Getting carried away? bulk conveyors make their mark

• the existing stockyards;
• the shiploading circuit; and
• the train-loading station.

Innovation is often cited by business gurus as being vital for business growth and sustainability. For the folks at Edge however, Innovation isn’t just in the name, it’s in the blood.

Based in Northern Ireland, Edge Innovate has its own in-house design academy. Equipped with the latest 3D modelling technology and backed by local universities and colleges, Edge engineers have gained a reputation for the creation of new and inventive solutions to age-old problems. The latest piece of equipment born from the design academy is the all-new RTU2200. The ‘Radial Truck Unloader’ is a high capacity track- mounted truck unloader.

The new RTU2200 will be showcased at the Hillhead exhibition in June. The Radial Truck Unloader has been developed with feedback from dealers and end users. It can be utilized in various applications and is as comfortable on the port as it is in the harsh environment of a quarry.

The RTU220 provides operators with a greater efficient loading method. Designed to allow operators to continuously load directly from trucks into train wagons or barges. The full HMI control panel and remote control functions provide operators easy control of the RTU functions whilst loading. The panel interface provides easy fine tuning for accurate application performance. The HMI allows for automatic start/stop operation and provides visual data output such as engine load, hydraulic oil temp and fuel consumption displayed while the machine is still operating. The RTU220 is an independent track-mounted unit that provides flexibility and reliability. Powered by a Cat4.4 96KW (129BHP) diesel engine, the RTU220 offers huge torque whilst only consuming 12–15 litres per hour (3–4USG). Further cost savings are provided by a dual power option allowing the RTU to be tracked into position and then connected to on-site three-phase electrical supply to power conveyors at a higher level of efficiency.

The machine has a range of applications but is specifically designed to receive material from lorries and dump trucks. The RTU can accept a full 20m3 (26yd3) load. Its high torque drive system allows the speed of the conveyor belt to be adjusted meaning the output of the machine can be regulated. Further applications include material stockpiling, and loading of ships, containers and railway carriages. Material is fed into the RTU220’s large 20m3 (26yd3) hopper and is carried to the radial conveyor via the 2,200mm (87”)-wide heavy duty belt. Full length impact bars prevent belt sag thus reducing material roll back and prolonging the life of the conveyor belt. Variable belt speed via the HMI control panel controls the flow of material to the Radial conveyor. The massive 20m3 hopper capacity increases cycle times and increased on-site production. With dual access, hydraulic flared sides, the RTU hopper can be fed directly by wheel loaders and grab cranes. Unlike feeder belt systems driven via a drum roller, the RTU220’s sprocket and chain design ensure against belt slippage or stalling. The RTU has the capacity to convey at 750tph [tonnes per hour] (826 US tons per hour) with a maximum feed size of 600mm (23”).

Material is stockpiled via the 1,200mm (48”)-wide radial product conveyor which provides a discharge height of 6,800mm (22’4”). The 180° radial function enhances the flexibility of the RTU allowing it to be utilized in a number of applications. The hydraulic folding head section allows for quick transition from transport to operating position.

All Edge products are designed, manufactured and built in a new state-of-the-art manufacturing plant based in Ireland. With a strong focus on quality assurance as a result of decades of experience, Edge products are leading the way in the materials handling and recycling equipment sectors.

The Edge material handling portfolio boasts a wide range of mobile conveying systems that includes the MS-Series (mobile stockpilers) the TS-Series (track conveyors), the RTS series (Radial Track Stockpiler), the FS-Series (Mobile/Track Feeder Stockpiler) and new LTS-Series (low-level track stockpiler) launched in 2013 along with the 360° Unlimited Range. This growing range of equipment caters for the various needs of a rapidly growing customer base with a wide range of applications including rail loading/unloading, construction and demolition waste (C+D), sand and gravel, compost, topsoil, wood waste, mulch, scrap metal, aggregates and coal.

Edge Innovate’s mobile conveying range has been developed through close collaboration with equipment re-sellers and end users. In many applications an Edge stacker can eliminate the need for a wheel loader and often removes the need to double handle material. There are therefore clear advantages in terms of reducing operational costs from investing in Edge equipment. The benefits of mobile solutions are becoming more and more apparent to people in the industry, with port and quarry managers recognizing the mobile option as being a viable cost saving alternative to fixed installations which in some instances are required to pass through lengthy planning control procedures.

The staff at Edge Innovate are constantly striving for innovative solutions. New product ideas regularly make their way to the marketplace. At the start of 2013, Edge launched the new patent-pending LTS Series. Boasting a discharge height of up to 10.3m and stockpile capacity of up to 1,718m3, the LTS has proved hugely successful and many units have been exported to over five countries since its launch. Its robust design, available in conveyor lengths from 50ft to 75ft, enables it to convey heavy aggregate such as oversized iron ore whilst providing the customer with superb manoeuvrability around site with rapid set-up times.

There were further additions to the product offering in June 2013 with the launch of the new 360° Unlimited Series. Two customized LTS 360° units along with two FTS 360° units were successfully installed and put to work in a heavy duty iron ore application just outside Sao Paolo in Brazil. By allowing the user to rotate an LTS or FTS through 360° without stopping, the 360° range maximizes operational efficiency in several applications including loading of ships, trains and barges. This unique design enables the operator to position the tracks parallel to a vessel or train, allowing the stockpiler to travel along the side of the vessel or train without the need to adjust the orientation of the machine. This option still only requires one operator to run an entire stacker that will offer up to 1,000tph for continuous loading.

Edge Innovate is exhibiting its wares at the world renowned Con-expo Show, at the Las Vegas convention centre from 4–8 March, and will be showing a selection of its product portfolio including: the Slayer XL, an LTS tracked stacker, the new upgraded TRM622 Trommel and the new EDGE Roll Sizer.

Aluminium rollers from Horizon Conveyor Equipment have proved to be a lightweight alternative to steel and an innovative solution to the problems of fire risk.

Four years ago, Horizon Conveyor Equipment launched an innovative range of aluminium rollers that have gone on to be tested in demanding conveyor installations all over the world. But while site operators have been quick to embrace the major health and safety advantages of using these lightweight rollers, their unique design is also providing an altogether new solution to a potentially explosive problem.

In hostile locations where conveyor reliability and the risk of fire are critical concerns, Horizon’s tightly sealed aluminium rollers are proving to be a superior option. Specially designed to operate at stable temperatures and cut the risk of electrostatic charges, the rollers are not only lighter but also safer than conventional steel rollers in ATEX environments where any excess heat, sparks or fire could have catastrophic consequences.

SAFETY IMPROVEMENTS

Horizon originally developed aluminium rollers in response to industry concerns about the health and safety risks of using standard heavy steel trough and return rollers. Often weighing up to 90kg, steel rollers can require extra manpower and prolonged downtime to fit and replace safely, particularly in high or enclosed spaces. Increasingly stringent health and safety rules mean that operators also have to carefully consider the risks posed to personnel from steel rollers during regular conveyor running.

Alan Bowler, the managing director of Horizon Conveyor Equipment, says the aluminium rollers retain the durability of their steel counterparts but boast the weight advantages, noise reduction and energy saving features that have made plastic rollers popular. Importantly, their high strength also makes them an ideal option for use on wide belts and in high impact locations.

He said:“Our aluminium roller has all the weight and handling advantages of our HDPE plastic rollers but with the added advantage of extra strength especially for long return rollers. This is absolutely critical for operators who face real health and safety issues when attempting to replace failed steel rollers.”

LIGHT AND STRONG

Designed using 6mm-thick aluminium tube, the rollers contain a steel shaft and sealed bearings, with the bearing housings manufactured from electrically-conductive glass-reinforced nylon. A large stationary integral stone guard forms the outer primary labyrinth seal, which prevents any spillage building up between the roller and the frame which can jam the roller. Dust, debris and smaller contaminants are kept out by a greased inner cupped lip seal together with a sealed bearing.

For the past three years, the rollers have been in use at E-ON’s Kingsnorth Power Station, mainly on 1,350mm and 1,800mm belts. Clive Burfoot, materials handling engineer for E-ON at Kingsnorth Power Station, says the weight of the rollers has been a major benefit on site.

“We have tested Horizon Conveyors’ aluminium rollers for more than three years and have been very pleased with their performance,” he said. “We decided to install them into a position of high tension, close to the pulley tail, to accelerate the tests and they have performed very well.”

LOWER RISK

While the aluminium rollers offer immediate weight gains to site operators, their unique construction delivers superior performance and longevity in high risk environments. With heavy-duty seals and sealed bearings, the rollers offer greater resilience in areas where fine dust from the likes of biomass pellets, wheat, sugar, flour and cement can be hugely damaging to standard rollers.

Following its conversion from coal-power to biomass, RWE Tilbury Power Station began trialling the aluminium rollers after finding that its existing steel rollers were failing at an alarming rate.

Ron Pannell, lead maintenance engineer at RWE Tilbury Power Station, said that after careful monitoring and investigation it was found that extremely fine biomass dust was getting through the seals of the steel rollers and into their open cage bearings. “Once any dust ingresses the seals and bearings, the rollers were generating excessive heat and that is a real problem with biomass dust,” he said.

RWE’s team put Horizon’s aluminium rollers through an extensive trial, which involved running them for a period and then opening the seals. It found that there hadn’t been any ingress of biomass dust through the seals or into the sealed bearings.

NEW SOLUTIONS

For Bowler at Horizon, the introduction of the aluminium roller range marks the latest development in nearly 30 years of research and design innovation. He was originally involved in the invention and patenting of the first non-metallic plastic- polyurethane rollers which were introduced into the South African market in 1980. He brought the designs to the UK and European market in 1995 and since then has established a range of steel, plastic and now aluminium rollers.

He said:“We originally conceived the design for the aluminium roller with health and safety in mind. With tighter regulations and more consideration to the manpower and downtime needed to change failed steel rollers, there is certainly a need for a lightweight alternative. But the way we have constructed these rollers means they are also capable of solving a wide variety of problems and reducing risks in some very hostile ATEX environments.”

ABOUT HORIZON CONVEYOR EQUIPMENT

Horizon Conveyor Equipment Ltd is based in Halesowen, UK. The company designs, manufactures, supplies and supports a wide range of high quality conveyor equipment including scrapers, cleaners, rollers — in steel, aluminium and HDPE (high density polyethylene) — and magnetic protection equipment for the mining, quarrying, ports and materials handling industries.

TMSA Tecnologia em Movimentação S/A, is one of the big suppliers in the South American market for bulk solids material handling equipment. It is especially active in port terminals and heavy duty and long distance conveyors. It is estimated that about a third of the main Brazilian exports of grain/meals/sugar pass through TMSA’s equipment.

TMSA has supplied conveyors with capacities ranging up to 20,000tph (tonnes per hour), and shiploaders for sugar, iron ore, coal, alumina, kaolin, and other heavy duty commodities ranging up to 4,000tph.

TMSA is very well integrated in the Mercosur countries. It has:

• its head office in Porto Alegre, Brazil;
• 30,000m2 of manufacturing facility;
• 80,000m2 of land;
• significant and highly integrated engineering capabilities;
• in-house mechanical, structural, electrical, automation and de-dusting specialists (all ISO 9001:2000-certified); and
• a workforce of 500 (including those in the branch offices in Belo Horizonte, Sao Paulo and Buenos Aires).

CONVENTIONAL CONVEYORS

Troughed belt conveyor belts are the most widely used continuous transport system for bulk materials. Since its foundation in 1966,TMSA has designed and manufactured bucket elevators and belt conveyors, mainly for agro-industrial commodities, becoming the main reference in port terminals in Brazil. This equipment has grown enormously in length, installed power and capacity all while reducing specific energy consumption.

TMSA has designed high capacity bucket elevators up to 2,000tph using Super Starco 4B buckets in pressed steel, stainless, HDP (high density polyethylene) or nylon, depending on the application, to handle commodities such as grains, rice, soya meals, flours, animal feed, fertilizers, sugar, cement and others.

This allowed TMSA to enter in other heavy industries finding main applications in the mining and energy industry, where belts would allow for very long flights without intermediate drives. The length of individual sections is limited by economic reasons, as the savings on transfer stations are neutralized by the additional cost of the high-tension belts. Developments in belt fastener technology allowed the use of high-tension belts, with large installed power. With many years of good experience and confidence, combined with better understanding in the design of belt conveyors and their dynamic behaviour and loading systems, have allowed TMSA to use faster belts, with successful references for its belt conveyor installations. These include notably a particular project in Rio de Janeiro state, in the huge Porto de Açu. Here,TMSA has installed a 20,000tph conveyor to handle iron ore (density 2.20t/m3). This conveyor is 3.1km long, and offers a belt speed of 5m/s. The contract was completed with TMSA’s French technological partner RBL-REI, which has wide experience in long conveyors, even those with curves. [For more information on RBL-REI’s activities, please see p69 of this (MARCH 2014) issue. Ed.] TMSA has also supplied equipment to other

major projects, to convey materials include alumina, fertilizers, coal and iron ore. These include the Alunorte bauxite complex, with its port terminal (see picture above, left). Another example is the VALE Carajás mine expansion (see picture top, right), which added a further 40mtpa (million probably the biggest iron ore mining complex in the world, where TMSA has recently designed and installed 44 belt conveyors with a global extension of 3.2km long, capacities ranging from 1,200tph to 10,800tph, power drives totalling 9,980CV and 6,760 tonnes of steel works.

In the agro and mining industries,TMSA equipment is achieving the high capacities requested by its clients. These include truck receptions at 1,000tph, continuous railcar reception hoppers and continuous loading stations of 3,000tph, and internal link conveyors and shiploaders offering up to 4,000tph.

SPECIAL CONVEYORS:A UNIQUE TECHNOLOGICAL PORTFOLIO TMSA, has developed a technological portfolio with innovative bulk solids handling systems, by developing alliances and becoming a local solution partner with worldwide technological leaders. All its systems have a common pattern: designed to minimize dust emissions, reduce environmental challenges, improve safety and reduce costs.

1. ‘ROPECON®’ belt conveyors:

This is a technology, developed by Doppelmayr, Austria, a world market leader in ropeways. The RopeCon® is a bulk material and unit load handling conveyor which combines the benefits of well proven technologies: the ropeway and the conventional conveyor belt.

A flat belt with corrugated side walls and integrated wheel sets runs on fixed anchored track ropes guided over towers. The hauling function is performed by the belt. The conveyor system makes it possible to pass over geographical obstacles such as rivers, roads, buildings and valleys.

2. The pipe conveyor system

This is a Japanese design that overcomes several problems, including spillage of material, belt training, limited horizontal and vertical curves, and limited angles of incline. The open belt passes through a series of transition idlers to form a pipe shape, making it fully enclosed for the length of the conveyor.

TMSA manufactured and delivered a 2,400tph, 7,115m-long pipe conveyor to a privately owned Brazilian provider. It supplied another 2,400tph, 950m-long system, on a pier, to handle bauxite. Both of these were designed by TMSA and Bateman Engineered Technologies, under a licence agreement with Bridgestone from Japan for its JPCs (Japan Pipe Conveyors).

3. The Manutube®, a dustless conveyor technology

Designed by Absam France, this is an enclosed belt conveyor with a belt sliding inside a plastic tube with no idlers, generating a natural airflow fully enclosed. It is a dust-tight technology that can guarantee less than 1mg of dust per cubic metre of air, for cleaner working area and longer lasting equipments.

4. Overland conveyors & Curvoduc®

TMSA is currently installing, with RBL-REI (France), an overland conveyor/Curvoduc® at the Super Port of Açu in North Rio de Janeiro State for LLX/Anglo-American. This 20,000tph unit is 3,100 metres long, has a belt width of 2,200mm, and installed power of 5 × 1,000kW. The Curvoduc® makes it possible to follow horizontal and vertical curves, in order to eliminate or reduce quantity of transfer towers (which create noise, dust emission and extra maintenance);TMSA’s aim in Brazil is to propose long distance conveyors with horizontal and vertical curves.(SeeRBL-REICurvoduc® picture below.)

OTHER TECHNOLOGICAL PARTNERS

In recent years,TMSA has developed other partnerships for its South American territory, incorporating new solutions to solve chronic problems. These include:

DSH in New Zealand, for its dust suppression hopper while loading trucks, railcars, silos or vessels.

All the above, added to the long tradition of good credentials, makes TMSA a preferred and consistent supplier for market leaders and multi-national companies.

These innovative technologies might replace conventional conveyor belts or not, but rather complement them under specific conditions. TMSA has the knowledge and experience for the proper selection of a conveying system which will better fit the needs and budget of each project.

FLSmidth, a major supplier of equipment and services to the global cement and minerals industries, employs over 15,000 employees in more than 40 countries, writes Kenyon Sharp, Assistant Manager, Marketing Communications at FLSmidth. The group has project and technology centres located close to its customers around the world. Serving customers in the cement and minerals industries, FLSmidth offers a wide range of products, from single items of machinery to complete plants and facilities. In addition, the company also takes a full-service approach before, during and after installation; offering customers expertise in project management, engineering and other professional services. FLSmidth has been a leading supplier of cement plants for over 130 years. This extensive experience and expertise is now being applied in the minerals industry. FLSmidth’s material handling and minerals processing technology now covers the entire flowsheet. The best equipment solution can be tailored for a specific mining application such as in-pit or out-of-pit crushing and conveying, overland trough or pipe conveying, heap leach and dry tails handling solutions, and port handling facilities. FLSmidth’s crushing and conveying technologies range from fixed, semi-mobile or fully mobile solutions. 

A semi-mobile sizing station was just recently installed at Goldcorp’s gold mine Minera Peñasquito. This sizer station has a capacity of 12,500tph (tonnes per hour), making it the largest sizer station in the world. Currently in an out-of-pit configuration crushing waste rock, the crusher station can be moved as mining progresses. The semi-mobile crushing technology will allow for shorter haul distances and lower overall operating expenses compared to traditional plant technologies.

FLSmidth is also completing installation of a dry tailings management system at a major iron ore project in Australia. The technology behind the 371m mobile stacking conveyor is well proven and there are more than 25 such FLSmidth RAHCO® systems throughout the world, operating at capacities up to 12,000tph. This system will be the first of its type in dry tailings in Australia.

An area 2km × 2km (4km2) has been allocated for tailings storage. By comparison, should a more traditional pond storage system be utilized, an area of around 52km2 would be required to store the tailings the project will generate. The area required for such a pond storage system is based on a 3m-deep pond. For a fully-lined 6m-deep pond, the space requirement would be halved. However, even at 6m deep, the total area required is significantly more than that allocated for the dry storage system tailings. Initially operating at 14.6mtpa (million tonnes per annum), the system has been designed to meet the increased output from the processing plant as Stage 2 of this project comes on line. When fully operational, the mobile conveyor system will stack the tailings up to 90m high (in three stages) over a 20-plus year period.

FLSmidth’s material handling equipment is present in many applications including coal, copper, iron ore, gold, nickel, cement, molybdenum, and fertilizers. Additionally, FLSmidth’s RAHCO mobile stacking systems and overland conveyors handle spent ore, dry tailings, and overburden material at many mine sites throughout the world.

Smart FrameTM, a unique idler replacement system designed by Cove Engineering, is another equipment enhancement provided by FLSmidth. Traditionally, conveyor idlers are replaced using equipment to lift the belt and work within the confines of the conveyor structure. With Smart Frame, idlers are replaced from the safety of the walkway without lifting the belt, entering the conveyor structure or man-handling heavy idlers into position. Maintenance costs are reduced by eliminating the need for lifting equipment or elevated work platforms.

Smart Frame is the safest and easiest method of idler replacement. Even though FLSmidth’s equipment covers the complete material handling flowsheet with additional technologies like BulkExpert and Smart Frame, one of FLSmidth’s greatest strengths is the people supporting the equipment solutions. Once FLSmidth has supplied equipment to a client, aftermarket support is required to keep equipment performing at optimal levels. By continuing to build relationships with clients during mining operations, FLSmidth can help develop future mine plans that best fit their needs. With clients’ needs as their focus, FLSmidth truly becomes the one source solution for their clients.

ENGINEERED TO MOVE THE COMMODITIES THAT MOVE BUSINESSES

Mobile ship unloaders — superior technology for efficient port operations

Productive port and terminal operations are critical to growing and maintaining profitable logistics contracts. CDM Systems’ mechanical unloaders are extremely efficient unloading systems, due to the continuous column of product flow using the proven en-masse conveying principle and the company’s exclusive drop-forged chain. A CDM mobile leg unloader is not susceptible to horizontal or lateral misalignment as bucket style units are, and will operate at angles from horizontal through vertical. In addition, a CDM unloader also provides;

• vessel shifting is minimized when compared to fixed tower stationary units;
• mobile legs in eight standard sizes with capacities from 150–700tph (metric tonnes per hour) peak digging;
• multiple units working one vessel provide a more even draw-down of the vessel, which translates into better hourly unloading averages than larger single stationary units;
• the unloading legs are completely mobile and can be moved to different locations either on board the vessel or by truck;
• designed to be handled by auxiliary shore cranes or the ship’s gear. In many cases, several units can be applied to the customer’s operation and will not exceed the initial investment of one single larger stationary tower unit. 

En-masse conveying: efficient material movement technology

In horizontal applications the en-masse chain conveyor can handle up to 90% of the cross sectional area, resulting in a smaller piece of equipment to handle the same or greater capacities over other conveying technology. These chain conveyors also provide very efficient horsepower consumption keeping operating costs low. The en-masse conveyor is often known as the en-masse chain or drag conveyor, although very different in principle from a standard drag conveyor.

CDM Systems offers a wide range of horizontal, inclined, vertical, or combinations of both in its totally enclosed conveying systems.

Other notable features and application benefits include; v single and dual pit truck receiving; v inline shallow pit hopper rail car receiving conveyor — allows for the positioning of the entire rail car once; v bin/silo distribution conveyors — can be equipped with multiple intermediate gates that provide a positive mechanical sealed separation between the customer’s bins/silos;

Coal mining plays a major role in the Australian economy. Ten per cent of all coal deposits worldwide are ‘Down Under’, making Australia the world’s biggest coal exporter. Large deposits are found in the state of New South Wales, where the Newcastle Coal Infrastructure Group (NCIG) is based. It operates one of the most important export terminals at the port of Newcastle. A complex infrastructure is required to ship the coal from there to destinations all over the world. For the NCIG transport system, the ContiTech Conveyor Belt Group has produced and supplied several steel cord belts in recent years, helping to set up a total of three platforms.

After completion of the third terminal at the end of 2013, NCIG’s transport system will be capable of delivering around 66 million metric tonnes of coal per year. A total of 20 conveyor belts is used to handle incoming and outgoing coal as well as for interim storage on the platform. They make for handling capacities of 8,500tph (metric tonnes per hour) in the loading stations and storage areas, with that figure rising to as much as 10,500tph in the wharf and shiploader area. “Thanks to their robust and durable design, steel cord belts from ContiTech are up to meeting the challenges of transporting coal within a coal terminal,” reports Eric Van Leeuwarden, national sales manager at ContiTech Australia. “In addition, our conveyor belts represent energy-saving solutions that significantly reduce transport costs and thus help to improve the cost efficiency of the system.”

Via the project company Aurecon Hatch, NCIG awarded ContiTech Australia (formerly M.I.R.S.), the order to set up the first platform in 2008. The Conveyor Belt Group in Northeim/Germany produced an approximate length of 10,000m of ST 1400 steel cord belt with a width of 2,500mm. It is made of an energy-saving rubber compound that has made it possible to significantly improve visco-elastic properties, thereby minimizing indentation rolling resistance on the conveyor belt system. As a result, energy consumption during transport can be lowered by up to 25%, allowing for a reduction in energy costs and CO2 emissions overall. ContiTech additionally produced 280m of type ST2500 steel cord belting for this stage of the project. It is used to transport the coal onto the freight ships. In order to ensure that the individually delivered sectional lengths were correctly spliced on-site to form a conveyor belt, ContiTech arranged a training course at ContiTech in Northeim in 2009. At it, the Australian installation partner received instruction as to the correct procedures for splicing the sections. “By doing this, we were able to ensure the best possible outcome,” says Van Leeuwarden.

In the spring of 2010, an order then came in to set up the second platform. A further 8,000m of steel cord belting of the same belt types were used here. To help the team connect the individual conveyor belt lengths, ContiTech service staff members were on hand locally to set up the required vulcanization presses and further optimize the process. In 2012, thanks to the successful implementation of the first two subprojects, M.I.R.S. and the ContiTech Conveyor Belt Group also received the order for the third and final stage of the project — another 8,000m- long steel cord belt, which was delivered in several stages by September 2012.

“Thanks to the close global co-operation with the experts from ContiTech, we have been able to perfectly monitor and accompany the construction of the transport terminal in Newcastle during the last four years,” says Van Leeuwarden. “This project has further strengthened our position in Australia and is an important reference project on this market.”

NALC supplies a range of limestone products from its 243 Complex in Cloverdale, IN to a number of industries in the Midwest, including fine-grind materials and high-calcium crushed limestone. The company serves customers in such diverse applications as animal feed production, electric power generation, coal mining, industrial manufacturing and various construction segments. In order to efficiently produce a consistent volume and quality level, the facility employs an expansive series of crushers, mills, screens and other equipment, with material transported primarily by conveyor.

Over time, material handling system operators began noticing that a growing amount of material was being carried back from the unloading points, which would accumulate and eventually create mounds of spillage that piled up beneath the structure. In keeping with its long-range plans to employ industry best practices for bulk handling and fugitive material control in its operations, company officials conducted an assessment and contacted Martin Engineering for advice.

According to NALC vice president of operations Dana Boyd, “Carryback is a common problem within our industry. If not addressed, not only does spillage create safety hazards, but it also adds unnecessary work for the maintenance team, when they could be focusing on other priorities.”

To rectify the issue, Martin Engineering recommended the PV Primary Cleaner with TwistTM Tensioner for key locations along the conveyor network throughout the facility. The Martin® PV Cleaner is a durable, one-piece blade that contains approximately 20 percent more urethane than comparable primary cleaners, yielding a longer life in challenging service conditions. The aggressive blade angle is able to remove even wet, sticky sand from belts 18–72 inches (450–1,800 mm) wide.

The PV Cleaner blades feature Martin Engineering’s patented Constant Angle Radial Pressure (CARP) design for consistent cleaning throughout all stages of blade life. The specially- engineered curved blade maintains the same contact angle, even as the belt wears, helping to retain cleaning efficiency and allow for residual material fines on the belt to be deposited back into the material flow and not underneath the conveyor.

The belt cleaner and tensioner combination also helped eliminate material buildup on the return side of the belt, which could cause additional problems with the belt or return rollers. When foreign material is trapped between the belt and the pulley, it can allow the belt to slip, causing the non-carrying underside of the belt to wear prematurely. Even small particles and fines can grind away on the less durable, more easily damaged inside surface of the belt. Further, material that builds up on tail pulleys often causes the belt to wander, which in turn can damage the belt edge and/or the conveyor structure.

Belts at NALC include 2-, 3- and 4-ply construction, according to the load each one is designed to carry, and they run at 100–400 feet per minute (30.48–121.92 metres per minute).

Mechanical splices are used on all of them, which can be a concern with some belt cleaner designs. But the unique Twist Tensioner on the Martin design allows the spliced sections to pass smoothly, without damage to the belt or blade.

Initially installed in March of 2012, NALC has found that the PV cleaner has all but eliminated the carryback and spillage. The tensioner supplies consistent pressure to keep the blade against the belt for effective cleaning, regardless of the state of blade wear, with minimal re-tensioning required.

Engineered to simplify maintenance and reduce costs, the mounting system delivers ‘no- tool’ replacement, as it’s simply dropped into place and secured with a wire lock pin. “This cleaner uses an aggressive angle of attack to the belt for improved cleaning efficiency,” explained Martin Engineering senior product specialist Dave Mueller. “And the quick-replacement feature means never having to deal with corroded bolts or other fasteners during blade changes.”

According to the belt maintenance crews, the time and cost savings was an immediate return on the investment. Now that the maintenance crew spends less time cleaning up, they are spending more time focusing on core business tasks. “Our maintenance crews have crucial functions they need to address to keep the plant running,” said Boyd. “Not having to worry about carryback and spillage during these times is important.”

Founded in 1944, Martin Engineering makes bulk materials handling cleaner, safer and more productive. The

The cement industry is a growing market worldwide.The demand for this construction material continues, especially in China. The BEUMER Center of Competence (CoC) was established for the cement business unit to provide optimal systems and plants as a full-range supplier to customers all around the world. It is designed to optimize communication among the BEUMER experts worldwide. China’s biggest cement manufacturer also benefits from this.

“China and India are still the two main growth markets,” says Dr. Christoph Beumer, Chairman and CEO of BEUMER Group based in Beckum, Germany. “When we went to China during the late 1990s, the country produced approximately 700mt [million tonnes] of cement per year, today that is almost 1.2 billion.” According to the National Bureau of Statistics (NBS), production in China gained further momentum during the first quarter of 2013 and reached 417mt. This represents an increase of 8.2% compared to the previous year. “This positive long-term development is not going to change,” predicts Andre Tissen, head of the cement business unit at BEUMER Group. “Compared to international standards, the urbanization ratio in China is rather low with just over 50%. The rate for the USA and Japan is at over 70%. This explains the continuing high demand in infrastructure and urban construction.”

EXPLOITING SYNERGIES

“As a provider of full-range solutions, it is our goal to offer optimal support to international construction materials groups such as HeidelbergCement or Holcim for their projects worldwide”, says BEUMER expert Tissen. Therefore, the expertise of all BEUMER branches that are active in this field need to be pooled together and the resulting synergies need to be used effectively. For this, BEUMER established the Center of Competence for the cement segment. This centre is responsible for research and development, sales, project management, purchasing and above all the support of the group companies worldwide. Tissen explains that this requires smooth communication among each other, but it is worth it. The Chinese government supports large and profitable companies in order to further promote the cement industry and become a global leader in this segment. The supported companies benefit from low- interest loans, for example, or can acquire building areas more easily and quickly in order to expand further. The companies are also publicly supported when new projects are assigned.

GOOD CO-OPERATION IS BASED ON TRUST

China’s market leader produces about 12,000 tonnes of clinker every day at several sites for different applications and requirements, such as Portland or slag cement. The cement manufacturer was significantly involved in the construction of various large-scale projects, for example, the Oriental Pearl Tower in the Pudong district in Shanghai. At 468 metres, this is currently the third-highest television tower in Asia and the fifth- largest in the world. Further projects include the Shanghai Pudong International airport as well as the Beijing–Shanghai high- speed railway. This is the second longest high-speed line in the world with a length of 1,318 kilometres. The company is selling its products now in more than 20 countries in North America, Europe, Africa and Asia.

The manufacturer places particular value on production methods that are both energy-efficient and environmentally sound. They have been using BEUMER systems such as loading systems, belt conveyors and bucket elevators for years. “Our first order from the Chinese company was in 1995,” remembers managing director Dr. Beumer. In the meantime, the intralogistics expert has delivered and installed about 140 bucket elevators.

The cement manufacturer has ambitious goals to be able to compete with internationally leading companies and to stay prepared for the ongoing construction boom in China. The demand in cement is continuously rising. This is why they are permanently improving their technology and equipment and continue to rely on BEUMER. “The cement manufacturers know about the high quality of our plants and systems,” explains Tissen. “But our co-operation is mainly based on trust.” The president of Chinas’s market leader was able to see for himself the high quality of manufacturing of the products at the BEUMER Group headquarters in Germany. There are now also discussions about the supply and the installation of belt apron conveyors, filling systems and high-level palletizers. “As the competition from local companies is significantly increasing, we offer our products at favourable conditions to the Chinese manufacturer,” explains Tissen. “At the same time, our aim is to be more innovative and always one step ahead of our competitors.”

Another important aspect of good business relations is the BEUMER Group Customer Support. The agreements with the customer can range from only maintenance and inspection to a long-term placement of service personnel on site. In order to guarantee trouble-free intralogistic processes and a value-adding material flow, the BEUMER employees ensure the modernization of the plants and systems to meet upcoming performance and technology demands.

“On principle, our service agreements are specially designed to meet the individual requirements of the customer,” explains Tissen. “The service schedules as well as the reaction times are agreed upon in the contract.” The ‘BEUMER Belt Management’, for example, helps to avoid downtime through regular inspections and timely replacement of bucket elevator belts. The ‘Residential Service’ comprises technical support, preventive maintenance and inspection, emergency plans, system and process analyses and optimization as well as spare parts and facility management. “We make sure that the customers can keep pace with the increasing requirements,” explains Tissen.

BEUMER Group is an international manufacturer in intralogistics in the fields of conveying, loading, palletizing, packaging, sortation and distribution technology. Together with Crisplant a/s and Enexco Teknologies India Limited, BEUMER Group employs about 3,700 people and has an annual turnover of about €512 million in 2012. With its subsidiaries and sales agencies, BEUMER Group is present in many industries worldwide.

The importance of minimizing spillage and dust is crucial to the productivity of almost any bulk handling operation. Conveyor systems with inadequate material containment will regularly experience costly downtime, cumbersome clean-up and a high incidence of workplace injuries. According to the US Mine Safety and Health Administration (MSHA), 39% of conveyor-related accidents occur while cleaning or shoveling around conveyors. Now, more than ever, operators need to focus on improving efficiency, safety and productivity at today’s coal mines, coal preparation plants, bulk shipping terminals, and coal-fired power plants. Good housekeeping and dust and carryback reduction are increasingly important.

In today’s bulk material handling facilities, it is important to keep dust and product spillage in the load zone area to a minimum. Many plants struggle to keep these areas clean, due to not having enough time or manpower to properly adjust skirt rubber or fix holes in the chutes. Upon visual inspection of many load zone areas, it is not uncommon to find coal piles in between troughing idlers and on the floor. This product material spillage is expensive because there is a cost to remove the coal and if not properly fixed the coal piles will reoccur again and again.

Based on input collected from plant operators around the world, ASGCO®’s team of engineers set out to create the ultimate load zone containment system available today. ASGCO®’s Pro-ZoneTM system is a patent-pending modular conveyor belt load zone system that optimizes the seal for air/coal dust tightness on the receiving conveyor belt. This fully self-contained system is comprised of the company’s Slide-N- RollTM bed that supports the belt; eliminating the gaps found in a typical load zone with standard troughing idlers. The Slide-N- RollTM has an easy ‘slide out’ design for effortless removal of the UHMW support bars. The new centre roll design is simple to change out, just remove the retainer clips and the centre roller can be lifted out. Side guards attach to the Slide-N-RollTM frame to create a side enclosure that allows the angled hoods to be easily mounted. Hoods can be fabricated from aluminium or steel, which completely enclose the entire system. Inspection doors can be added to the hoods for quick assessment of chute conditions. Inside the Pro-ZoneTM are dust curtains and an internal splash sealing rubber system to effectively contain the coal dust.

CASE STUDY

Recommendations

ASGCO®’s team of inspectors identified the source of the containment problems and installed Pro-ZoneTM in the primary loading zones of the coal plant’s conveyors.

Findings

After eight months in service, the customer has found that the Pro-ZoneTM has been proven to: — and extend conveyor belt life

Conclusions

The customer has been extremely pleased with the performance of the new Pro-ZoneTM system as it has effectively eliminated product loss and dust, making it far les susceptible to costly fines and workplace injuries.

There are several key components of a well-designed conveyor system such as primary belt cleaners, wash boxes, and secondary belt cleaners, but few have been as innovative as the new Pro- ZoneTM load zone system from ASGCO® ‘Complete Conveyor Solutions’. Proprietary technology and practical application has quickly proven to yield immediate results for bulk handling operators worldwide, in a variety of industries.

Founded in 1971, in Allentown, PA- USA, ASGCO® ‘Complete Conveyor Solutions’ is recognized as an authority in bulk conveyor material handling systems. The company is focused on developing cost-effective and technologically advanced products, specifically designed for optimum conveyor performance and continues to strive to make the handling of bulk materials cleaner,safer,andmoreproductive.ASGCO® hasestablisheda global network of distributors and representatives around the world, located in Mexico, Brazil, China, Peru, South Africa, Canada and Chile.

Conveyor belts are as important for the bulk industry as veins are for the human body. Therefore, proper ‘housekeeping’ of conveying systems keeps these ‘veins’ clear, and keeps your blood pressure down.

Conveyor belts transport bulky or powdery dry raw material to the production area or to the stockyard or silos. Every service and maintenance manager knows that it is important to ensure that conveyors can run 24 hours a day, and that it is essential to have a cleaning system that efficiently removes the bulk material that falls off these conveyors. All those in the bulk industry know that even the best covered conveyor is not able to retain and transport 100% of the material that it transports over its lifetime; it is natural that, wherever bulk product is moved, there will inevitably be spillages, dust emissions, or grains that cause waste along these conveyor lines.

The industry therefore requires powerful tools that limit the amount of material wasted in the conveying process. These tools must be simple to use, and mobile, so that qualified — and sometimes unqualified — workers are able to use them quickly and efficiently where they are needed.

Nifilsk’s industry-focused Nilfisk-CFM brand has, for over 30 years, developed and distributed industrial vacuum cleaning solutions that combine the big material recovery containers or hoppers with efficient self-cleaning filter systems. At its core is the high vacuum positive displacement blower that can reach an 80% efficiency vacuum. This combination makes it possible to recover bulk material, or spillages, over long distances of over 100m.

An efficient vacuum ‘housekeeping’ system makes it possible to remove spills from around all systems such as crushers, milling equipment like ball mills, grinders, rotary kiln and silos — easily, quickly, and cleanly.

On conveying lines — in the case of horizontal conveyors like belts or screw conveyors, or in vertical conveyors like bucket elevators — it is necessary to keep the drive system, rubber belts and gear boxes clean and to avoid wear-and-tear on equipment, removing material fast in the case of unusual spills, perhaps as the result of a small accident.

With the right equipment, this spilled material is not only removed, but can also be directly returned to the production process, saving money.

Other applications are the cleaning of the conveyor that transports not only bulk material, but also bags in the case of rotary packers and conveying systems that transport the bags to the truck loading station. It is also possible to clean clogged screw conveyors below bag houses, and any other bulk material process.