BULK HANDLING TODAY July 2010

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BULK HANDLING TODAY July 2010 �

July 2010

ContentsCover Story5 Going to Great Heights

Trucking9 Euro Specification - Confusion11 Cleaner and Cheaper

Transport Management15 Is Your Tracker a Tracker?

Weighing19 Scaling the Weight

Lifting23 Some Time Before Crane Market Recovers25 Off to a Good Start

Conveying27 Regulating Material Flow

31 The Full Monty

34 Market Forum

Endorsing BodiesCMA (Conveyor Manufacturers Association)

HCASA (Hydraulic Conveying Association of SA)

LEEASA (Lifting Equipment Engineering Association of South Africa)

RFA (Road Freight Association)

SAIMechE (SA Institution of Mechanical Engineering)

SAIMH (SA Institute of Materials Handling)

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

Advertising Sales: Surita MarxDTP: Zinobia Docrat and Sanette Lehanie

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

Our e-mail address is [email protected]

Visit our website on www.promech.co.za

The monthly circulation is 4 016

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

Featured on the cover:

Sarens SATel: 011 8613800

Fax: 011. 861 3791Website:

www.sarenssa.co.za

Page 4: BHT: Jul 2010

� BULK HANDLING TODAY July 2010

CONVEYOR MANUFACTURERS ASSOCIATION

From the Chairman’s Desk

Simon Curry

All members subscribe to the CMA Code of EthicsABB IndustryAfripp ProjectsActomAtlanta Manufacturing Bateman Engineered TechnologiesBauer a Division of Hudaco TransmissionBMG (Bearing Man Group)Bearings InternationalBelt Reco RSA Bonfiglioli Power Transmissions Bosworth A Division of Hudaco Trading Brelko Conveyor ProductsCKIT Conveyor Engineers Continental Crushing & Conveying

CMA Members List as at July 2010

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

Hosch - FördertechnikLesa Mining and Conveyor Belt EquipmentM & J Engineering Martin EngineeringMelco Conveyor Equipment Moret MiningMS Conveyor Pulleys SANepean ConveyorsOE BearingsOsborn Engineered Products SARead Swatman & VoigtRema Tip Top SARenold CroftsRoymecRSV ENCO Consulting

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

D iscussions and a presenta-tion have been conducted with the conveyor inspec-tors of the DMR, with the

result that the way has been opened to allow representatives of the end users, CMA members and the DMR to debate the issue in open forum and to obtain resolution for these types of anomalies.

It is with great anticipation, therefore, that I am pleased to announce that

a one-day Safety Symposium will be held on Tuesday 31 August in Johan-nesburg, chaired by the CMA.

The Agenda for the day’s proceedings includes for presentations from the DMR on the importance of safety, the CMA on the Safety Guideline (available as a download from the website www.cmasa.co.za), as well as from the mining houses on practical implications related to the safety legislation.

Get involvedThe afternoon will be spent in estab-lishing a way forward for industry,

and deciding whether or not amendments to the Act will have to be recommended.

Seating is limited, so if you wish to be part of the discussions and get involved in this extremely important issue, please contact the Secretariat by email to [email protected] to make a booking. A nominal charge to cover some of the costs will be levied for the event.

My message to you all this month is to get involved, get “buy-in” to major decisions, stay informed and let’s keep this industry for which we feel such passion as safe as we can humanly make it!

Simon CurryCMA Chairman

Safety in the workplace is of paramount interest, and never more so than in the mining sector. Now at last we may be on the eve of something momentous for our industry! Some time ago the CMA Directors identified a need to examine how new safety legislation is impacting the day to day operation of belt conveyors. Specifi-cally, such issues as for example, belt training, where currently legislation does not allow for work to be car-

ried out on a moving belt.

Get involved, get “buy-in” to major decisions

Page 5: BHT: Jul 2010

BULK HANDLING TODAY July 2010 �

COVER STORY

“The Sarens Group is focusing on expan-sion into Africa in 2010,” Andrew Hunter, Director Business Support at Sarens SA tells “Bulk Handling Today.” “We believe

it offers tremendous potential for growth. Sarens SA is ideally positioned to tap into this and we plan to manage the rest of our African ventures from our base here.”

Going to Great HeightsTackling new markets is a priority for many international

companies with an eye for future growth, and global lifting specialist, Sarens, has set its sights on our continent.

African prospectsThe company has already committed to the programme with a number of ventures. “We have a depot in Namibia, and we’re running sales in Mozambique, Zambia and the Congo,” Andrew tells us. “Sarens is also involved in a number of large projects in Ethiopia and Angola, among others.”

Some of these projects have given the company an opportunity to showcase its impressive know-how and lifting equipment. Sarens SA’s 260t crawler crane has been assigned to the extension of the terminal at Pointe Noire for French group, Bolloré Africa. On completion, the container quay will accommodate the new 7000 TEU container vessels which are

capable of carrying 7000 twenty foot containers.

Andrew adds that while projects are varied, some clear trends are becoming visible. “Energy is the next big thing,” he assures us. “Projects like Medupi are going to draw a lot of attention.”

Monster movesSarens is no stranger to tackling major assignments. While it capably handles small ‘jobbing’ projects such as moving of goods and materials, the company truly shines when it deals with large-scale tasks. “We have some of the most specialised lifting equipment in the world, and we’re able to move it anywhere in the world it’s needed,” he says.

The Sarens lifting fleet is constantly expanding, with recent additions rank-ing among the world’s most noteworthy. “Our LTM400 and AC650 are the largest hydraulic cranes available, and we have another coming,” continues Andrew. “We offer the kind of equipment you’d see on Monster Moves on TV,” he laughs. “Self-propelled modular trailer lines, as well as jacking and skidding systems form part of our fleet.

“We are also in the process of completing a new crane which will be the largest in the world. It will be available for projects in 2011,” he adds. The new SGC 120 is the only Third Generation, 120 000 Tm (3200 metric ton lifting capacity) in production, designed to accommodate the heavy lifting requirements of refinery, petrochemical, offshore platform and third generation components for both advanced Pressurised Water Reactor (APWR) and Boiling Water Reactor

Sarens is involved in growing number of projects on the African continent

Energy is the next big thing

Page 6: BHT: Jul 2010

� BULK HANDLING TODAY July 2010

MOSTPRODUCTIVE

www.joy.com

South Africa Operations20 Fuchs St., Alrode 1450 & Pvt Bag 123924, Alrode 1451, AlbertonAustralia China India Poland Russia South Africa United Kingdom United States

Most Productive Equipment

Zero Harm Mentality

Lowest Cost Per Tonne

When it comes to your crushing and materials handlingrequirements, you need reliable equipment that performsin the toughest conditions.Joy Mining Machinery offers STAMLER feeder-breakers and reclaim feeders, and CONTINENTAL conveyors and conveyor equipment. They are at work in some of the world’s most productive materials handling applications.

STAMLER PRODUCTS are engineered to cut operating costs and increaseproductivity by allowing operations to work at their most efficient rate.

CONTINENTAL CONVEYOR PRODUCTS are a perfect fit to meet today’smining challenges. CONTINENTAL conveyors and conveyor equipment areproven in some of the most demanding applications.

Complete crushing and conveying systems integration is available with our wide product range and engineering teamwork that assures your materials handling system will work together as designed.

And, we stand behind our design and equipment with unsurpassed customer service and support.

THIS IS

Longwall Systems Bolting Cutting Haulage Crushing & Conveying

14567 SA Mining Weekly Full_v3a_Layout 1 3/18/10 9:51 AM Page 1

Page 7: BHT: Jul 2010

BULK HANDLING TODAY July 2010 �

The company offers some of the most specialised lifting equipment in the world

The Sarens fleet is constantly expanding and can be relocated to handle projects wherever necessary

(ABWR) nuclear power plant designs. Not bad for a family-run company that started fifty years ago with equipment that was largely horse-drawn.

Time and commitment “Right now business is really pumping, but it takes time and commitment to get to this point,” smiles Andrew. “The Sarens Group has a clear vision of the potential for positive growth here, and it’s encouraging to see a foreign company investing so enthusiasti-cally in our future.

“The most important thing, however, is that we of-fer an all-encompassing professional service,” he emphasises. “We work to global standards regard-less of the location. Whether it’s here, Ethiopia or the Netherlands, there is no difference in the level of technical knowledge, safety requirements and quality of workmanship.

“Large jobs often require specialised equipment with a skilled crew who plan projects months in advance. Our aim at Sarens SA is to ensure that all of this is managed in a way that compares with any profes-sional project anywhere in the world, whether we’re employing locals or sending in specialists. There simply is no room for compromise.”

Andrew Hunter, Sarens SA, Tel. 011 8613800, Fax. 011. 861 3791, Email. [email protected], Website. www.sarenssa.co.za.

COVER STORY

Not bad for a family-run company that started fifty years ago with equipment that was largely horse-drawnMOST

PRODUCTIVE

www.joy.com

South Africa Operations20 Fuchs St., Alrode 1450 & Pvt Bag 123924, Alrode 1451, AlbertonAustralia China India Poland Russia South Africa United Kingdom United States

Most Productive Equipment

Zero Harm Mentality

Lowest Cost Per Tonne

When it comes to your crushing and materials handlingrequirements, you need reliable equipment that performsin the toughest conditions.Joy Mining Machinery offers STAMLER feeder-breakers and reclaim feeders, and CONTINENTAL conveyors and conveyor equipment. They are at work in some of the world’s most productive materials handling applications.

STAMLER PRODUCTS are engineered to cut operating costs and increaseproductivity by allowing operations to work at their most efficient rate.

CONTINENTAL CONVEYOR PRODUCTS are a perfect fit to meet today’smining challenges. CONTINENTAL conveyors and conveyor equipment areproven in some of the most demanding applications.

Complete crushing and conveying systems integration is available with our wide product range and engineering teamwork that assures your materials handling system will work together as designed.

And, we stand behind our design and equipment with unsurpassed customer service and support.

THIS IS

Longwall Systems Bolting Cutting Haulage Crushing & Conveying

14567 SA Mining Weekly Full_v3a_Layout 1 3/18/10 9:51 AM Page 1

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� BULK HANDLING TODAY July 2010

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A division of Mercedes-Benz South Africa (Pty) Ltd

QUALITY SERVICE

ON ROLLING.JUST KEEPTHE WHEELSASSURANCE,

WITH 100%

Expect 100% results, Expect 100% updates, quick turnaround and no nonsense focus

on your every concern. Because from our parts to our heart, our staff to our craft and

everything between, 100% is what you can rely on because we’re 100% committed.

It takes a lot to stop a Freightliner.

CALL 0861 114 001 OR VISIT WWW.FREIGHTLINER.CO.ZA AND CHOOSE FROM OVER 20 DEALERSHIPS NATIONWIDE

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Page 9: BHT: Jul 2010

BULK HANDLING TODAY July 2010 �

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AN

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2991

A division of Mercedes-Benz South Africa (Pty) Ltd

QUALITY SERVICE

ON ROLLING.JUST KEEPTHE WHEELSASSURANCE,

WITH 100%

Expect 100% results, Expect 100% updates, quick turnaround and no nonsense focus

on your every concern. Because from our parts to our heart, our staff to our craft and

everything between, 100% is what you can rely on because we’re 100% committed.

It takes a lot to stop a Freightliner.

CALL 0861 114 001 OR VISIT WWW.FREIGHTLINER.CO.ZA AND CHOOSE FROM OVER 20 DEALERSHIPS NATIONWIDE

5B�����)/�%XON�+DQGOLQJ����[����LQGG���� �������������������$0

TRUCKING

South Africa is lagging far behind most countries in the world in terms of emission requirements for trucks and buses over 3 500kg GVM. The next move in South Africa

will only be in 2012, when it shifts to Euro IV, inevitably skipping Euro III.

“By contrast, European countries have adopted Euro V in 2008 and the next move for them will be to Euro VI in January 2013. (These latter limits will be comparable in stringency to the United States’ 2010 regulations),” says Casper Kruger, general manager of Hino in South Africa.

The Euro 1-VI regulations all specify decreasing amounts of carbon monoxide (CO), hydrocarbon (HC), nitrous oxide and particulate matter (PM).

The sulphur issueSulphur in diesel fuel contributes to the formation of PM in engine exhaust gases, as well as the forma-tion of secondary particulates. As PM emissions are linked to particular respiratory conditions, there has been a major worldwide focus on reducing sulphur

Euro Specification –Confusion

Due to the change in South Africa’s emission regulations

from Euro I to Euro II specifica-tions for diesel engine trucks and buses from the beginning

of this year, many operators are worried that they will have to

deal with technologies that will affect their engines.

levels in diesel fuel to below 500 parts per million (PPM). The sulphur content in the fuel must decrease as the Euro emission levels increase from 1-VI.

“South Africa has moved from 5 500ppm to 3 000ppm sulphur content in its diesel fuel in 2002 and subsequently went from 3 000ppm to 500ppm in 2006,” states Casper.

At the same time 50ppm low sulphur diesel became available for the first time, mainly made by Sasol’s coal-to-oil process.

“The next move must be to make 50ppm fuel avail-able on a wider geographic basis to permit the use of the latest low-emission engine technology and then the requirement will focus on a further shift downward to 10ppm, which is already available in certain countries,” he states.

Blocked by fuel companies“At present we have the truck manufacturers who are able to provide the latest low emission engine technology, but its introduction in South Africa is being blocked by the fuel companies.

“The fuel companies say they will have to invest R40 billion to convert their refineries to produce cleaner fuels and the motor industry is asking for this programme to be accelerated. We have the technology to make meaningful reductions to emis-sions in the atmosphere with our new, so now it is up to the fuel producers to speed up the process,” concludes Casper.

Hino, Casper Kruger, Tel: 0800 139-111, www.hino.co.za

South Africa is being blocked by the fuel companies

Page 10: BHT: Jul 2010

10 BULK HANDLING TODAY July 2010Website: www.scaw.co.za

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

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

grades 3 to grade 8 to national and international standards.

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

Grinding Media:• Heat treated high alloy (high chrome) balls• Heat treated forged steel balls• Eclipsoids and cylpebs - high & low alloy

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

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

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

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

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

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

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

Grinding Media: Tel: +27 11 842-9322 • Fax:+27 11 842-9721

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

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

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

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SCAW NEW MINING AD 6/2010 18/6/10 09:42 Page 1

Page 11: BHT: Jul 2010

BULK HANDLING TODAY July 2010 11

Andreas Renschler, the board of manage-ment member responsible for Daimler Trucks and Buses does have a vision, and this vision is to produce commercial

vehicles that will consume 20 percent less fuel and reduce CO² emissions by the same amount. This, he says will be no easy task, but is certainly achievable.

Pull out all the stopsIn a statement, Andreas set the bar pretty high for the engineers of the Stuttgart-based commercial vehicle manufacturer. To overcome these chal-lenges, the engineers will have to pull out all the

stops, from enhancing the aerodynamics of the truck plus trailer or semi-trailer and fine tuning today’s conventional drive systems to using alter-native fuels and perhaps, partially hybridising the power-train.

These measures will be needed because during the past several decades, traditional vehicle tech-nology has already been pushed to the limits of what is technically feasible. This is because fuel efficiency and economy have always played a key role in truck development.

Then and nowEngineers conducted extensive measurements of a modern Mercedes-Benz Actros 1844 and

With truck fuel consumption and PM emissions down by 30 percent since 1960 and at the same time, freight

transport efficiency up by 80 percent, it is baffling how Daimler aims to

improve on these percentages in the next decade. The company does

however have a plan.

TRUCKING

a 1964 model Mercedes-Benz LP 1624, which they drove on a long-haul route from Stuttgart to Milan and back.

The results showed not only a nearly 50 percent difference in fuel consumption and CO² emissions per tonne of payload, but also a drop in particulate matter and nitrogen oxide emissions of up to 98 percent.

Driver strainThe physical and mental strain on the driver has also been significantly reduced, while transport performance has doubled and driving safety has improved substantially.

Transport performance, measured in tonnes per kilometre, is increasing in the European Union each year. According to the European Commission, transport performance amounted to about 4 120 billion tonne-kilometres in 2006, having increased by 2.6 percent a year from 1995, when it totalled about 3 100 billion tonne-kilometres.

Road vehicles were the only means of freight trans-port to post increases in performance and there were concrete economic reasons for this. Not only has the efficiency of modern commercial vehicles improved dramatically, but also their active and passive safety, their driving comfort, and lastly, their environmental compatibility.

The figuresDuring the approximate 1 160 kilometre test drive from Stuttgart to Milan and back, the Mercedes-Benz LP 1620, which was one of the world’s most advanced trucks in the 1960s, consumed almost

Cleaner and Cheaper

Fuel efficiency and economy have always played a key role in truck development

Huge advances were achieved in rapid succession, which is why a truck from the 1960s is hardly comparable with a modern long-haul vehicle.

Website: www.scaw.co.za

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

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

grades 3 to grade 8 to national and international standards.

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

Grinding Media:• Heat treated high alloy (high chrome) balls• Heat treated forged steel balls• Eclipsoids and cylpebs - high & low alloy

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

SPECIALIST PRODUCTSFOR THE MININGINDUSTRY

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

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

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

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

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

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

Grinding Media: Tel: +27 11 842-9322 • Fax:+27 11 842-9721

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

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

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

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SCAW NEW MINING AD 6/2010 18/6/10 09:42 Page 1

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12 BULK HANDLING TODAY July 2010

TRUCKING

20 percent more fuel, than the Actros 1844. The measurement results were even more impressive if fuel consumption was calculated in relation to payload.

They showed that the veteran truck consumed 2.34 litres of fuel per tonne transported over a distance of 100 kilometres, while the Actros needed only 1.27 litres. This represented an almost 50 percent reduc-tion in fuel consumption and CO² emissions.

Other emission values have also been dramatically reduced, with nitous oxide and paticulate matter-concentrations in the exhaust gas almost 98 percent lower in the Actros 1844 than in the LP 1620. As a result, the Actros’ performance exceeds the require-ments of the Euro 5 emissions limits.

The Daimler engineers are now preparing for the Euro 6 standard, which will go into effect in 2014 and stipulate limits close to what is detectable with today’s technology.

Efficient yet fastWhile reduction of fuel consumption and emissions is one of the goals of the engine development engineers at Mercedes-Benz, their other aim is to increase performance and torque. These factors have a big impact on a commercial vehicle’s efficiency and economy, making them one of the most important selling points.

In 1960, a truck with an output of about 150 kW and 700 Nm of torque was still considered to be a powerhouse for the transport of 32 tonnes. Several truck generations later, it is considered appropriate in Europe for a truck transporting about 40 tonnes to have more than twice the output and three times as much torque.

Today’s most powerful Actros engine, a 15.9 litre V8 unit, has an output of 440 kW and 2 800 Nm of torque.

Speed and timeDuring the comparative drive from Stuttgart to Milan and back, the Actros travelled at an average speed of 76 km/h while carrying a payload of 25 tonnes. The LP 1620 carried only 16 tonnes and travelled signifi-cantly slower at an average speed of 58 km/h.

While the Actros took 12 hours and 36 minutes to travel the 1 159.6 kilometre route, the LP 1620 took almost eight more hours.

Driving safetyThe driver of the Actros semi-trailer truck could rely on the vehicle’s active and passive safety systems at all times.

Mercedes-Benz introduced the ABS anti-lock braking system to heavy-duty trucks in 1981. The progress is demonstrated by the braking distance needed to

The driver of the Actros semi-trailer truck could rely on the vehicle’s active and passive safety systems

Page 13: BHT: Jul 2010

BULK HANDLING TODAY July 2010 1�

decelerate the vehicle from 80 to zero km/h. In the case of the Actros, this amounts to only 38.5 metres, whereas the LP 1620 needed 56 metres.

Other advances include the emergency braking feature Active Brake Assist as well as a whole series of assistance systems that make trucks safer.

Comfort featuresDaimler recognised that features truckers would once have called luxurious are in fact now important basic pieces of equipment for reducing physical and mental strain. This equipment consists not only of cab air-conditioning, but also includes a comfort suspension seat instead of a simple bench and a comfort bed with a continuously adjustable-level control instead of a Spartan cot.

Whereas clutches had to be pressed with a force of about 30 kilo-pounds for each gearshift, the truck today has a fully automated transmission.

On the stretch between Chur and Lostallo, where the trucks have to cross the San Bernardino Pass, the measurement devices in the Actros registered only 175 gearshifts, and none at all when a fully automated transmission was used. By contrast, the driver of the LP 1620 had to operate the gear stick a total of 290 times.

EEG measurements in a truckObjective measurements were also conducted in a truck during the comparative drive. Electroencephalographic measurements (EEGs) of the drivers’ brainwaves were made to obtain insights into the mental strain suffered by truckers in stressful situations.

To take the measurements, the drivers donned a cap with EEG sensors that registered when the brain became aware of an acoustic signal that reached the ears.

The results showed that the driver behind the wheel of an Actros truck had almost as much time to react when travelling along a difficult stretch of road as when he drove along easily navigable highways.

Meanwhile, in the LP 1620 the EEG showed that it took the driver up to 400 milliseconds longer to respond to sensory stimuli in a dangerous situation.

www.mercedes-benzsa.co.za

Electroencephalographic measurements (EEGs) of the drivers’ brainwaves were made to obtain insights into the mental strain suffered by truckers in stressful situations

TRUCKING

Page 14: BHT: Jul 2010

1� BULK HANDLING TODAY July 201036 Supply Chain Today May 2010

RFAConvention 2010

RFAConvention 2010

Wild Coast Sun

WITHOUT TRUCKS, SOUTH AFRICA STOPS!

Sunday 22 August to Tuesday 24 August 2010Shift into Overdrive

Supply 2010 May10.indd 36 2010/07/09 03:33:22 PM

Page 15: BHT: Jul 2010

BULK HANDLING TODAY July 2010 1�

TRANSPORT MANAGEMENT - ROUTING & SCHEDULING

T racker operates on two levels,” he begins. “There’s the stolen vehicle recovery side and then we also offer fleet management and monitoring systems.These systems included

Tracker SkyTrax, Tracker Fleet and Execu Fleet, a suite of fleet management tools with varying levels of complexity. SkyTrax allows the company and the user to track vehicles online, as well as monitor route history, speed and other information,” Gareth explains.

“Tracker Fleet offers these capabilities along with more intricate functions such as route optimisation and ring fencing of no-go areas. ExecuFleet is all this and more. The system allows you to bolt on extras such as sensors on door handles and fuel caps. Other options include monitoring of cold freight and driver handling.

“While the actual management is handled by the companies involved, we obviously get involved if the vehicle in question is stolen or hijacked,” he tells us.

Getting on trackHere is where the company truly shines. “As the only tracking company in South Africa with a for-mal association with the SAPS, we have 1 300 vehicles and 50 aircraft at our disposal, as well as power of arrest,” says Gareth. This concession was hard-won; awarding of the 5-year SAPS contract inspires heated competition in the tracking industry, and Tracker has had it for the past three terms.

“I think that the SAPS/Tracker venture is the most successful Private-Public sector collaboration in South Africa to date,” he continues. “Since 1996, together with the SAPS, we’ve apprehended 8400 criminals, closed down 320 syndicates and chop shops, and have had 48 000 recoveries.” While these figures are impressive, Gareth puts things further into perspective by adding that the average prison holds about 7 000 inmates. “We’ve filled an entire jail and more,” he says.

Behind the scenesTracker’s technology base is two-pronged, relying on both Radio Frequency (RF) and GSM/GPS, and

Is Your Tracker a Tracker?

Energetic and consistently on the move, Gareth Crocker speaks with the speed of an automatic weapon, which is ap-

propriate, since he’s the Communications Manager at Tracker. When “Bulk Handling Today” chats to him about vehicle re-covery, along with some of the sophisticated management

products provided by the company, it’s all we can do to keep up with his train of thought.

We’ve apprehended 8400 criminals, closed down 320 syndicates and chop shops, and have had 48 000 recoveries

Gareth Crocker, Tracker

36 Supply Chain Today May 2010

RFAConvention 2010

RFAConvention 2010

Wild Coast Sun

WITHOUT TRUCKS, SOUTH AFRICA STOPS!

Sunday 22 August to Tuesday 24 August 2010Shift into Overdrive

Supply 2010 May10.indd 36 2010/07/09 03:33:22 PM

Page 16: BHT: Jul 2010

1� BULK HANDLING TODAY July 2010

TRANSPORT MANAGEMENT - ROUTING & SCHEDULING

Gareth explains the reason for this. “Our Tracker Retrieve and Tracker Alert units use radio frequency technology and are basic tracking services. Until the unit is activated, it lies dormant in the vehicle. The technology is not new, but it’s the most successful stolen vehicle recovery technology in the world.

“SkyTrax products use GSM/GPS technology which allows you to do all the ‘fun’ stuff on maps, etc that isn’t possible with RF. It’s a more sophisticated

system, but is yet to prove itself as successful in stolen vehicle recovery as the RF devices which have been around for years,” he elaborates.

Action stationsConsidering that lives often rely on the team’s ability to track a vehicle effectively, it’s hardly surprising that the company has opted for the most stable platform. A typical tracking scenario generally involves confirmation of a vehicle theft, followed by activation of the tracking device which allows identification of location and deployment of tracking vehicles.

When lives are at stake, reliable tracking is vital

You can’t expect a guy earning R1 000 a month to face a hardened criminal with a machine gun

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“The Tracker team will have a device on board that directs them,” Gareth goes on. “They’ll be able to follow an arrow on a screen or a strength bar which gets bolder as the target gets closer. An alarm will sound once you’re on top of them. Track-ing is also possible with the GPS system, which triangulates the location, and provides coordinates to the locale.”

Once at the site, Tracker’s recovery units step back, allowing the police to get on with the job of ap-prehension and arrest. “We stay out of the frontline for the most part,” says Gareth. “It’s important for the SAPS to arrest the criminals because very often they’ve been involved in other crimes. We believe that there’s an underlying social responsibility that goes beyond getting the car back. Vehicles are central

to many other criminal activities. Often the motive is to find a getaway car for an armed robbery or some other violent crime. Getting the criminal off the streets means that event won’t happen.

Police backgrounds“Many of our guys have police backgrounds so they’re familiar with the procedures, and are able to assist effectively from this perspective. However their principal role is to look after the vehicle. They try to ensure that it’s kept safe during the recovery and see that it’s returned to the owner.”

This doesn’t mean that they’re low-level employees. “We hire the best people we can find and train them according to Tracker standards,” he says. “You can’t expect a guy earning R1 000 a month to face a hardened criminal with a machine gun.”

Criminal behaviourGareth gives us some insight into criminal behaviour, saying: “We’re all worried about being victims of hijacking, and most of us are afraid that we’ll be injured or taken with the car, or worse yet, that our children will be taken. But in reality, this happens more rarely than people believe, because criminals know that if they’re caught, their sentence will im-

mediately be doubled, with other charges such as assault and abduction being added.

“Often, a hijacker will stop some distance from the scene and pass the vehicle on to a driver. If this person is apprehended, it’s unlikely that the victim will be able to identify him in a line-up, meaning he’ll face a minimal sentence,” he explains.

“Alternatively, the hijacker will park the car some-where and wait nearby to watch it. If a Tracker team arrives, they’ll get away, and if not, they keep the car. However, we have our strategies and tactics to deal with this.”

Motor misperceptionsAccording to Gareth, the public has many misper-ceptions about the motives behind vehicle theft. “A lot of people think ‘Well, I drive a clapped out sedan; nobody wants that.’ But they’re wrong. Of the cars stolen in South Africa, about half are taken out of the country and sold to neighbouring countries, perhaps in response to a specific request. The rest are stolen for parts, largely to be sold to South Africans.”

This is part of a much larger sociological problem related to poor financial planning and overspending. “Consider the guy with a job who earns six grand a month and lives with his mother, yet drives a luxury vehicle. Half the time he can’t afford to put fuel in it. Then the alternator packs up and he’s quoted several thousand rand to replace it. So he finds a ‘spare’ for five hundred bucks from a friend who knows a friend. Usually, these ‘spares’ are stolen parts; he’s unwittingly become part of the chain that fuels much of our crime.”

Jewel in the crownAs a reminder that crime is not a purely South African issue, some of Tracker’s technology is actually American. “Our RF system is used under

Often the motive is to find a getaway car for an armed robbery or some other violent crime

TRANSPORT MANAGEMENT - ROUTING & SCHEDULING

South African roads require a vigilant eye

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1� BULK HANDLING TODAY July 2010

licence from LoJack in the States, where it was devel-oped,” advises Gareth. In spite of its origins, it is the third world countries which truly test the technology. Brazil, and Columbia, along with South Africa, are tough training grounds.

“We’re the jewel in the crown in terms of recovery methods. The average car thief in the States or the UK would possibly be a lot easier to deal with,” he suggests. “Often vehicles in these countries are stolen for joyrid-ing and not by expert and aggresive criminals who are often armed with automatic weapons, as is the case in South Africa.”

Where things are goingSuch is Tracker’s success in dealing with these situations that they’ve actually been called upon to advise foreign affiliates on recovery practices. They don’t use this as an excuse to rest on their laurels, though, and a close eye is kept on industry trends. “The technology has reached the point where you can track most things now,” Gareth says. “There’s interest in putting trackers on individual items and even on people and livestock.

“We prefer to focus on products to add value to our exist-ing offering rather than going overboard with extras. As it stands, I think we tick almost every box on our clients’ wish-lists,” Gareth smiles in conclusion.

Gareth Crocker, Tracker, Tel. 011 380 0300, Fax. 011 215 8900, Email. [email protected], Website. www.tracker.co.za

TRANSPORT MANAGEMENT

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Scaling The WeightFrom the moment we are born and throughout our daily lives, weighing and measuring is an important and of-ten vital part of our existence. Our bodies, the food we eat and all the products we use as an integral part of modern living have all been weighed and measured at some stage in their development.

In fact, commerce would not have progressed beyond the barter system without the invention of a system of weights and measures.

Bulk weighingWhen it comes to materials handling systems, weighing is integral. Whether it’s raw minerals in tonnages or processed food in kilograms, a weighing system is used to regulate the packaging of these materials from bulk into smaller quantities. “Bulk Handling Today” visits WestWeigh System in Spartan to talk to general manager Frankie de Jesuz, about weighing systems in general.

“We design and build weighing systems that measure anything from two grams to two tonnes,” he says. “Bulk bag packag-ing in the mining industry, for example, usually requires measured quantities of materials to fill the bags. For this we can either use the nett bulk bag weighing or the gross bulk bag weighing principle to design the system.”

A bulk weighing system going through final testing in the workshop

Frankie de Jesuz, general manager at WestWeigh Systems

Either use the nett bulk bag weighing or the gross bulk bag weighing principle

WEIGHING

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WEIGHING

The systemsThe nett weighing system pre-weighs the material before it is discharged into the bulk bag and is used when fast filling is required. “While the bag removal system is in operation, the pre-weighing system is already filling up again and by the time the next bag is fitted, the system is ready to discharge again,” explains Frankie. “The nett weighing system is for high tonnages per hour and costs a bit more than the gross weighing system.”

When low tonnages are processed, gross weighing takes centre-stage. “In this case, the bag itself is used as the weighing hopper as it does not have a pre-weigh hopper unit” says Frankie. “The bag actually hangs directly on the weighing mechanism and feed is shut off when the required weight is reached. Regard-less of the system, both can be automated to various degrees depending on each customer’s requirements so that only the bag change takes place manually.”

DesignDesigning a system depends on the flow and density characteristics of each material but in principle it should a least be a free flowing material. “We’ve just completed an ore dust bagging system for an iron ore operation where we fill two-tonne bulk bags on a fully automated nett weighing system,” says Frankie.

“The dust from the tip trucks is collected and The steel box that helps to keep the bag in shape while filling

The aim is to get the material nicely compacted into the bag to optimise the fill

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BULK HANDLING TODAY July 2010 21

fed into the system, bagged and stacked be-fore being processed. We’ve done very similar systems for the platinum mining industry as well and also for really heavy minerals where we could only bag into one-tonne bags due to the weight of the raw material.”

Filling the bagBut it’s not just a matter of bagging the mate-rial and carting it off. In the weighing process, the aim is to get the material nicely compacted into the bag to optimise the fill. At the inlet nozzle into the bag, the system therefore has an air extraction system to ensure a smooth flow of material into the bag without the air being pushed out causing turmoil. This air containing product dust is either fed back into the feeder hopper or it is diverted to a filtration system for cleaning before being released.

While being filled, the bag rests on a vibrating platform to ensure uniform compaction as the product settles into the bag. Bulk bags naturally tend to bulge and to minimise this tendency for better stacking when loaded onto a truck or storage, the weighing system also has a retractable boxing system to keep the bag in shape while being filled. A pneumatically-oper-ated steel box holds the bag in shape and once filled, the box lifts to free the bag before the integrated conveyor takes it out of the weighing machine to a discharge conveyor.

The controllerAt the heart of a weighing system is an electronic Pneumatic control of the weighing system under the hopper

Providing the right equipment for the right application is crucial

WEIGHING

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controller, an in-house design at WestWeigh Systems. “We have a dedicated basic controller for each of the nett weigh, the gross weigh or the process weigh-ing systems we manu fac tu re , ” says Frank ie . “Depending on the complexity of the system, this controller is inte-grated with a PLC system according the client’s requirements. Control varies from a manual system with buttons for each stage, to a one-touch button system where only the bag is changed manually, while everything before and after is fully automated once the button is pressed.”

Frankie takes us through his workshop where technicians are busily carrying out final adjustments on a fully-automated bulk bag weighing system. “All our systems, standard or customised, are fully assembled in the workshop and tested before we break them down for rigging on site,” says Frankie. “For some of the mining applications, it’s a bit difficult to get the actual material in here to do a full test, in which case we do a final test with the actual product on site.”

ServiceWeighing systems are generally on a par and therefore the differentiator is all about service. “We have several service teams because we strongly believe that it sets us apart from the rest,” Frankie says in conclusion. “Providing the right equipment for the right application is crucial but so is servicing and maintaining the equipment regularly. Apart from working to SABS standards, we strive for high accuracy and are fortunate that we can offer cost-effective solutions for all budgets.”

Frankie de Jesuz, WestWeigh Systems, Tel: (011) 974-8858, Email: [email protected]

A vibrating floor helps to settle the product in the bag

WEIGHING

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LIFTING

According to Marc Kleiner, general manager of Condra, “The market followed the world into dramatic decline in 2009, and we are now standing still.

“There is perhaps some slight growth that we can expect to see over the next year or two, but nothing substantial,” he says.

Markets abroadMarc says that mining projects in the planning phase hold promise, notably in the South American states of Chile, Columbia and Peru. “The outlook for coal and iron is particularly rosy, with demand

from China exceeding supply.

“There are new mines planned for Central Africa, notably in the Democratic Republic

of Congo, and, of course the world is waiting for Zimbabwe’s mining

sector to return to some sem-blance of normality. There

are also mining devel-opments planned

for Australia and Canada,” he

contin-ues.

Some Time Before Crane Market RecoversStalled projects, rising input costs and increasing technical sophistication are the trends at the forefront of the overhead crane and hoist market as the new decade kicks off. Today, the South African market for cranes and

hoists comprises some R500 million per annum and is currently stagnant after a period of dramatic growth from 2006 to early 2009.

Still some timeBut very little of substance has yet emerged from these plans, and it will be some time before concrete developments trickle down to the worldwide market for cranes and hoists.

“I think orders will start picking up towards the end of the year, but at the moment many project start dates are somewhat nebulous and characterised by ongoing postpone-ments and delays,” he continues.

Rising costsHe says that rising input costs remained a serious concern for all manufacturing enterprises.

“In South Africa we pay more for steel than the Europeans do, and the local prices keep on rising. The fuel price has gone up because of an additional government levy and labour remains expensive. We may be on the road to pricing ourselves out of the market.

Cheap and nasty“In terms of threats, both to South African and to European manufacture, China remains a problem. Buyers are tending to buy cheap and nasty in Shanghai while obtaining a test certificate to serve as a job umbrella.”

Even when the unit fails early in its life, these same buyers often go back to China for the re-placement.

“It is definitely a problem, and it presents a chal-lenge in terms of re-educating buyers in the wisdom of buying high-quality engineering that will deliver

a lower overall lifetime cost.

“I do believe that quality cranes will emerge as the winning choice in the long run,” Marc concludes.

Marc Kleiner, Condra, Tel: (011) 021-3712, Fax: (086) 669-2372, E-mail: [email protected]

Marc Kleiner

At the moment many project start dates are somewhat nebulous

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LIFTING

Says Moshe Motlohi, Cape Town terminal executive, “The advantage of the RTG is dense stacking - six rows wide, five containers high

and 30 deep - thereby providing better utilisation of space.”

Increased stacking capacity“These converted RTG blocks boast a stacking capacity of 6900 TEU (twenty foot equivalent unit) slots in total, present-ing an increase in stacking capacity of up to 40%. This will assist in increasing the overall container capacity of the terminal from 740 000 TEUs to 1.4 million TEUs by our end target of 2012,” he says.

Additional buffer storage of 1 200 TEU slots was provided in the old South African Container Depots yard which is located adjacent to the container terminal, to enable further reconfiguration work on the long quay.

Haulers rolling in“Towards the end of 2009, the terminal received the second and third batches of 25 haulers which brought the total number received to date by the terminal

Off to a Good StartTransnet Port Terminal has reported that its R5.6 billion, five-year investment plan aimed at increasing the

capacity of the Cape Town Container Terminal is progressing according to schedule. Under its reconfiguration programme on the long quay, the container stacking yard is being converted from a straddle carrier operation

to a rubber tyred gantry (RTG) operation.

Increases the overall container capacity of the terminal from 740 000 TEUs to 1.4 million

To date the terminal has received 47 haulers valued at R87m

The container stacking yard is being converted from a straddle car-rier operation to a rubber tyred gantry (RTG) operation

to 47 haulers valued at R87m,” he adds.

TrainingTransnet Port Terminals is aligning its human capital development programme at the terminal to meet the requirements of the expansion through an operator training programme.

69 operators for lifting equipment have been trained and signed off as competent - 43 on the Liebherr twin lift cranes and 26 on the Kalmar RTG’s.

The training programme extends through to Sep-tember 2010, by which time a total of 83 RTG Operators will have been trained.

Lunga Ngcobo, Transnet Port Terminals, Tel: (083) 288-9653, Email: [email protected]

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When it comes to dry free-flowing pow-ders, granules, crystals, or pellets, rotary airlock feeders are widely used, especially where a negative pressure

is maintained in the bin, filter or hopper in order to separate or filter waste from the main mate-rial. Typical materials include cement, ore, sugar,

minerals, grains, plastics, dust, fly ash, flour, gypsum and lime as well as foodstuffs and pharmaceuticals.

These feeders are also ideal for pollu-tion control applica-tions in wood, grain, food, textile, paper, tobacco, rubber and paint industries where they usually operate beneath dust collectors and cyclone separators to remove material without causing a

Regulating Material FlowRotary feeders, also known as rotary airlocks or rotary valves, are commonly used in industrial applications

as an integrated component in a bulk materials handling system. They are primarily used for discharge of bulk solid material from hoppers, bins, receivers and cyclones into a pressure or vacuum-driven pneumatic convey-

ing system.

drop in the various pressure differentials.

Specialists“Bulk Handling Today” visits AMD-Rotolok in Mara-isburg, a specialist South African manufacturer of rotary valves, screw conveyors and bucket elevators. “Besides our standard rotary valves that range from 50 mm to over two metres long and one metre in diameter, we can customise our equipment to fit into any unusual configuration a customer may have,” says Peter Frara, sales manager at AMD-Rotolok. “All our rotary valves are built for heavy duty requirements and a wide choice of options is available in order to meet the needs of most materials handling applications.”

“These valves, constructed in mild steel, cast iron, aluminium and stainless, with a variety of plating and lining alternatives available for abrasive ap-plications, are imported from our principles in the UK, but everything else we manufacture locally,” explains Peter. “This includes flap valves and knife gates, typically used in power station applications such as the new ones being built in South Africa

right now.”

ValvesDouble flap valves are suitable for discharging dry dust, powder granules and fibrous materials, while maintaining an effective seal. They are offered in fabricated and cast construction, and can be operated by gravity, pneu-matic or electric motors. “Knife gates, designed in a range of square and round outlet valves are available as shut-off gates for the gravity flow of granular, powdered bulk solids from bins and hoppers,” says Peter.

“A full range of this equip-ment is standard in heavy-duty construction and is fabricated in manual, pneu-

Peter Frara, sales manager at AMD-Rotolok

The rig to demonstrate the various componets ina materials handling system

CONVEYING

We can customise our equipment to fit We can customise our equipment to fit into any unusual configurationinto any unusual configuration

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Valves ready for delivery

matic and motorised versions. One of our specialities is a coal feeder system which is a variation of the knife gate principle.”

RigAlthough the different components form indi-vidual parts of a materials handling system, they are often used in conjunction with each other to make up a complete system. To demonstrate this principle, Peter shows us a small demo configuration rigged in the workshop. Directly under the bin, filter bag or cyclone you first get the flap valve to regulate the waste material falling to the bottom. This valve can be operated manually, motorised or activated purely by the weight of the material as pre-set by a counterweight. The valve prevents air from leaking into the negatively pres-surised system above it.

CONVEYING

The valve prevents air from leaking into the negatively The valve prevents air from leaking into the negatively pressurised system above itpressurised system above it

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A rotary valve, ready for fitting

Next you’re likely to find a knife gate and then a rotary valve to regulate the flow of the material into a screw conveyor that takes it away to a di-verter chute for distribution in various directions.

DivertersAll the components needed to regu-late and control the flow of material anywhere along a line for various purposes are offered by AMD. “The diverter chute, for example, is de-signed for the diversion of powdered or granular material under gravity flow,” adds Peter.

“It is available with twin or multiple outlets and can be designed for manual, pneumatic or motorised operation. The diverter valves we manufacture are usually used in pneumatic conveying lines and can be made with twin or even multiple outlets. Like all our equipment, the material we use for manufacture depends largely on the type of ap-plication.

Gates and elevators“Flow control gates are used to provide a dust-tight shut-off for discharge spouts on silos and for controlled discharge of pulverised bulk material,” he continues. “Control is achieved through an internally rotating roller-shaped gate system. To complement our range of gates, we also make a range of clam shell gates as well as low-maintenance rod gate systems.”

One of AMD’s specialities is bucket

CONVEYING

Our solutions are well-suited Our solutions are well-suited to African conditionsto African conditions

An old impeller can be overhauled by fitting new blades

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Flap valves on the production line

New impellers

elevator systems with capacity ranging from 5 tonnes an hour to around 100 tonnes an hour. “We‘ve had huge successes in developing this product over the years by coming up with a simple but efficient machine for elevating bulk solids in many different process and handling installations,” says Peter.

Forty-odd years“We now make chain or belt type elevators that cover a wide range of materi-als. As we’ve been operational since the 60’s, our many years of experience has allowed us to develop a modular system which means it’s often just a matter of assembling a unique system using different combinations of our standard modules. Handling capacities vary from 23 to 270 cubic metres per hour.”

“In the forty-odd years we’ve been around in South Africa, our solutions are well-suited to African conditions, but we’re still regularly confronted with new challenges,” Peter says in conclusion. “Through our sister companies spread across the globe, we have a large knowledge base to tap into be-sides our in-house expertise and, if needs be, we can bring in special design engineers from our UK branch to assist in sorting out new challenges when they arise.”

Peter Frara, AMD-Rotolok, Tel: (011) 674-1166, Email: [email protected]

CONVEYING

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CONVEYING

The task of overseeing the design and manufacturing of these various components is usually undertaken by a a project house, which can

make the construction of an intricate plant even more complex as more and more people join the supply chain.

A company that does the ‘Full Monty’ in terms of bulk materials handling plants is Rula Bulk Materials Handling in Hon-eydew. “Bulk Handling Today” talks to Roelf Odendaal, managing director of Rula, about the diversity they’re offering the South African market.

All roles“We offer the full scope from under one roof,” he says. “Ours is truly a full turnkey solution, anchored in a core of excellence,

The Full MontyA bulk materials handling plant encompasses a number of dif-ferent specialised mechanical handling systems. The goal is to make one functional system for a specific material as it pro-

gresses through its various stages of processing. The norm the world over is for each of these specialised components to be

designed and built by specialist manufacturers who often only do a single aspect of the handling system.

Our EPMC approach means we can provide a unique comprehensive service that includes all aspects of materials handling. The absolute distinction of Rula lies in our capability to not only achieve, but excel in all phases of a project.”

Roelf explains, “We are equally involved in all roles, from the initial stages of concept design right through value-engineering, shop detailing,

project management, procurement and manufacture, to installation and com-missioning. This is accomplished by a variety of expertise in civil, mechanical, structural, C&I and electrical engineer-ing. We also have specific skills in the design and engineering behind pneumatic and mechanical conveying plants and equipment.”

Project perfectionGiven Rula’s extensive base of knowledge and skills, built on the foundation of experience, the company is equipped to deal with the formalities of a project as well as the finest technical details of practical work. “We have perfected the art of pneumatic and mechanical conveying as well as silo storage solutions, making us a major player in the bulk materials handling sector,” says Roelf.

“There are no sub-contractors involved as we deal with the client directly, from concept development to handover. This direct relationship allows for responsive

Roelf Odendaal, managing director of Rual Bulk Materials Handling

A typical Rula double pressure vessel system

The ‘Full Monty’ in terms of bulk materials The ‘Full Monty’ in terms of bulk materials handling plantshandling plants

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communication and concurrent engineering to ultimately produce project perfection.”

Benchmark On the strength of new technology developed in-house, Rula has been recognised internation-ally with turnkey projects in Turkey, Reunion and Mauritius. “We thrive on design challenges,” says Roelf. “As technology keeps unfolding, we never cease to strive toward greater heights by embracing new benchmarks.

“Quality and precision in manufacture is accom-plished through an extensive workshop on our premises, allowing a direct link between the skilled labourer and the design engineers,” adds Roelf. “Undoubtedly one of our strengths is the ability to learn, assimilate, adapt and improve significantly on existing systems and to implement this knowl-edge in new designs. A variety of problems, often calling for unexpected solutions, has allowed us to develop a rare sense of creativity in our approach to all challenges. This is a definite competitive advantage in the industry.”

Flow dynamicsMaterials such as ash, coal and alumina are just

A conveyor systeminstalle at a power station

a few on Rula’s checklist. “Over the years, our engineers have acquired a great understanding in the field of flow dynamics with integrated dynamic piping systems to cater to individual applications,” says Roelf proudly.

“A defining attribute of our business is our belief that prevention is better than cure.

For example, in process design, we will rather implement preventative methods concerning is-sues such as wear protection, than have to tackle problems later on. It is not just a matter of simply reinforcing areas of high stress. Right up front, we pride ourselves on designing elegant flow patterns for each material flow application.”

Not optimalAn example of Rula’s pioneering work is their continuous long distance pneumatic conveying system. It has been developed and successfully implemented to convey material on a continuous basis with a constant conveying line pressure.

The system is briefly explained: Figure 1 shows conveying in a fairly typical system. Some have described such a system as continuous, but it is not an accurate description. The curve shows the conveying line pressure (in kPa) vs. time. The conveying sequence of each pressure vessel is quite distinct as a pressure peak at approximately 400kPa. The troughs (at approximately 160kPa)

Perfected the art of pneumatic and mechanical Perfected the art of pneumatic and mechanical conveyingconveying

CONVEYING

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are the breaks between alternate vessels conveying. Such a system is not optimal for two reasons:

Non-continuous conveying means that the conveying capacity is reduced. There is a time lag before each vessel can convey.

The non-constant conveying line pressure means that the air velocity in the conveying line is also not constant. This leads to wear throughout the system as each low-pressure trough has a corresponding high air velocity.

Figure 1 is a curve from an actual Rula installa-tion at a power station before optimisation. Figure 2 shows the same plant after optimisation. The

1.

2.

Figure 1 – Typical pneumatic conveying pressures, Line Pressure (kPa) vs. Time

Figure 2 – Rula Continuous Long Distance Pneumatic Conveying System, Line Pressure (kPa) vs. Time

conveying line pressure is now almost constant, at approximately 390kPa. There is no time lag between vessels. When the first vessel finishes conveying, the second one is ready to start immediately. Thus the conveying line pressure never drops. Figure 2 represents an RCT System with higher capacity and less wear than a typical conveying system.

All-inclusiveRoelf says in conclusion, “We believe in value en-gineering, holding paramount the ethics of integrity and intellectual honesty. From project management and engineering right through procurement and manufacture, to installation and commissioning, we possess all of the required expertise to provide all-inclusive, turnkey solutions.”

Roelf Odendaal, Rula Bulk Materials Handling. Tel: (011) 795 1040, Email: [email protected], Website: www.rula.co.za

A great understanding in the field of A great understanding in the field of flow dynamicsflow dynamics

CONVEYING

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Market Forum

Coal mine handlingBLT supplies a range of radial boom stackers and apron belt feeders designed for efficient bulk handling in the coal mining industry.

“Forming part of this range are the B&W automated handling systems, which require minimal civil works, offer the mining industry flexibility for materials handling procedures and offer an economical alternative to expensive fixed installations,” says Clinton van den Berg, product manager for BLT.

Operating costs and maintenance requirements are significantly lower than with conventional materials handling systems.

“These bulk materials handling systems are designed to join together fixed and mobile equipment, and are also suitable for the conveying of materials in vertical and steep angle applications,” he says.

For example, the Samson surface feeders receive bulk materials directly from tipping trucks and loading shovels, providing a buffer storage capacity, without the need for large ramps or underground pits. Since material is drawn from the tipping truck in a controlled stream, dust generation is significantly reduced.

The Samson, which is an alternative to conventional under-ground hoppers, is installed above ground by being bolted to a flat concrete slab foundation. Even in fixed installations, this portable system can be easily relocated for future plant development.

A wide belt design, with vertical hopper sides, enables fast truck discharge and the efficient conveying of any material, without the risk of blockage. Steel apron bar technology pro-vides the strength of an apron feeder, with clean operation. Conveyor chains are always outside the material flow, which means chain wear is reduced and inspection is easy.

BLT, Clinton van den Berg, Tel: (031) 274 8270, Fax: (031) 205 8002, Email: [email protected], www.biglifttrucks.com

The Stormajor radial boom stacker, which offers high handling rates, receives coal for stockpiling

Maximum mobilityOff-road conditions exist everywhere, even within a city precinct, and when it comes to off-road demands for trucking, Isuzu’s new N and F-Series models provide the answer. The 4X4 Isuzu N and F-Series match requirements for excellent angles of approach and departure and are combined with an optimum wheelbase for ground clearance while still providing a useful cargo body length. Add to these the need for manoeuvrability in tight comers and Isuzu 4X4 trucks will deliver the goods, service or people.

At a 6 tonne gross vehicle mass (GVM) the NPS 300 makes a lighter footprint than the 13.5 tonne GVM FTS 750 which also has an important role in soft underfoot conditions. The N-Series boasts a shorter wheelbase advantage of 3 365mm compared to the heavier F-Series with a wheelbase of

4 250mm, thus making the NPS 300 more manoeuvrable. Overall width of the N-Series and F-Series models is 1 995mm and 2 400mm respectively.

Both models enjoy the benefit of a limited slip differential, which requires no driver intervention when any rear wheel starts to spin, automatic lockup ensures positive traction on both rear drive wheels. Both models are also equipped with a 6-speed transmission.

The 4X4 Isuzu N and F-Series match requirements for excellent angles of approach and departure combined with an optimum wheelbase for ground clearance

Promech Publishing has a BEE rating of 97.2%

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Market Forum

Sound economic senseWith South Africa ranking among the top 15 global CO² emitters, Finance Minister Pravin Gordhan announced that a carbon dioxide vehicle emissions tax will be introduced on new cars from 1st September 2010, with taxes based on certified CO² emissions.

The new tax is designed to promote purchases of fuel-efficient vehicles and thereby reduce greenhouse gas emissions.

As transporters, it is important to evaluate the various op-tions available in the market that not only can reduce CO² emissions, but can also make economic savings.

As transporters, it is important to evaluate the various options available in the mar-ket

A distinct off-road technical feature of the FTS 750 is full-time all-wheel drive. Isuzu research has shown these heavy trucks are not engaged in long-distance operations and that consistent mobility, without complex judgement on surface conditions on the part of a driver, is the key factor.

Isuzu’s medium N-Series, heavy F-Series and extra-heavy Gigamax include turbo-intercooled, electronically-managed engines to match the Euro 2 requirements which lose no power at altitudes.

As for off-road conditions, the NPS 300 and FTS 750 develop torque outputs of 404Nm @ 1 500rpm and 706Nm @ 1 450rpm respectively.

Utilising common rail fuel-delivery systems, improved fuel consumption is a feature of these new engines. The advantage in common rail diesel engines is very high injection pressure – over 1 600 bar, that is consistently maintained from idle to maximum engine speed. This ensures clean burning in a diesel engine’s compression ignition cycle with the benefit of improved fuel economy and reduced exhaust emissions.

www.isuzu.co.za

Local is lekkerIt was a case of ‘local is lekker’ when Transnet Port Terminals chose local heavy machinery manufacturer, Desmond Equipment SA, to supply a R1.1 million front end loader for the Agriport terminal in Durban.

The Dezzi 2300 articulated front end loader with 5m³ bucket was delivered to the terminal recently, and will be used at Agriport’s new 80 000 tonne bulk warehouse.

The new warehouse will be used for the storage of soya meal, most of which enters the country via Durban.

Ernest Bell, Commercial Specialist in TPT’s Procurement Department, says the supplier’s delivery within tight deadlines bore testament

The challenge to truck body and trailer manufactures to play a role in reducing carbon emissions in the light of the impact of greenhouse gases on the environment has been taken up by Serco Industries.

One of the key factors is reducing vehicle tare weight and roll-ing resistance. With that in mind, Serco developed the ‘Super Reefer Lite’ trailer, which was launched at Automechanika in 2009 and has a weight saving of up to 1 000kg compared to the standard trailer.

The ultra lightweight 30-pallet show trailer weighs in at 8 380kg including the cooler unit. The weight saving delivers a reduction over a seven-year period of 37 tonnes in CO² emissions and a reduction of 0.81 litres of fuel per 100km in comparison to a standard trailer with single tyres. This amount increases to a 58.9 tonne saving in CO² emissions and a 1.27 litre saving in fuel per 100km when compared to a trailer with dual tyres.

Serco’s MD, Clinton Holcroft says the reduction in weight over the standard trailer not only allows more freight to be carried but also provides a bigger tolerance to prevent overloading from incorrect weight distribution.

“The latest technology and materials have been used, and the end result is a new age trailer with a modern styling, offering tangible benefits to customers and one which plays a big role in reducing carbon emissions in today’s polluted world,” he says.

Another key area for transporters to reduce emissions, is maintaining tyre inflation. Clinton says that it was found in a recent survey that almost a quarter of vehicles inspected had under inflated tyres which increase fuel consumption and carbon emissions. In this respect, Serco has introduced the ‘P-eye’ tyre pressure sensors as a simple cost effective way to remedy this problem while saving on tyre wear and fuel at the same time.

Serco Industries, Clinton Holcroft, Tel: (031) 508 1000, Cell: (082) 453 4436

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Market Forum

Pictured onboard the new Dezzi 2300 front end loader: (Left to right): Sipho Dube, Fleet Manager of TPT’s Agriport; Harry Dickinson, Project Manager for TPT; Ron Stroebel of Desmond Equipment SA; Robert Teale of TPT, Ernest Bell of TPT and Desmond Gutzeit of Desmond Equipment SA

Good vibrationsMartin Engineering has announced the acquisition of Cougar Industries (Peru, IL), a manufacturer of vibrators made in the USA.

Cougar also supplies a family of 12- and 24 VDC vibrators specifically for truck and mobile applications

to the capacity of local manufacturers.

“Our technical managers have already visited the manufacturing plant on two separate occasions and have confirmed that the standard and quality of the equipment satisfactorily meets Transnet’s standards,” says Ernest.

Based in Port Shepstone, Desmond Equip-ment SA has been in operation for over 30 years, manufacturing and supplying a variety of earthmoving equipment to the Southern African construction, mining, quarrying, forestry, sugar, industrial and harbour bulk handling markets.

Robert Teale, Project Manager at TPT, says the establishment of the bulk warehouse formed part of several investments aimed at realising capacity and generating new business at the Agriport terminal.

These include the establishment of bio-directional conveyor routes enabling TPT to load and offload at the same berth, extension of the rail structure, and invest-ment in a new pneumatic ship unloader to offload wheat.

Transnet Port Terminals, Lunga Ngcobo, Email: [email protected]

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R70 million crane for SAIn a major investment to the tune of R70 million, Vanguard, in a joint venture with Grindrod and private investors, procured one of the most sophisticated mobile cranes in the world. Designed and manufactured by Grove Cranes in Germany, the GTK 1100 arrived in South Africa a few months ago.

“When I saw the GTK 1100 being operated for the first time, during the construction of the boiler sections at a power station outside Cologne, Germany, I was convinced of its capabilities in South Africa. The GTK 1100 brings with it a whole range of opportunities for South African engineering companies in terms of greater flexibility and reduced project costs,” says Bryan Hodgkinson, Director, Vanguard.

The GTK 1100 was designed to lift ultra heavy loads to extreme heights. It can accommodate lifting 100 tonnes to heights of more than 100m and has a 56m working radius, centre operated. It was designed to compete in the super lift market dominated traditionally by large, crawler cranes with lattice booms.

Another of the innovations of the GTK 1100 is that compared to other large super lift cranes, which would need between 20 and 40 truckloads of parts to be mobilised in order to perform such heavy lifts, the GTK 1100 only needs four truckloads.

A further advantage is that the GTK 1100 can operate at these heights with very heavy loads without a counterweight.

This crane is one of only seven of its kind in the world and has a small footprint of 18x18m (including the boom set-up) for a minimised job site area and its self-levelling function results in minimal ground preparation.

The vertical rigging of the self-erecting tower contributes to the fast set-up, one of the key benefits of the GTK 1100 is that it can be ready for operation in just four to six hours.

Vanguard, Bryan Hodgkinson, Tel: (011) 616 1800, www.vanguard.co.za

Market Forum

Truco conveyor belting is manufactured according to the SANS-specification

More than just a productTruco, a South African rubber manufacturer recently became a member of the Conveyor Manufacturers’ Association of South Africa (CMA), and appointed Christo van der Linden as manager of its conveyor belting division.

Truco strives to supply its customers with quality service and products from its mining and industrial textile and steel reinforced rubber conveyor belting. All Truco conveyor belting is manufactured according to the SANS-specification.

The company is able to provide customers with a complete solution, rather than just a product and also offers value-added services, such as belt splicing, conveyor surveys, belt rationalisation and standardi-sation.

Truco is able to customise specifica-tions thanks to its ability to supply textile and steel cord up to 3 200mm wide on an ex-manufacture basis, resulting in optimised conveying capacities.

The company has supplied a number of mines in Africa, and Truco products are available in several African countries, in-cluding South Africa, Namibia, Botswana, Zambia, Tanzania, the DRC, Zimbabwe and Mozambique.

Truco, Christo van der Linden, Tel: (011) 762 5291, Email: [email protected]

Martin Engineering CEO, Scott Hutter says that plans are to retain the Cougar name and continue operations in Peru as a division of Martin Engineering.

“This move will give us complete control over our vibrator quality and delivery,” Scott continues. “It will also allow us to quickly design, engineer and manufacture vibrators for special customer applications.”

Martin Engineering will now be able to more actively pursue worldwide applications for all types of vibrators, especially 12 and 24 volt models used on mobile equipment, which is one of Cougar’s strengths.”

Cougar has grown through expansion and acquisition and designs and manufactures an electric line of single and 3-phase vibrators in a wide range of force outputs. The firm also manufactures piston, ball, ring and turbine pneumatic vibrators and a complete line of hydraulic powered units.

Cougar also supplies a family of 12 and 24 VDC vibrators specifically for truck and mobile applications, a broad line of equipment to evacuate material from storage vessels. Its Air Cannons, Gyro-Whip Bin Cleaning and Power Lance Bin Drill Systems will continue to be made in Peru, IL.

Martin Engineering, Tel: (031) 656 5135, www.martin-eng.co.za

Parting the seaThe construction of one of the largest tide barriers in Europe, which is being built to protect Venice from flooding is entering the critical phase.

Bosch Rexroth has put the hydraulics for a caisson transfer system into operation which

moves concrete blocks, each weighing up to 23 000 tonnes, to the loading station. They form the foundation of the ‘mo-bile’ tide barrier, the Modulo Sperimentale Elettromeccanico, (MOSE), that protects the Venetian lagoon from the spring tides of the Mediterranean.

MOSE is based on the principle of air buoyancy. In a concrete construction, situated on the seabed at the lagoon openings between the islands off the coast of Venice, are 79, tightly spaced, hollow flood gates made of steel. They are connected

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Market Forum

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In just 30 minutes, 79 hollow tidal gates rise up at the threat of high water levels to block the lagoon off from the Mediterranean.

to the foundation by means of a joint and while at rest, they lie flat on the bottom.

If high water threatens, compressed air pushes the water out of the 20m wide and five metre thick steel bodies and pushes them upright within 30 minutes. The mobile tide barrier seals off the lagoon from spring tides as great as three metres high. The highest spring tide to date measured 1.94m.

Bosch Rexroth is locally represented by the Hytec group and the project is scheduled for completion in 2012.

Willem Gijzelaar, Hytec Holdings, Tel: (011) 979 4630, Fax: (011) 979 4635: Email: [email protected]

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�0 BULK HANDLING TODAY July 2010

www.elephantlifting.co.zaGauteng: 012 661 6105 | Kwa Zulu Natal: 031 569 4131

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