BHT: Feb 2010

BULK HANDLING TODAY Feb 2010

Feb 2010
Featured on the cover: Contents

Bearing Man Group
Tel: (012) 803-7254
Cover Story Endorsing Bodies
5 Movers and Shakers... • CMA (Conveyor Manufacturers
Web: www.bmgworld.net
Association)
Crushers & Screens
9 Local Impactors • HCASA (Hydraulic Conveying
11 The First Line of Defence Association of SA)
• LEEASA (Lifting Equipment Engineering
Mining Association of South Africa)
15 Mining Dust Control
27 Beating the Costs • RFA (Road Freight Association)
• SAIMechE (SA Institution of Mechanical
Conveying Engineering)
17 Understanding Electric Motors
• SAIMH (SA Institute of Materials Handling)
30 Market Forum
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The monthly circulation Proprietor and Publisher: Advertising Sales:

is 4 016 PROMECH PUBLISHING Surita Marx
Tel: (011) 781-1401 DTP: Zinobia Docrat and
Fax: (011) 781-1403 Sanette Lehanie
E-mail:
bulkhandling@promech.co.za Printed by:
Our e-mail address is
Website: www.promech.co.za Typo Colour Printing
bulkhandling@promech.co.za
Managing Editor: Tel: (011) 402-3468
Visit our website on www.promech.co.za Susan Custers
Joint Editor: Andrew Lanham

CONVEYOR MANUFACTURERS ASSOCIATION
From the Chairman’s Desk

With the rain pouring down in torrents, certainly here in
Gauteng, it’s a wonder that most of the mines haven’t been CMA Members List as at February 2010
washed away or at least flooded. But no, and the conveyor sys- All members subscribe to the CMA Code of Ethics
tems carry on regardless, transporting materials to their allocat-
Member Company
ed destinations. Albeit rather muddy, wet and sludgy materials!
ABB Industry (Pty) Ltd
W
Afripp Projects cc
e at the CMA carry on as well, Actom (Pty) Ltd
Atlanta Manufacturing (Pty) Ltd
and even though it is still early in
Bateman Engineered Technologies Ltd
the year, committees are already Bauer a Division of Hudaco Transmission (Pty) Ltd
hard at work on behalf of our BMG (Bearing Man Group)
members, preparing for events and publications Bearings International
and, of course, some fun stuff as well! Belt Reco RSA
Bonfiglioli Power Transmissions (Pty) Ltd
The first issue of ‘The Conveyor Express’ has Bosworth A Division of Hudaco Trading (Pty) Ltd
been distributed to members. This will appear Brelko Conveyor Products (Pty) Ltd
every few months, and contains snippets on CKIT Conveyor Engineers (Pty) Ltd
just about anything that is of interest to you Continental Crushing & Conveying
all. It is also a forum for members to ‘convey Conveyor Watch (Pty) Ltd
and express’ their opinions, views, industry CMG Electric Motors South Africa (Pty) Ltd
CPM Engineering (Pty) Ltd
news etc.
CT Systems (Pty) Ltd
One of the special projects high on the agenda David Brown Gear Industries (Pty) Ltd
Simon Curry this year is to complete the CMA Handbook Delras Engineering (Pty) Ltd
on Conveyor Design. A great deal of progress DRA Mineral Projects (Pty) Ltd
Dunlop Belting Products (Pty) Ltd
has been made in the last few months, and the chapters
Dymot Engineering Company (Pty) Ltd
are taking shape nicely with much appreciated input from ELB Engineering Services (Pty) Ltd
our technical team and knowledgeable advisors, many of Facet Engineering cc
whom are familiar names in the industry. It’s a tough and Fenner Conveyor Belting (South Africa) (Pty) Ltd
often tedious job, but we’re doing it! Flexible Steel Lacing SA (Pty) Ltd
Hansen Transmissions SA (Pty) Ltd
No rest for the wicked Hosch - Fördertechnik (SA) (Pty) Ltd
As is said, there’s no rest for the wicked, and just as the M & J Engineering (Pty) Ltd
last bits of admin for Beltcon 15 have been cleared away, Martin Engineering
so we are already deep into the planning of Beltcon 16. A Melco Conveyor Equipment
call for papers is being distributed worldwide, so if you wish Moret Mining (Pty) Ltd
MS Conveyor Pulleys SA (Pty) Ltd
to participate as a speaker, let us know as soon as possible.
Nepean Conveyors (Pty) Ltd
We have set even higher standards for the 2011 Beltcon, OE Bearings (Pty) Ltd
and are determined to meet these. Osborn Engineered Products SA (Pty) Ltd
Read Swatman & Voigt (Pty) Ltd
If you wish to participate as a speaker, let us know as Rema Tip Top South Africa (Pty) Ltd
soon as possible Renold Crofts (Pty) Ltd
Roymec (Pty) Ltd
Another event to add to your calendar is the Annual Dinner RSV ENCO Consulting (Pty) Ltd
on 19 May at Bryanston Country Club, always a sociable Sandvik Materials Handling SA
and friendly evening together with wives and ‘significant oth- Schaeffler South Africa (Pty) Ltd
ers’. Space is limited, so again, book early. It’s a wonderful Secrivest (Pty) Ltd
opportunity to entertain customers and clients in a relaxed SENET
SET Agencies (Pty) Ltd
environment.
SEW Eurodrive (Pty) Ltd
Don’t forget the Members Meeting on 14 April. Shaft Engineering cc
Shaw Almex Africa (Pty) Ltd
On a sad note, we extend our condolences to the family, Siemens Southern Africa
friends and colleagues of Jan Detlof-Wismer, who passed SKF South Africa (Pty) Ltd
away unexpectedly on 20 December 2009. He will be re- Technique Avant Garde cc
membered, as was quoted at his memorial service, ‘with a ThyssenKrupp Materials Handling (Pty) Ltd
vodka and diet coke in one hand and the other outstretched Transmission Components (Pty) Ltd
in friendship’. Unitek Engineers (Pty) Ltd
Veyance Technologies Africa (Pty) Ltd
Simon Curry Voith Turbo (Pty) Ltd
Chairman Zest Electric Motors (Pty) Ltd

COVER STORY
Movers and Shakers ...

I
When n an exclusive interview with Gavin Pelser,
we talk Movers BMG’s director of engineered products, “Bulk
and Shakers, we’re generally Handling Today” learns that this expression is
referring to people who wield power and have also used by Gavin to describe what BMG’s OST
a strong influence in a particular field or activity, but it is bulk handling systems are all about. “OST (Oscil-
lating Systems Technology Africa) is a company
also a very apt description for some of the typical
now wholly owned by the Bearing Man Group,”
equipment you find in bulk handling
he explains. “OST’s materials handling, screen and
applications.
transmission products, available from
BMG’s distribution network, are supported
by specialised design and installation
teams who ensure these custom built
systems meet exact requirements in
any application.
“With the world becoming more competi-
tive every day, the manufacturing sector
is under huge pressure and therefore the
OST range of equipment is exactly what
industry needs as it gives the manufacturer
maximum production with the minimum
maintenance and maximum return on
investment,” says Gavin. “At the same
time our products are geared for energy
efficiency at maximum production.”
Competitive
The screen range includes vibrator motors,
screens, screen mounts and feeders, as
well as anti-vibrator units. Chain ten-
The self-tensioning motor base on vibrating screens sioners and self tensioning motor bases
make up the transmission
range. Materials handling
products include dynamic
impact beds, torsion bars,
skirt wings, belt scrap-
ers, impact zones and
H-Links.
Says Deon Crous, general
manager of OST-Africa.
“The modern trend in
global packaging, filling
and weighing operations
is to put more product
into a container and to
use smaller containers for
the same weight product
whereever possible.
Tables
“Our range of vibratory
tables, which combines
the benefits of compac-
tion and transportation,
produces more dense and
uniform distribution of
product in a container,”
The dynamic impact bed continues Deon. “This

COVER STORY
applications throughout the world. “Advantages

of the corrosion resistant Neidhart unit include
natural, oscillation and vibration damping,
as well as shock load capabilities
and extended service life,”
explains Deon.
“Most standard frames can
be converted to suit Neidhart
impact suspensions and
mounting pitches are suited
to fit existing stringers. No
special support structures are
required when using standard con-
veyors.”
Vibratory feeder
Spillage
Then there’s OST’s spillage solution which is designed
On start up, this skirt wing supports the complete to prevent production losses. It encompasses ten
conveyor belt system products that operate together to form one highly
efficient system. “This cost efficient spillage system
method reduces volume and acts as an interior
has important benefits over conventional systems
support for the packaging. Vibratory compaction
which are labour intensive, costly to operate and
can be applied to diverse packaging applications.
require additional equipment,” says Deon.
The vibratory tables include flat top, grid top,
outboard, belt top and weigh top tables. They are “Advantages of the OST system include simple
fitted with various types of liners to suit different installation, modular components for extended
applications.” service life of the system, reduced maintenance
and a low cost solution to spillage problems.”
Damping
At the core of OST’s range is the High Impact Tor- Functions
sion (HIT) design, based on the Neidhart system, Deon explains the functions of the various acces-
which is used in specialised materials handling sories offered by OST. “The dynamic impact bed, a

COVER STORY
shock absorbing trough, is mounted underneath a “This mobile feeder system can be quickly and
conveyor belt. It is installed at transfer points where easily dismantled and relocated when necessary.
fine or caurse heavy material is being transferred It is specifically designed for no spillage. Electrical
and where there is a build-up of materials in the panels for these feeders are also available.”
transfer chute. Says Gavin in conclusion, “Our engineers are
The HIT system combines a heavy duty idler frame constantly out in the field to assist customers
with a high impact torsion arm system to absorb in making the right choices. We have so much
the impact of material which falls onto the belt.” confidence in our product range that we needn’t
even offer maintenance plans as our equipment
Skirt clamp
simply doesn’t require maintenance. But ours is
Then there’s the skirt clamp, a conveyor system’s
not a ‘now you see us, now you don’t’ relation-
spillage controller, which also uses the Neidhart
ship, we concentrate on becoming partners with
system to allow for shock load absorption. The
our customers for life.”
skirt clamp ensures that positive pressure is always
applied to the side wall. Deon Crous, OST-Africa, Bearing Man Group, Tel: (012)
803-7254, E-Mail: deon@ost-africa.co.za
It is specifically designed for no spillage
“The skirt wing is yet another innovation and is

designed to support a conveyor belt between the
idler and frames when sagging occurs, in order to
prevent overflow spillage,” says Deon. “On start
up, this skirt wing supports the complete conveyor
belt system.”
Impact panels
OST impact zone panels are used at high impact
points in transfer chutes which are continually put
under high stress and therefore have the highest
maintenance requirements. This impact zone
panel absorbs impacts, and high wear resistant
liners ensure efficient operation and extended
service life.
Chute vibrators
Chute vibrators prevent material blockage in a
chute from forming while the Duff feeders are
Vibratory screen
used for the removal of
dry or wet material from
underneath belt scrapers
down to collection points.
“The primary belt scraper
blade tip is kept in posi-
tive contact with the belt
surface while the secondary
belt scraper is segmented
for maximum life from
all scraper components,”
explains Deon.
“The bias plough is a piece
of equipment that prevents
the duff remaining on the
belt from damaging the
return pulley.
Feeders
“Our materials handling
product portfolio also in-
cludes the Grizzley Feeder
System (GFS) which is
custom made to suit each
application,” adds Deon.
Primary belt scraper

2010
Tarkwa Unlocking potential

Building on the success achieved in diamond applications, recent major minerals
comminution operations have successfully incorporated Polycom HPGR technology.
In some cases the resource could only be developed using HPGR's inherent low wear
and energy cost, complimented by high throughput and machine availability
comparable with that of ball mills. In addition, the HPGR potentially improves liberation
which benefits overall recovery.
The wide variety of applications, including replacing SAG mill based flow sheets, pebble
crushing, fine crushing and heap leach preparation, is testimony to the versatility of the
Polycom HPGR. Gold, copper, platreef, platinum UG2, molybdenum and iron ore count
amongst the important “hard rock” ores which are successfully treated.
Polycom HPGR -
The key to efficient Comminution
Northam Cerro Verde Mogalakwena
Voorspoed
Polysius Service Centre Johannesburg South Africa
Global acceptance
Since 2007 the following significant Polycom HPGR installations have been operating
successfully:
•South Africa – Mogalakwena, Platinum
•South Africa – Khumani, Iron ore
•South Africa – Voorspoed, Diamonds
•South Africa – Northam, Platinum
•Peru – Cerro Verde, Copper
•Indonesia – Freeport, Copper
Boddington
•Canada - Snap Lake, Diamonds
•Canada – Victor, Diamonds
•Australia – Boddington, Gold
•Ghana - Tarkwa, Gold
with many more Polycom HPGR's currently being installed and commissioned in
•Australia •Brazil •Canada •China •Japan •Mauritania •Mexico
Local service and customer support

Advanced Service Centres in South Africa, Australia, South America and
Germany ensure dedicated after sales support.
Khumani Polycom HPGR success – A tribute to innovative process design
Polysius
A division of ThyssenKrupp Engineering (Pty) Ltd Visit us at
71 Nanyuki Road, Sunninghill 2191 / Republic of South Africa Electra Mining
Tel: +27 (0) 11 236-1218. Fax: +27 (0) 11 236-1301 Hall 6, Stand J3
e-mail: pia.guertler@thyssenkrupp.com 4 - 8 Oct 2010
www.polysius.co.za
CRUSHERS & SCREENS
Local Impactors
Buying capital equipment
locally has distinct
advantages in terms of spares
availability and support, but the
biggest benefit is being able to
Customising
custom engineer certain aspects on
The company kicked off with the design and manu-
machinery to suit specific conditions. In facture of a horizontal shaft impactor (HSI) and
rock crushing this is particularly convenient as so far have completed several installations with
the same raw material often differs from one region this machine as the primary crusher. Their vertical
to the next and a customised crusher can make a huge shaft impacter (VSI) has now been designed and
difference on the throughput. the company expects sales to take off this year.
“Most impact crushers in South Africa come from
B
ulk Handling Today” speaks to Shane Be- overseas but ours are entirely manufactured here
attie of Crushrite about the niche market in our workshop from locally sourced materials,”
this engineering company has created in says Shane. “Because we design ourselves, we
the local industry. “There’s always been have the flexibility to modify machines to very
this debate about choosing between a horizontal specific customer requirements.”
or a vertical impact crusher, but there is a place Turnkey
for both and therefore we decided to manufacture Although Crushrite sells their own series, they also
both,” he says. “From experience we know the make spares, service, maintain and upgrade other
advantages and shortcomings of impactors, so we makes of impact crushers for a broad spectrum of
decided to design our own series for both types existing customers in the lime, chrome and cement
of crushers.” processing industries. “We can supply anything from
Ours are entirely manufactured here in our workshop an impactor to full turnkey systems that include
from locally sourced materials conveyors, chutes and screens,” says Shane.
“We’ve just supplied the entire plant for a rubble
recycling operation and also a whole plant for a
lime processing application where our installation
functions as the primary processing machine.
Most recently we supplied a new Crushrite HSI
machine as a tertiary crusher in a cement pro-
cessing plant.”
Semi mobile
The system on both impactors is modular and can
be adapted to each individual situation while being
either semi-mobile or fixed. The semi-mobile unit
Shane Beattie of Crushrite
The semi-mobile impactor

CRUSHERS & SCREENS
comes complete with VSD drive, control systems, modifications have been made to make the ma-
conveyors, impactor and screens. “Clients who are chine uncomplicated. “From the start our objec-
using our design have been impressed with the tive was to make our machines more user-friendly
reduction rates they’re getting,” says Shane. in general,” says Shane. “As we do a lot of the
maintenance ourselves, we paid a lot of attention
We’re reducing lump sizes of 450 down to 60 with a to ease of access, not only for servicing, but also
99% pass rate to replace parts.”
“At the lime installation, for example, we’re reducing Impact
lump sizes of 450 down to 60 with a 99% pass Although Crushrite’s two types of impactors work
rate. Lime stone is easy to work with though, but on completely different principles, the choice
in our chrome processing installation, which is a between the two depends mostly on the material
much more abrasive material, we’re also getting being processed and the reduction rate required.
feedback of above average reduction rates. Impact crushers involve the use of impact rather
Lump sizes than pressure to crush material.
“The rubble recycling company which is using our As an HSI crusher breaks rock by impacting the
semi-mobile unit says they can do lump sizes of rock with Blow Bars that are fixed on the outer
600 even with pieces of metal and rebar going edge of a spinning rotor, the particle size can be
through without damage to the machine.” controlled by the gap setting between the outer
Although the design of the Crushrite series is edges of the blow bar to the face of an impact
not unique in terms of the principle of operation, plate. The practical use of HSI crushers is limited
to medium to soft materials and non abrasive
materials, such as limestone, phosphate,
gypsum, and weathered shales.
Velocity
VSI crushers, on the other hand, use a different
approach involving a high speed rotor with
wear resistant tips and a crushing chamber.
This impactor predominantly utilises autog-
enous crushing (rock on rock) rather than
surface force to break rock. Final particle
size is controlled by the velocity at which
the rock is thrown against a Rock Box.
The product resulting from VSI crushing is
generally of a consistent cubical shape such
as that required by modern highway asphalt
applications. Using this method also allows
materials with much higher abrasiveness to
be crushed compared with an HSI and most
other crushing methods.
VSD drives are used on the impactors
Coal
“We’re targeting the coal industry as our
machine will show very low wear costs while
easily coping with the required tonnages as-
sociated with coal processing,” says Shane.
“Compared with cone and other crushing
methods, our machine is also about 30%
lower in capital costs. Because we manufac-
ture locally we’ve been able to offer a good
pricing structure and are able to make the
impactor a bit more affordable, especially
on the primary side.
In the aggregate industry the good product
shape and high percentage of sand makes the
impactors attractive while the high reduction
ratio of the H.S.I is a bonus.”
Shane Beattie, Crushrite, Tel: (011) 826-662, Email:
shane@crushrite.co.za
A VSI impactor under construction
10 BULK HANDLING TODAY Feb 2010

CRUSHERS & SCREENS
The First Line of Defence

Keeping customers happy is not just about selling them the of the people at each branch to pinpoint the best
correct equipment to do the job, but rather, tailoring a pack- solutions for each application is a vital asset. “Our
age that maintains the sustainability of their business long people have determined that the pre- and after-
after the order is signed. sales service requirements of our customers are
O
definitely a matter of individual choice, but there
ver the past 12 years the level of skills is a common element, being able to discern the
requirements versus available skills has optimal manner in which to increase productivity
influenced mining houses to re-evaluate and reduce downtime in each specific applica-
their business strategies and consider tion,” he says.
sourcing skills externally. “This is an ability which stems from skills, com-
Why a specific panel has to be replaced after a shorter mitment and experience gathered over many years
of industry exposure.”
period than planned
Flexible approach
Multotec was one of the first companies in the This flexibility in approach is evident in the structure
industry to actively embrace this trend and has of each branch of the business and the variety of
built up a strategic branch network to cater for the packages available to customers. “Although we offer
demand and to learn more. “Bulk Handling Today” the same basic elements to customers such as 24/7
speaks to Derrick Alston, service, preventative maintenance programmes,
managing director of Mul- service teams, strategic parts availability and so
totec Manufacturing. forth, each customer liaises with the branch man-
“In the past, the branches agers and the field service teams to determine the
we had in place served best fit for their particular operation.”
solely as sales outlets for “It would therefore be true to say that while some
our product range,” he says. of our branches are still in their infancy, all of the
“However, we identified a branches have the same work ethos and strive to
need to service our custom- find the most cost effective and workable solutions
ers more comprehensively to customers’ production and maintenance require-
by being located in close ments,” Derrick adds.
proximity to their opera-
tions and thus the branch Software
network was expanded for The company uses its in-house developed Hawkeye
this purpose.” software programme to monitor screen maintenance
processes. “This Web-based application, accessible
Common element anywhere in the world, offers both our people and
Derrick points out that be- our customers an easy-to-use interface which allows
cause each customer has accurate and efficient recording of maintenance
Derrick Alston, managing director of Multotec different needs, the ability
Manufacturing
activities,” says Derrick. “These entries are stored
in a database, and can be called up as required
in a number of ways so as to zoom in on what is
actually happening on the screen.”
“This is important information for us to have from
a costing perspective since it provides accurate
data on average usage and the cost implications
involved,” he adds. “In addition, the benefit to both
the customer and our maintenance team is that
Hawkeye provides us with accurate trends. For
example, it may indicate an inferior chute design
which is resulting in excessive wear and tear with
associated downtime. This then allows us to make
recommendations to customers to improve critical
elements within their plants.”
Correct stock
This also allows maintenance teams to be directed
to a specific problem area with the correct stock
Training is paramount at Multotec on hand. “Variance reporting records show why a
BULK HANDLING TODAY Feb 2010 11

CRUSHERS & SCREENS
problems can also be identified.”

The Hawkeye system is used for most Mul-
totec Group products with the potential to
roll it out for the entire basket of metallurgi-
cal processing equipment it supplies to the
mining industry.
Saving millions
Martin Jonck, branch manager of Multotec
in Middelburg, has a maintenance staff of
over twenty who run the gamut in what is
known as the Eastern Area, from Delmas to
Barberton. “Within this region we provide
scheduled preventative maintenance for
more than fifteen coal and gold mines. In
each instance, we work around the schedules
of our customers who inform us when our
services are required on site.”
Preventative maintenance
Martin says this service goes beyond just
maintaining equipment in working order. “This
Screen panels being replaced
includes the total management of product
specific panel has to be replaced after a shorter maintenance which entails stock ordering
period than planned, for example,” says Derrick. and stock keeping, transportation of stock and its
“This means that underlying causes such as process installation. We closely monitor the consumption
levels of, for example, magnetite, before the start
Costing currently based on the number of square metres of a replacement programme and we would also
of product maintained recommend a specific screen panel for an applica-
tion with regard to sizing.”
Martin cites an example where over a three year
period they were able to assist in reducing the
downtime at the plant from 90 hours per annum to
a mere 24 hours per annum. “Even in conservative
terms this equates to a saving on lost production of
between $14 million and $20 million,” he says.
Tobie Rudolph, field services manager at Multo-
tec’s Rustenburg branch, has a team of over fifty
technicians, artisans and installers servicing the
maintenance needs of the company’s customers
in the 150 km linear area between Rustenburg
and Thabazimbi.
“We have provided a preventative maintenance
service to customers in what is referred to as the
Western Section for 10 years and in the Eastern
Section the packages have been in place even longer,
so we are well versed in this arena,” he says.
Familiarity does not breed contempt
Multotec’s Secunda Branch inherited the mainte-
nance contracts previously undertaken by Debex.
“These contracts, with a major mining house and
a petrochemical company, have been in existence
for over 15 years and incorporate tailor-made
procedural and billing solutions, with the mining
customer electing for a costing currently based
on the number of square metres of product main-
tained,” Cliff Snyman, Multotec branch manager
in Secunda, says. “In essence, we sell the product
and parts to the collieries, and then we send a
team to undertake repair work.”

CRUSHERS & SCREENS
Pinpointing potential problem areas branch develops, to extend the full preventative
Success breed success, especially when the ser- maintenance package to other customers in the
vice offered to customers is of such a level that surrounding areas.”
downtime is consistently minimised. “We provide
Future hotspots
preventative maintenance services to a number of
“We have the capacity to customise products to
mines in the Northern Cape region including iron ore
customer specifications which means that the prod-
and diamonds,” Mark Mannel of Multotec’s Sishen
uct is the best fit from the outset, resulting in both
Branch says. “At this branch supply maintenance
increased productivity and decreased downtime,”
packages depend on the application demands, and
Derrick says in conclusion.
offer a high degree of flexibility to the customer. For
instance, we have a fixed rate with a permanent We have the capacity to customise products to customer
team on site or a variable rate, calculated in ton- specifications which means that the product is the best
nage of product passing over the panels. fit from the outset
“In the first case, a predetermined portion of the
“What is apparent throughout our branches is a
plant is shut down on a daily basis to allow inspec-
credo of reducing production costs for our cus-
tion and replacement of screen panels, sideliners
tomers through analysing their specific needs,
and nozzles to ensure the seamless running of the
monitoring their operations to proactively pinpoint
process. The other option is to dovetail mainte-
future hotspots, planning for maintenance that will
nance requirements with the customer’s shutdown
have the least negative effect on the production
schedule, again minimising plant disruption or
process, and retaining adequate and appropriate
shutdown.”
stock levels in order to facilitate maximised uptime
Shipshape for our customers’ operations.”
Unlike its counterparts which deal with land-based Bernadette Wilson, Multotec Group, Tel: (011) 923-6193
customers, Multotec’s Cape Town branch is actively Email: marketing@multotec.co.za, Website: www.mul-
involved in maintaining the screens, mills, cyclone, totec.com
magnetic separators and other process related
equipment such as chutes on vessel-based diamond
processing plants. “Our maintenance periods are
also governed by statutory regulations of maritime
law and very specific wear patterns related to
mining at sea. In other words, we often wait until
we are informed by our customer that a ship is
coming into port and then we encamp ourselves
on the ship for the duration of the running repairs
and replacements,” Vivian Rocher, Multotec’s Cape
Town branch manager, says.
“In other instances, a ship may be forced into port
because it has lost an anchor or some similar mishap
has occurred and then we seize the opportunity to
conduct required maintenance. In cooperation with
the customer, breakdowns and other emergencies
are also dealt with at sea.”
Building on a concept
Such has been the success of Multotec’s philosophy
of providing a total support solution through the
establishment of branch offices in close proximity
to its customers that new locations are constantly
being investigated and developed.
Dawie van Eeden, who was responsible for setting up
and developing the Sishen and Kimberley branches,
is now in the process of establishing an office in
the Lephalale area, previously known as Ellisras.
“In addition to Lephalale, this area extends from
Thabazimbi into Botswana and northern Limpopo
where we currently provide a full time maintenance
programme to one of the largest diamond mines
in South Africa as well as an ad hoc maintenance
service to other mines in the area,” he says. “The
aim is to develop this service offering and, as the Trommel aperture panel replacement underway

Why men shouldn’t write
advice columns
Dear John, Dear Sheila,
I hope you can help me. The other day. I set off for work, A car stalling after being driven a short distance can be
leaving my husband in the house watching TV. My car caused by a variety of faults with the engine. Start by
stalled, and then it broke down about a mile down the checking that there is no debris in the fuel line. If it is
road, and I had to walk back to get my husband’s help. clear, check the vacuum pipes and hoses on the intake
When I got home, I couIdn’t believe my eyes. He was manifold and also check all grounding wires. If none
in our bedroom with the neighbour’s daughter! of these approaches solves the problem, it could be
I am 32, my husband is 34 and the neighbour’s daugh- that the fuel pump itself is faulty, causing low delivery
ter is 19. We have been married for 10 years. When pressure to the injectors.
I confronted him, he broke down and admitted they I hope this helps,
had been having an affair for the past six months. He John
won’t go to counseling, and I’m afraid I am a wreck
and need advice urgently. Can you please help?
Sincerely, Sheila

MINING
Mining Dust Control

It’s natural to think that a mine is not in operation if there isn’t a dust cloud, however slight, hanging over the
processing works. It’s also natural to assume that it’s just natural rock dust which could hardly be described
as pollution. However, in actual fact this dust could come directly from the minerals being mined and is so
fine that it not only enters the human body through breathing, but can actually penetrate the skin to cause
health problems.
T
his dust is generally not released intention-
ally, but more often than not comes from
leaking dust conveying and dust collecting
systems that have not been maintained
properly or worse, not installed correctly from the
start. “Bulk Handling Today” speaks to Jeremy
Kirsch, executive director of Clyde Materials Han-
dling Africa, an expert in pneumatic conveying and
dust collection systems.
Only to let most of it escape again along the way
“If you look at the collection of fine dust in bag

filters and the conveying away of this dust from
the dust collection systems, you’ll inevitably find
that 80% of these systems are leaking,” he says.
“This not only causes air pollution, but is also a
waste of energy.”
Focuses
Air pollution of this kind where sub micron particles Jeremy Kirsch executive director of Clyde Materials
are spread beyond the mining area to surrounding Handling Africa
communities, is becoming a problem and Europe is
already busy with legislation to curb this. Jeremy controlling air pollution of this nature through im-
says, “Our focus, on the one hand, is directed at proved filtration technology. It doesn’t stop there
though, you also have to
get the material out of the
filtration system once it has
been collected and trans-
port it to a place where it
can be stored safely without
releasing any of it back to
atmosphere.
“Our second focus area is
examining the amount of
energy spent on controlling
air pollution,” explains Jer-
emy. “It’s no use spending
huge amounts of energy to
collect dust generated by
the process, conveying it
to a filtration system and
then on to safe storage
only to let most of it es-
cape again along the way.
More energy then has to
be expended to collect the
dust spillage and even if it
goes back into the system,
The system Clyde Materials Handling designs it all adds up to a lot of

MINING
energy being thrown around. opportunity to introduce our technologies,” says

Jeremy. “Companies where we’ve installed our
Pain levels
solutions immediately see the benefit and as result
“We believe the two areas, pollution and energy,
retrofit our technology in other applications as well.
are increasingly becoming important, not only
Although the driving force is not yet pollution or
from an energy cost point of view, but also from
the energy aspect, we’re making headway into the
an environmental point of view,” says Jeremy.
marketplace.”
“Companies in Europe that don’t comply with the
relevant legislation face strict punishment to the The technologies
point where they can be closed down if they don’t The technology Clyde Materials Handling uses is
comply. This type of legislation has been tabled not new. Lean phase and dense pneumatic convey-
in South Africa and its enforcement is set to come ing and bag filter technologies have been around
our way soon.” for ages. “It’s the body of knowledge we’ve built
up over the years, applied to these technologies,
which is the differentiator,” says Jeremy.
“Most of the 80% of systems that are leaking dust,
will have a lean phase pneumatic conveying system
that is leaking purely because it wasn’t designed
correctly. Both lean and dense pneumatic conveying
have their place in the market, but they have to
be designed with a knowledge base of experience
in the materials being conveyed.”
A reduction in energy consumption of at

least 15% and greater which is a
quantum leap
New developments
Continuous dense conveying has always been a chal-
lenge but the engineering team at Clyde Materials
Handling in South Africa has now found a solution.
“We have come up with a technology whereby we
can go from the traditional dense phase conveying,
which is a batch-wise process, to true continu-
ous dense phase conveying,” Jeremy says. “The
continuous dense phase conveying system we’ve
developed shows a reduction in energy consumption
The CD-Pump system from Clyde Materials Handling of at least 15% and greater, which is a quantum
leap in terms of savings in industry.
Clyde Materials Handling Africa has the technol-
ogy to prevent dust pollution while saving energy “In addition, we have paid attention to mechani-
at the same time. “Several institutions have begun cal problems in order reduce maintenance to the
installing our systems, because of the air pollution minimum. Better, longer lasting sealing arrange-
and energy saving benefits,” says Jeremy, “but ments, new valve systems and injector technology
mostly from a maintenance perspective. In our for furnace feeding are some of the improvements
experience, the only companies that are prepared that are now standard on our products.”
to make dramatic changes away from traditional Jeremy Kirsch, Clyde Materials Handling Africa, Tel: (011)
technologies are those that have experienced im- 704-0580, Email: jeremyk@cbz.co.za
mense pain.
Unworkable
“Let’s say there is something in a plant that is
not working very well, but due to high production
pressure, nothing is done about it. Quick fixes are
When the business world lights up again, and
the order of the day until the issue gets to manage-
the clarion call for skills is heard once more,
ment level where they realise they’re losing money,”
will you be on our database for us to contact
explains Jeremy. “This is when they will open up
you?
and start looking at other technologies to try and
www.engineerplacements.com
solve their problems.
or email us at:
“Situations like these, where maintenance prob- admin@engineerplacements.com
lems have become unworkable, have given us the

CONVEYING
Understanding Electric
Motors
T
here are two
main types of
electrical mo-
tors found in
industry: AC motors
and DC motors. For
the purposes of this
paper, we will deal
only with AC motors
as DC motors are used
very infrequently and
are only be applied in
very specialised ap-
plications. AC motors
are available in three
types: Asynchronous
AC induction motors,
synchronous AC in-
duction motors and
slipring AC induction
motors.
Of these three types
Figure 1: “Squirrel Cage” Motor only the asynchronous
AC induction motor
needs to be considered
for conveyor applications. This type of motor is also known
as a “squirrel cage” motor or even just as an AC motor.
IP Rating Definition Prime mover
First Numeral Second Numeral Due to its construction and
Protection against solids Protection against liquids
electrical characteristics, this
motor has become the prime
0 No Protection 0 No Protection
mover in all industries. These
1 Protection against solid objects > 50 mm 1 Protected against vertically falling drops of water motors are simple to operate,
(hands) (condensation)
very robust and adaptable to
2 Protection against solid objects > 12 mm 2 Protected against sprays of water up to 15º from most applications. Because
(fingers) vertical
there is no physical connec-
3 Protection against solid objects > 2.5 mm 3 Protected against sprays of water up to 60º from tion from the rotor to any
(tools / wires) vertical
external electrical power
4 Protection against solid objects > 1.0 mm 4 Protected against water sprayed from all directions
(small tools / wires) (outdoor rain)Limited ingress permitted supply, the standard AC motor
can be designed to an IP55
5 Protection against dustLimited ingress per- 5 Protected against low pressure jets of water sprayed
mittedNo harmful deposits from all directions (hosepipe)Limited ingress per- or even an IP66 degree of
mitted protection. Different electri-
6 Totally protected against dust 6 Protected against strong jets of water sprayed from cal designs are also possible,
all directionsLimited ingress permitted for example, such as motors
7 Protected against immersion between 15cm and that need either a high or low
1m torque to start.
8 Protected against long periods of immersion under
pressure (> 1 m) The IP rating of a motor is a
specification of it’s degree of
Table 1: IP rating definition

CONVEYING
Figure 2: The principle of operation of an electrical motor
protection against the ingress of external contaminants ie, wound around a part of the stator core. Each phase produces
solids and liquids. “IP” is the abbreviation for “Increased a magnetic field. As the AC voltage fluctuates, the magnetic
Protection”. The higher the IP rating the higher degree of field changes and rotates. The movement of the magnetic
protection. Table 1 details the meaning of the various IP field in the stator magnetically induces a voltage and current
ratings. in the rotor. (Hence the term induction motor).
The higher the degree of protection, the more The current flowing in the rotor also produces a magnetic field.
The stator and rotor magnetic field interact. The stator field
robust the item must be
attracts the rotor field causing the rotor to rotate following
the stator field. Except for VSD applications, the stator field
Practical implications always rotates at a speed that corresponds exactly with the
It would seem then that the best you can do is to specify
frequency of the supply. In South Africa this is 50Hz. When
that all motors and VSD panels be IP68 or IP66. Unfortu-
a motor has 2-poles the speed of rotation is 3000 RPM,
nately, there are practical implications to achieving the above
4-poles is 1500 RPM and 6 poles is 1000 RPM. This can
protections. The higher the degree of protection, the more
be calculated as follows:
robust the item must be. Due to the simplicity of construc-
tion an AC motor can easily and practically be manufactured
to a high degree of protection. Guidelines for IP ratings for
standard AC motors as per figure 1 on previous page are
given below.
This is known as “synchronous speed”. It is synchronized
• Cast iron totally enclosed – IP66
with the mains supply frequency.
• Large AC motor of fabricated steel construction – IP55
• Large AC motor terminal box – IP65 The rotor and hence the motor shaft never turns at the same
• VSD panel for indoor use – IP42 speed as the stator field. The difference in rotational speed
• VSD panel for outdoor use – IP54 is termed the motor “slip”. Typical slip values are between
0.3% and 4% of stator speed. The actual value of the slip
Magnetic field differs from motor to motor and is dependant on many de-
A three-phase alternating current (AC) voltage is applied to sign factors. A 4-pole motor can thus run at 1450 RPM or
such a motor. Each phase is connected to a winding, which is perhaps 1460 RPM or even 1490 RPM. This is the motor’s

CONVEYING
Item Description teristics are shown in Table 2.

Nominal Power The mechanical power that the motor is rated to deliver on its shaft There is no specification that gives
Nominal Voltage The nominal voltage at which the motor is designed to be used exact values for these characteristics.
However there is an acceptable and
Full Load Current The current drawn from the supply at 100% of motor power
normal variance. Each motor has a
Nominal Speed The speed at which the shaft will rotate when the motor supplies data sheet applicable to that motor
100% load
only. The data sheet for a motor
Locked Rotor Torque The torque that the motor will supply at starting when started direct of the exact same rating but from
on line
a different manufacturer or even
Breakdown Torque The maximum torque that motor can deliver before stalling
from a different range by the same
Nominal Torque The design or nominal torque manufacturer will have a different
Locked Rotor Current The current the motor will draw from the supply at starting when data sheet. For example, two mo-
started direct on line tors each rated as 525 V, 250 kW,
Locked Rotor Time The time for which a motor can endure locked rotor current without 4-pole will have a differing starting
exceeding its thermal limit
torque, current etc. One may have
Table 2: Different motor characteristics a starting torque of 130%, another
may have 200%. One may have a
nominal speed and is always quoted at 100% rated load. If nominal current of 334 A, another of 348 A. One may have
the mechanical load is reduced the motor will run faster. For a nominal speed of 1485 RPM, another of 1490 RPM. One
example, a 1460 RPM motor will run at 1480 RPM at 50% design is not necessarily better than the other; there are just
load. AC motors have common features or specifications but always slight differences.
there is a possible range of values for these.
Graph 1a and 1b show two motor data sheets and charac-
Exact values teristic curves with an example of these differences.
Before considering different motor characteristics, let us
understand these different characteristics. The main charac- In terms of torque characteristics there are two types of
motors: (See graph 2)
• Normal torque –
IEC34 Design N (or
Nema MG.1 Design
B)
• High torque – IEC34
Design H (or Nema
MG.1 Design C)
High starting torque
motors, Design D,
uncommon and not
considered here.
Normal torque motors
have a starting torque
that varies from 1.9 for
a small motor to 0.9 for
a large motor. Break-
down torque varies
from 2.0 to 1.7. These
values are per unit of
nominal torque.
High torque motors
have a starting torque
that varies from 3.0
for a small motor to
2.0 for a large motor.
Breakdown torque var-
ies from 2.1 to 1.9.
Correct performance
Selecting a motor as
either a Design N or
H is not a guarantee
of correct performance.
It is always better to
Graph 1a: Motor Data Sheets and Characteristic Curves check the exact motor

CONVEYING
characteristics from its

data sheet. There is also
no definite industry stan-
dard stating that motors
normally kept in stock are
to be of a certain design.
This should always be
checked.
An AC motor has three
windings. One is connected
to each phase of the sup-
ply voltage. In order for
current to flow the ends
of the windings must be
connected to one another.
They can be connected in
star or in delta. As illus-
trated in figure 3:
The individual motor wind-
ings are designed to operate
at a certain voltage, eg,
400 V.
Star/delta
When a motor is connected
in delta, the line voltage is
connected directly to the
two ends of the winding.
Graph 1b: Motor Data Sheets and Characteristic Curves Therefore the voltage on
the winding is the same
as the supply voltage. When a
motor is connected in star, the
line voltage is connected to one
end of the winding and the three
windings are connected to each
other at the other end.
When connected like this, the
voltage across the winding is
only 58% of the line voltage.
For example, 400 V line voltage
will result in 230 V across the
motor phase voltage.
The effect of this is like connect-
ing the motor to a low voltage. It
has a low starting current, low
torque and slow acceleration. This
is what is done when motors are
started star/delta. It is a simple
method of “soft start”.
Correct motor selection
From an electromechanical per-
spective, there are four main
considerations when selecting
a motor:
1. Nominal power – This defines
the rated output power of the
motor. This must exceed, but
be closely matched with the
absorbed power requirement of
Graph 2

CONVEYING
Figure 3: Connections for three-phase systems
/ 0.7 = 143 kW. The

two nearest standard
motor sizes are a 132
kW or a 150 kW.
2. Nominal RPM – This
defines the motor speed
of rotation at full load.
Generally 4 pole mo-
tors, e.g. 1460 RPM are
most commonly used.
However, certain loads
may require 2-pole, 6-
pole or another nominal
speed. The number of
poles affects the motor
nominal speed and
torque. A 4-pole motor
runs at 50% the speed
of a 2-pole motor and
at 200% the torque of
a 2-pole motor of the
same power rating.
(See equation 1)
3. Starting torque
the mechanical load. When a motor runs at a load between – This defines the torque that the motor will deliver at the
70% - 100% of nominal power it is at its best efficiency. The moment of starting DOL. For high inertia loads such as a
safety margins in the design should then aim to not exceed large fan, one would want a low starting torque to avoid
this. Therefore, for example, if the load absorbed power is undue mechanical stress at startup. Conveyors require a
100 kW, the installed motor should not be greater than 100 relatively high starting torque.
For this reason a motor with high or sufficient starting torque
must be selected. The nominal starting torque also affects
the acceleration time. The higher the starting torque, the
Equation 1 quicker the acceleration.

CONVEYING
4. Locked rotor time – This defines the length of time for ambient temperature of 40°C the hottest spot in the motor
which a motor can draw starting current without overheating. would reach 130°C, while the motor insulation system is
Starting current is drawn during acceleration; therefore the capable of operating at 155°C. This gave a margin of safety
motor locked rotor time must exceed the time required for of 25°C. In recent times, and especially in the 525 V mining
acceleration. Motor manufacturers may provide either a hot industry, this has changed so that the motors have a Class
or cold locked rotor time. The locked rotor time considered H insulation system. This then gives a safety margin of
should be the hot locked rotor time so that the load can be 50°C. In addition, it is seldom that motors are run at 100%
started without undue delay after a trip. A high inertia load of nominal power.
such as a fan will require a long locked rotor time. Conveyors These temperature classes have nothing to do with dielec-
have a low inertia and do not require a long locked rotor tric strength or voltage insulating strength or capability to
time. It is desirable for a conveyor to have a very gradual withstand peak voltage capability.
acceleration over a fairly lengthy period.
The second consideration in terms of motor insulation is
This is normally achieved by using an electronic variable dielectric strength or peak voltage rating of the motor insu-
speed drive or a mechanical fluid drive coupling. In both lation. When a motor is used with 525 V, it does not have
cases the motor is not subjected to starting current during 525 V insulation because the peak values of the sine wave
the acceleration time. and other voltage peaks present are much higher. When
These are not the only considerations. A complete design used in DOL applications, the voltage rating is not a major
would consider the mechanical mounting arrangement, concern. This is because most insulation systems can cater
type of bearings, type of coupling, ambient and altitude for voltage peak values >1000 V. This far exceeds any volt-
de-rating, etc. age peak that occurs on a DOL system. In resent years, the
percentage of motors used on AC variable speed drives has
Specific motor features for conveyor applications
increased greatly. On VSD applications the motor insulation
From a motor electrical design perspective, conveyor applica-
dielectric strength is very important. The requirements for
tions do not require any specific features. Selection should
VSD applications are dealt with later in this article.
be as described in the previous section. Often conveyors are
in locations where the ambient conditions and mounting VSD motor applications
arrangement must be taken into account. There are many benefits to using VSD driven motors on
conveyor applications:
Not a pure smooth sine wave such as Eskom 1. The conveyor start-up can be controlled optimally and
supplies thereby the stress to the belt and structure is minimised
2. The conveyor speed can be varied to cater for differing
Different types of motor insulation product or process delivery requirements
In terms of motor insulation, the main consideration is ther-
3. At times when full production is not required, the conveyor
mal characteristics. This defines the maximum temperature
can be slowed down resulting in reduced electrical power
that the motor can reach before the insulation material is
consumption and also reduced mechanical wear
damaged. For practical purposes, there are three tempera-
ture classes to consider: Class B, Class F and Class H. The There are many concerns as to AC motor compatibility for
temperature class is determined as follows: VSD applications. In principle, any normal AC motor can be
used in conjunction with any AC VSD. The VSD will start and
Motor insulation Thermal Classes in °C control the motor speed. The issue of compatibility affects
medium and long term durability and reliability. So, while
Insulation Class: B F H
any AC motor can be driven by any AC VSD, this does not
Ambient 40 40 40 necessarily guarantee compatibility. Fortunately, this is not
Heat rise 80 100 125 difficult to achieve. Compatibility can be considered from
Hot spot allowance 10 15 15 four perspectives:
Total maximum temperature 130 155 180 1. The motor thermal capability
Table 3: Summary of thermal class values 2. The motor insulation suitability
3. Mechanical adaptations required on the motor
Total maximum temperature = Ambient + heat rise + hot 4. Mechanical speed limitations
spot allowance The voltage and current that an AC VSD supplies to a motor
Ambient temperature is 40°C is not a pure smooth sine wave such as Eskom supplies. The
distortion is known as harmonic distortion. This distortion
Heat rise is the motor rise in temperature when it supplies
creates additional heat losses of 1 – 5% in the motor. The
nominal power. Hot spot allowance makes allowance for the
motor thermal capability and hence it’s torque delivery is
reality of a non-uniform heat rise resulting in certain points
reduced by this amount. An AC VSD driven motor current
within the motor being hotter than others.
is illustrated in graph 3.
Table 3 gives a summary of the thermal class values.
Loss of cooling
Until recently almost all motors were designed and specified An AC motor is dependant on a shaft-mounted cooling fan on
with a Class B heat rise and a Class F insulation system. the non-drive end for cooling air flow. When a VSD is used
This meant that when operated at 100% full load in an to slow the motor down, this air flow is reduced. As a result,

CONVEYING
permissible current
at which the motor
can run is reduced.
Current and torque are
roughly proportional,
therefore the motor
capability to deliver
torque on its output
shaft is reduced. The
relationship between
speed and torque is il-
lustrated in Graph 4.
For example, a motor
may be rated at 100
A and 200 Nm. When
used in a VSD ap-
plication, this motor
can only deliver 95
A and 190 Nm for
an extended period
Graph 3
of time. If this same
motor runs at 25%
the motor thermal capability is reduced. This means that at speed it can only deliver 75 A and 150 Nm at that speed.
speeds below 100%, the motor can no longer run at 100% This is a purely thermal consideration and this limitation only
nominal current. To compensate for the loss of cooling, the applies to constant operation. The motor may be overloaded
Graph 4: The relationship between speed and torque

CONVEYING
Magnetic flux weakens

Above 100% speed, the motor mag-
netic flux weakens. This is known as
“field weakening”. Motor torque is
proportional to motor flux therefore in
this area, the motor torque capability
is reduced proportionally to the inverse
of the speed. (See equation 2)
Equation 2
The theory behind this does not

need to be known and considered in
depth for correct motor selection. The
curve as provided in graphs makes
this easy. On the curve there are two
torque rating curves. The bottom or
lower curve is for standard EFF2
WEG motors and the top curve is
for EFF1 WEG motors when used in
conjunction with a WEG VSD.
Figure 3 Peak voltage

The second consideration in terms of
for short periods. For example the motor may deliver 150 A motor selection is dielectric strength or peak voltage rating
and 300 Nm for 60 seconds once every 10 minutes. of the motor insulation. IEC60034 Part 17 defines motor
insulation requirements for VSD use. The requirements are
not however given in a manner that is practically very easy
Photograph 1

CONVEYING
to apply. This standard deals with ≤500 V and then ≥600 fit an insulated non-drive end bearing and a shaft grounding
V. This leaves a gap exactly for the South African 525 V device on the drive end.
market. Furthermore, the IEC standard links the voltage The final consideration is the mechanical speed limitation.
rating requirement to the rise time of the VSD pulses. This The motor bearings are limited to a certain maximum speed.
value is very seldom known and therefore not a practical On small motors, this is in the region of 6000 RPM, but on
and useful specification. larger machines the limit is lower.
The American Nema MG1 Part 31 has a more practical
Motor standards
specification. Nema requires insulation that is ≥ 3.1 x the
There are three standards for general industrial use AC
supply voltage and inverter output rise time > 0.1 µsec.
motors.
This rise time requirement is generally met and therefore not
of concern. Both Nema and IEC refer to “General Purpose” SANS / IEC 60034
motors and “Definite Purpose” or VSD motors. SANS / IEC 60072
SABS 1804
Differentiate
How does the user differentiate between a general purpose These standards cover all the specifications and require-
and a VSD purpose motor? Which of these motors are stocked ments. They are well known and applied by the South African
and supplied by the motor suppliers? While this may seem motor industry.
problematic, the situation is really simple. In South Africa Maintenance
nobody stocks and supplies “VSD Purpose” motors as a One of the benefits of standard AC motors is that they re-
standard. These motors are always specially labeled and quire very little maintenance. The requirements are listed
identified. below:
Differences are so small that they are negligible 1. Visual inspection – weekly.
2. Bearing vibration check – monthly.
There are however, local suppliers that stock and supply 3. Greasing of bearings – according to the motor greasing
“General Purpose” motors that are also designed and manu- plate requirements. This is normally every 2 – 4 months.
factured to be suitable for VSD use. These motors have an 4. Check and clean terminal box – annually.
insulation rating that is ≥3.1 VAC supply in accordance 5. Complete overhaul, i.e. dismantle, clean, re-paint, replace
with the Nema MG1 Part 31 mentioned above. So for 525V bearings, replace any parts that are damaged, re-assemble
systems the motor insulation must be ≥ 525 x 3.1 = 1627 and re-grease – 3 year intervals.
V and on 400 V systems the motor insulation must be ≥
400 x 3.1 = 1240 V. The above proposed maintenance schedule may be varied
according to individual end-user or site requirements. Some
Individual pulses motors are small and drive unimportant items. The user may
If motors of this standard are used then the user does not elect to do no maintenance and simply replace them as and
have to be concerned about the suitability of either new or when required. Some motors drive very critical applications
spare motors for either DOL or VSD use. This means that and should be inspected on a daily basis.
motor selection on this basis is easy and that these motors
If a motor has been inspected regularly, the bearings have
are readily available.
received grease according to the stipulated intervals and
The normal 3-phase voltage that a DOL motor would be vibration monitoring does not indicate any problem, then
connected to when started DOL is a balanced sinusoidal the suggested complete overhaul may be ignored.
waveform. At any point in time, the three phases are bal-
In terms of maintenance, the single most important con-
anced and their vector sum is zero. In reality, the balance
sideration is alignment. The majority of motor failures can
is not perfect but the differences are so small that they are
be attributed to misalignment. The initial installation must
negligible. When supplied from a VSD, the motor voltage
ensure correct alignment. Once in operation ongoing bear-
consists of many individual pulses that add to produce a
ing vibration analysis will show if there is any problem with
near sinusoidal voltage waveform. (See figure 3) The three
alignment.
voltages are not balanced.
This results in voltage being induced into the metal frame Conclusion
of the motor and in the motor rotor. This voltage will Some of the issues related to motors are complicated at a
cause a current to flow from the motor down to earth. The design level. However, the solutions and application thereof
current flowing from the rotor can only pass through the for the user are simple and clearly defined. This paper has
bearings to go down to earth. The result is pitting, which aimed to present this. When the various issues as dealt with
damages the bearing and leads to failure, as illustrated in in this paper are properly considered the user or designer
photograph 1. can have confidence of a successful installation that will
operate correctly and efficiently for many years
Frame size This paper has been condensed due to space constraints. The author
It is a rather complex phenomenon. The solution however is Johan van Niekerk of Zest Electric Motors & Drives.
is simple. This phenomenon can only build up sufficient This paper was first presented at Beltcon 15 held in Johannesburg
electrical field in motors with a frame size greater than a on September 2 and 3, 2009 and copyright is vested with the IMHC.
280 frame. On all VSD application motors of frame size Enquiries can be made through the website; www.beltcon.org.za
>280, the vendor must be informed. The vendor will then

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2010 ● Customer Careline: 0860 KOMATSU (0860 566 2878)
Pr.e.A.SA4-18/10/07 - RSA
MINING
Beating the Costs

I
Cost effective mining revolves around n response to these further requirements in the market”.
keeping the cost per unit of raw ma- rising energy costs, Shovels
terial moved to a minimum. Increas- conveyor systems and Besides their electric shovels ranging from 9 to 104
ing fuel and energy costs have a di- bulk handling equip- tonne capacity, P&H also manufactures a range
rect influence on this unit cost which ment – like mining trucks, of blasthole drills and draglines. To provide mine
has changed the face of mining op- shovels and front-end load- operations with an alternative material handling
erations in that higher tonnages have ers- have steadily grown in option that can help contain the fixed and variable
to be moved and processed in shorter capacity and size over the costs associated with truck-based systems as mines
periods of time in order to make ends last decade to accommo- increase in depth and scope amid sometimes volatile
meet. date the growing demand diesel fuel, tyre and road infrastructure mainte-
for higher throughput. nance costs, P&H Mining Equipment is developing
Trends high-throughput in-pit crusher-conveyor systems.
To talk about these This equipment is supported by extensive service,
trends “Bulk Handling maintenance and upgrade capabilities, not only
Today” meets with mechanically, but also for control systems.
Lee Paterson, Gen- The company also supplies a range of spares for
eral Manager of P&H the rebuilding, refurbishing and upgrading of other
MinePro Services in similar bulk handling equipment.
Southern Africa, an
affiliate company of Lowest cost per unit
Joy Global SA. “Our business is based on the principle of achieving
the lowest cost per unit for our customers,” says
“Change started in the Lee. “Mining operations are highly capital intensive
early 1990s when our and to achieve that cost objective, they tend to
customers wanted to work around the clock, especially in applications
move more material where they have to move a lot of waste to get to
with fewer trucks. the mineral deposits and, therefore, materials have
Haul truck manu- to be moved quickly and continuously. For high
facturers brought production/low cost mining operations, the rope
out a truck with a shovel we manufacture has become the equip-
240 short ton (218 ment of choice.
tonne) capacity,” he
says. “This prompted “However, our rope shovel isn’t only for this type
development of load- of application,” adds Lee. “In the harsh conditions
ing machinery with of iron ore mining, for example, customers want
higher capacities and structural integrity and longevity and here the rope
Lee Paterson, General Manager P&H MinePro
we developed a shovel shovel has also become the machine of choice,
Services Southern Africa
with a payload of 80 not only in South Africa, but also in other parts of
short ton (73 tonnes) capacity to facilitate a three- the world with extreme mining and environmental
pass load of the bigger trucks. conditions. Although from a capital perspective
the rope shovel carries a price premium over the
Developing high-throughput in-pit crusher-conveyor loading equipment, ultimately the maintenance
systems and operating costs are significantly lower which
leads to a lower cost per tonne loaded”.
Gradual increase Features
“This combination of higher-capacity shovel and P&H shovels feature efficient planetary propulsion
trucks was very successful and it led to further and swing systems, as well as powerful and du-
development to increase sizes gradually up to rable motors which are built in-house and feature
trucks with a 330 to 400 short ton (298 to 362 modular components that speed up erection and
tonne) capacity,” continues Lee, “and we in turn maintenance. The machines are designed with
have designed shovels that now have a payload powerful tools including 3D solid modeling and finite
capacity of over 100 tonnes. element analysis to help ensure robustness against
“At present it seems that this evolution has stabi- the rigors of mining. “Every shovel is custom built
lised at this level, but our principals in Milwaukee to meet specific customer needs,” says Lee.
in the USA work closely with our customers and “Application-specific dippers, or buckets, are
truck manufacturers to monitor and respond to any designed to maximize production and minimize

MINING
maintenance costs. Our series of shovels feature the aimed specifically at lowering the costs per unit of
Centurion control system, a platform for technology material loaded by the machine”.
Feedback
The system represents a real breakthrough in its
P&H has engineers on the ground at mines around
integration with the features of our shovels the world. “On some sites in Southern Africa we
even have personnel based there
permanently, not only to help custom-
ers, but also to provide feed-back to
designers at headquarters on specific
requirements” says Lee. “Before mak-
ing recommendations to a customer,
we conduct a thorough review of the
customer’s mining challenges and
objectives.”
“The customer’s needs might for
instance be a shovel or perhaps a
dragline, a drill, a dipper or just a
productivity-improving moderniza-
tion package for an older machine.
Whatever the need, our analysts
will assist in reaching these goals
and achieving the lowest possible
operating costs”.
New Equipment
A new innovation was made possible,
with the acquisition of Stamler crush-
P&H 4100XPC Electric Rope Shovel in a Copper mine ers and sizers as well as Continental

MINING
Conveyors, giving P&H access to

crushing and conveying technol-
ogy. “Rounding off our product
line is the in-pit crusher conveyor
system we’re now introducing to
the market,” says Lee. The IPCC is
a self-propelled unit that receives
material directly from a shovel
and reduces it to a conveyable
product size for transfer to a fi-
nal destination. The fully mobile
crusher, or sizer, is based on
proven technology from Stamler
and Continental.
“This system provides a turnkey
solution for overburden removal”,
explains Lee. “Unlike previous
mobile crushers, the system
represents a real breakthrough
in its integration with the fea-
tures of our shovels, resulting in
synchronized maintenance and A P&H 9020 Walking Dragline – State of the Art Technology
dramatic efficiency improvements
in the removal of overburden. A system like this cost per tonne in moving material”.
cuts out truck hauling and all the costs associated Lee Paterson, P&H MinePro, Tel: (011) 869-1237, Email:
with a fleet of trucks, talking a big step forward in lpaterson@minepro.com, P&H MinePro Services, visit
helping the mining industry to achieve the lowest www.minepro.com

Market Forum
and slippery conditions.
Ceramic pulley lagging is
used in instances where
the pulley operates in
extremely aggressive con-
ditions, such as on bucket
elevators or where the pul-
leys operate where users
cannot prevent material
from becoming trapped
between the pulley shell
and belt.
Ceramic pulley lagging
offers better wear proper-
ties and, in spite of the
aggressive environment, an
extended lagging ‘life’.
Multotec’s highly effec-
tive, locally manufactured
studded tile lagging is
applied to drive pulleys,
while smooth high alumina
ceramic tiles are applied
to non-drive pulleys.
Faan Viljoen, technical
director of Multotec Wear
Linings, cites an example
at an iron ore mine where
the installation of Multotec
Direct bonded ceramic pulley lagging reduces downtime as the ceramics have a significantly longer Ceramic Pulley Lagging
lifespan compared with conventional lagging material resulted in much lower
wear rates on pulley lag-
Time and cost savings ging as well as significant improvements in productivity as
Conveyor belt slippage can contribute to significant losses in a result of reduced downtime owing to not having to replace
productivity with resultant negative financial implications. the lagging.
Multotec’s direct bonded ceramic pulley lagging is a cost-
effective solution which virtually eliminates slippage and The 6 mm thick ceramic lining has been in operation for 14
ensures optimum traction of drive pulleys under most wet years without any maintenance, compared to a wear rate of
1.5 mm a month on the conventional
rubber lagging which it replaced.
“The ceramic material is only slightly
more costly than conventional rubber
lagging, yet offers a lifespan of at
least 200 months compared with
a mere eight months for rubber in
this application,” Faan says.
Bernadette Wilson, Multotec Group,
Tel: (011) 923-6193, Email: market-
ing@multotec.co.za, Website: www.
multotec.com
Log onto
www.promech.co.za
to read
back issues of
‘Bulk Handling Today’

Market Forum
above the plant floor. The drum platform is raised
by a single hydraulic cylinder, creating a dust-tight
seal between the rim of a drum and the underside
of the discharge cone.
A second hydraulic cylinder raises the platform-hood
assembly vertically before tipping it to a dump angle
of 90 degrees, causing the vertically oriented cone
to mate with a gasketted receiving ring. The ring can
be fitted to the lid of an optional hopper with integral
flexible screw conveyor or pneumatic pick-up adapter,
or to existing process equipment.
A pneumatically actuated slide gate valve prevents
material flow until the discharge cone has been
properly seated in the gasketted receiving ring. The
all-stainless unit can be finished to hygienic or in-
dustrial standards. Other models are offered in mild
steel with durable industrial coatings, or with material
contact surfaces of stainless steel.
For information contact Flexicon Africa (Pty) Ltd.,Tel:
(041) 453-1871, Email: sales@flexicon.co.za, Website: www.
flexicon.co.za
Enhancing the cost of ownership

Technological advancements in vibrating screen design,
Tip-Tite High Lift Drum Tipper seals a drum rim against a discharge cone, over the last few years, have improved classifica-
raises and tips the drum, mates the cone against a gasketted connection
tion and efficiencies as well as lowered total cost of
that is 1525 to 3050 mm above the plant floor, and discharges bulk material
dust-free through a slide gate valve ownership. “Everyone realises how important it is to
reduce downtime by improving machine availability
Hygienic tipper and by achieving this, the end result is a lower total
A new hygienic high lift drum tipper allows drums to be cost of ownership,” Ian Chapman, engineer with Humboldt
loaded at floor level, sealed against a discharge cone, elevated Wedag, says.
and tipped, mating the cone to a gasketted receiving ring on
“The ‘cradle to grave’ approach is not new, but it is some-
downstream process equipment.
thing that is not always emphasised, especially in the current
Trademarked Tip-Tite, the tipper accommodates drums market where companies are hard pressed to reduce capex,”
from 114 to 208 litres and can discharge bulk material into he says. “While it is essential to contain costs and most
process vessels and equipment inlets 1525 to 3050 mm mines are looking at getting the most competitive pricing

Market Forum
redesign by Humboldt
Wedag to incorporate
the new technology.
“The new design elimi-
nates the need for string-
ers, with the panels
being fixed directly to
the cross members. This
means that should a
cross member need to
be replaced, it is a fairly
simple exercise whereby
only two rows of panels
need to be removed to
gain access to the cross
member. This concept
lends itself towards the
incorporation of further
technological advances
in equipment develop-
ment,” he concludes.
Johannes Kottmann, KHD
Humboldt Wedag Interna-
Technological advancements in vibrating screen design have improved classification and efficiencies as tional, Tel: (011) 397-4660,
well as lowered total cost of ownership Website: www.humboldt-
wedag.co.za
on capital goods, there is also a drive to achieve the lowest
total cost of ownership.
“As a supplier we need to achieve high machine availability,
lower power consumption and better equipment performance
for our customers,” he says. “High machine availability equals
less manpower required to maintain the equipment and it
also means less downtime and less maintenance required. An
example is the pinless system we installed on screens at some Accolade
of the Anglo Coal and BHP Billiton coal mines,” Chapman Sandro Scherf, the CEO of Pilot Crushtec, was named this
says. Use of this innovative pinless system required a screen year’s Business Person of the Year award winner at the

Market Forum
SIL-2 certification
Honeywell’s Enraf Servo Gauge has
received SIL-2 certification from TUV
Rheinland for use in safety applica-
tions, such as tank overfill protection,
that help prevent hazardous incidents
in bulk-liquid storage facilities.
The approval enables terminals
and storage facilities utilising exist-
ing Honeywell Enraf Servo Gauge
technology to comply with stringent
environment and safety regulations
without installing additional or new
hardware. There are more than 30
000 Servo Gauges installed that can
become SIL-2 compliant for overfill
protection with a simple software
upload. Additionally, new users can
integrate the Servo Gauge SIL op-
tion seamlessly into their existing
infrastructures by integrating with
(Left to right). Nicolina Di Santolo, Chairperson of Italian-South African Chamber of Trade
and Industries; Sandro Scherf, CEO of Pilot Crushtec and Jerry Vilakazi, CEO of Business safety systems, such as Honeywell’s
Unity of South Africa (BUSA) Safety Manager.
Italian-South African Chamber of Trade and Industries FNB Honeywell Enraf gauges are widely
Business Excellence Awards 2009. In addition, Pilot Crushtec, used in bulk-liquid storage facilities around the world to as-
the business Scherf co-founded in 1990 with his father, was sess holding tank content and manage tank inventories. TUV
a Business Enterprise of the Year finalist. Rheinland also determined the Servo Gauge exceeded SIL-2
requirements for quantified safety loops, therefore customers
“I am naturally deeply honoured by this recognition, and also
very pleased that the company did so well in the enterprise
category. This is deserved recognition of the commitment
everyone who works at Pilot Crushtec has shown to the
company,” said Sandro after the dinner.
The awards recognise business people of Italian descent,
as well as enterprises that are Italian or that enhance the
image of the Italian-South African business community.
Previous winners include Domenico Cioffi of Mimmo’s Piz-
zeria, Mark Lamberti of Massmart Holdings and Giovanna
Secco of Kudu Farms.
In summarising Sandro’s achievements, the Chamber noted
that he had built up the company to become a leading
manufacturer and distributor of mobile and semi-mobile
equipment for the open-cast mining, quarrying, civil engi-
neering, construction, and recycling industries. He was also
the driving force behind Pilot Crushtec’s dynamic expansion
into foreign markets, selling to countries in Africa, Europe,
Asia and Australasia.
Pilot Crushtec now has an annual turnover in excess of R440
million, and employs over 150 people. It is also the sole
southern Africa distributor for Terex Finlay, Trio Engineered
Products and Rubble Master crushing and screening equip-
ment, and has consistently been Terex Finlay’s biggest or
second biggest dealership in the world.
Pilot Crushtec (SA) (Pty) Ltd, Boksburg, Tel: (011) 842-5600, Fax:
(011) 842-5610, Website: www.pilotcrushtec.com
Contact Surita Marx on Tel: (011) 781-1401,

E-mail: bulkhandling@promech.co.za
to book your advertising space

Market Forum
that use redundancy can also dependent
utilize the device in SIL-3 third party
applications. a u t h o r i t y,
“It’s never been more im- TUV Rhe-
portant for terminals and inland.
hazardous liquid storage The range
facilities to ensure safe of “ATEX”
operations and comply with - suited
local regulations,” said Henri manual
Tausch, vice president and general chain hoists is available
manager for Honeywell Field Solutions in capacities between 0.5
and a Certified Functional Safety Expert. and 20 Tons. He explained
“With this SIL certification, many of our global that, because the temperature
customers have an easy and cost-effective way to of the brake is critical, a special brake
meet regulatory requirements and keep employees cooling design was incorporated.
and their communities safe.” Test results exceed the European
Website: www.honeywell.com/ps. Directive 94/9/EC.
Graham adds that Yale Industrial
Products has recently changed its
name to Columbus McKinnon Corporation
(Pty) Limited as part of the consolidation
and reconstruction of the group’s global
corporate identity. The “Yale”, “Little Mule”
Explosive Atmospheres and “Tigrip”, brands will remain in place
The Columbus McKinnon Corporation has announced under the new name.
the availability of a wide range of Yale lifting and ma- Columbus McKinnon Corporation in South
terials handling products that are specially designed Africa is a wholly owned subsidiary of Yale
and manufactured for use in potentially explosive Industrial Products GmbH in Germany.
environments such as paint factories, spray painting This, in turn, is part of the multi-national
operations, foundries, oil and gas production facilities, Columbus McKinnon Corporation, a world
oil refineries, oil storage facilities, electroplating shops leader in the field of materials handling
as well as within the automobile, shipping, printing, equipment.
textile and paper industries.
The group boasts more than 130 years
This range of material handling products being developed experience in the development and pro-
includes manual chain hoists, beam trolleys, electric duction of hoists, cranes, winches, pallet
chain hoists, winches, air hoists, actuators, pallet handling, chain and forgings.
stackers and lifting tables.
Colmbus Mckinnon Corporation (Pty) Ltd, West-
According to Columbus McKinnon SA sales director, mead Pinetown, South Africa, Tel: (031) 700-4388,
Graham Campbell, the first range of products launched Fax: (031) 700-4512, Email: sales@yale.co.za,
comprises manual chain hoists and trolleys. The range also Website: www.yale.co.za
includes a low headroom hoist and trolley combination
unit. These have been ATEX zone tested and approved by in-

Market Forum
“My discussions around the
country have highlighted
the increased importance
of top-rate after-sales ser-
vice in these tough trading
times. Downtime is a “no,
no”. Parts supply is an area
I have identified for special
attention, while we will
put more resources behind
improving the skills of our
dealership technicians,
which will include ongoing
support for the recruitment
of apprentices.
“During the year we will
be rolling out initiatives to
cut operating costs – cents
per kilometre – which will
include extended service
intervals depending on the
operating conditions of a
fleet,” Casper concludes.
Ignatius Muthien, Hino
A tough call Division, Tel: (011) 809-
Forecasting the 2010 SA truck market is a very tough call, 2064/2255, Fax: (011) 809-9064, Email: imuthien@hino.co.za
according to the newly-appointed vice president of Hino,
Casper Kruger. He says that the conservative approach
sees growth of 4-5% over the 2009 figure, which equates
to about 19 600 units for 2010.
However, he says unexpected strong demand, driven by
transport requirements for World Cup-related activities, could
skew this figure substantially and result in growth as high Class III grab-crane
as 20%. Casper adds that the quandary for manufacturers Crane manufacturer, Condra, has delivered a Class III grab-
or distributors is whether or not to order extra stock in the crane to Impala Platinum, building further on experience
hope of a possible upswing
in the first and second
quarters of the year, but
believes meaningful, long-
term growth in the local
truck market will occur
only from 2013.
Casper Kruger, who took
over as head of Hino in
May 2009 following the
retirement of Piet van Wyk
de Vries, has now been
promoted from general
manager to vice-president
of the division that previ-
ously operated as Toyota
SA Trucks
“Currently more than 40%
of our sales are to loyal,
strategic fleets and I want
to grow that percentage
further as it is mainly
repeat business,” Casper
continues. Condra Class III grab-crane for Impala Platinum

Market Forum
gained with heavy duty cranes exported since 2003. R2,5-billion deal
The operating speed of this latest heavy duty design has been Hatch South Africa’s R2,5-billion part of the R8,462-billion
increased by some 50 percent over its predecessors, with Kumba Sishen South megaproject sees the company respon-
travel and lift speeds of 6,4 and 20,0 metres per minute sible for EPCM on the plant and stockyard areas, including
respectively. design, process development, full engineering, procurement,
construction management, and project management.
The 10-ton double-girder overhead travelling crane is fit-
ted with two K-Series hoists incorporating slip-ring motors Hatch project manager for Sishen South Floyd Botha says
instead of the usual squirrel-cage induction motors with that the mine will produce 9-million tons of iron ore within
variable speed drives. months of completion, which is scheduled for H1 2012.
Slip-ring motors deliver a higher torque, making it easier for Located near Postmasberg in the Northern Cape, the new
the operator to control grab movement, particularly closure. project - which includes a crushing and sizing plant, stock-
Motor resistance is managed so that close-rope tension is piles and a rail-truck loading station – is 80 km south of the
greater than lift-rope tension during lifting, ensuring that principal Sishen Mine.
the grab stays shut. Floyd’s area of responsibility in the plant starts at the feed-
Impala Platinum will use the Condra unit to augment existing point and runs through the entire plant – including primary,
grab capacity at its mineral processes refinery. secondary and tertiary crushing of material with screening
in between – through the stockyard, into the load out sta-
Josef Kleiner, Condra (Pty) Ltd, Tel: (011) 021-3712, Fax: 086-669-
tion and finally into the rail chase. Completion is set for
2372, Email: condra@mweb.co.za
mid 2011.
Hatch’s Manager: Rail Projects Flip Gous is also upbeat: “A
separate contract calls for the engineering and construction
of 23 km of rail and two bridges, for which we have around
Engineer Placements
180 people on site. Hatch was involved in the initial feasi-
bility study and we’re extremely pleased with our progress
www.engineerplacements.com so far.”
The rail project progress includes 100% completion of the

Market Forum
engineering; earthworks and civils are 40% complete and as part of the CSD Debottlenecking Project.
procurement 50% complete. Capex for rail siding is R450- The material being conveyed is high carbon ferrochrome
million, and Hatch fees run at around R21,5-million. Gous with a chrome solid density of up to 7.1 tpm3 and a total
says that his project is on track to meet its H1 2011 dead- bulk density of 2.45 tpm3. The particle size distributed is
line. This rail section will link up to the 37km rail portion minus 260 up to minus 3 mm.
linking the Sishen South mine to the Sishen Saldanha Iron
Ore Export line, currently being constructed by Transnet The chute in the bin feed section is fed by a front end loader
Freight Rail. and from there the material is conveyed to the crushing build-
ing via conveyor. This chute is more robust in construction to
Hatch, Woodmead, South Africa, Tel: (011) 239-5300, Fax: (011)
facilitate the impact of the loader bucket while discharging
239-5790, Website: www.hatch.ca the material.
“Engineered to take product impact without blockages
occurring, Weba Chute Systems are designed using a ‘su-
pertube’ or cascade effect where 95% of the material runs
on material at the same time,” Weba Chute Systems’ Ted
Cruikshank says.
When viewed in slow motion it becomes apparent that the
Debottlenecking project bottom layer of particles in the product screen moves in a
Weba Chute Systems have been installed at the crushing tumbling motion instead of gliding down the chute. “This
and screening plant at Assmang Chrome in Machadodorp results in significantly reduced wear and,
in many cases, the lip remains completely
covered by material and never needs
replacement. This manner of control-
ling material movement is taken a step
further by designing the internal angle of
the transfer chute to match the product
with the belt speed and in doing so,
spillage is either completely eliminated
or greatly reduced,” says Ted.
Mark Baller, M & J Engineering (Pty) Ltd,
Tel: (011) 827-9372, Fax:(011) 827-6132,
Website: www.weba.co.za
Health of greases in the field

Lubricant analysis is a vital part of a
predictive maintenance strategy. However,
until now, this analysis has been almost
completely related to oils, despite the
fact that around 80% of bearings are
lubricated with grease.
After years of research, SKF has devel-
oped a new methodology to evaluate
grease condition directly in the field.
In order to perform this methodology,
the newly-launched SKF Grease Test
Kit TKGT 1 is the latest addition to the
extensive range of SKF bearing greases,
automatic lubricators, lubrication tools,
lubrications systems etc, included in
the SKF Lubrication Platform.
“By using the methodology and perform-
ing quick and easy tests, users will be
able to assess the condition of fresh
The chute in the bin feed section is more robust in construction to facilitate the impact and used greases directly in the field,”
of the loader bucket while discharging the material

Market Forum
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These tests provide a good understanding of the condition of
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the grease and enable decision-making directly in the field.
The TKGT 1 includes guidelines for a proper interpretation
of the test results.
Samantha Joubert, MarComm Assistant - SKF South Africa (Pty) Ltd, Index to Advertisers
Tel: (011) 821-3500, Fax: (011) 821-3501, Email: samantha.joubert@
skf.com, Website: www.skf.co.za AST Inside Front Cover
Bearings International Outside Back Cover
Correction BMG Outside Front Cover
Brelko 30
Rema Tip Top did not acquire Dunlop as reported in the
Chorus Call 12
Jan issue.
Dymot 34
Rema Tip Top has, in fact, purchased shares in Dunlop
Industrial Products. FLSmidth 31
We apologise for any inconvenience caused. Joy Mining 14
Komatsu 26
Multotec 29
Forthcoming Features 2010
Polysius 8
April
Quadrant 32
Power Transmission – drives, motors, gearboxes,
couplings, etc SCAW Inside Back Cover
Lifting equipment – chains, hoists, slings, cranes, Silver A 33
forklifts, etc SKF 28
Industry Focus – Earthmoving
Industry Focus – Construction ThyssenKrupp 6
Transmission Components 24
Contact Surita on Tel (011) 781-1401,
bulkhandling@promech.co.za Zest 36

SPECIALIST PRODUCTS
FOR THE MINING
INDUSTRY
Fabform Graphics cc (011) 622-9917

The Scaw Metals Group (Scaw) is an international group, manufacturing a diverse range of steel products. Its principal
operations are located in South Africa, South America, Canada and Australia. Smaller operations are in Namibia, Zimbabwe
and Zambia. Scaw’s Specialist products manufactured for the shaft mining and surface mining industries include:
Haggie® Steel Wire Rope Products: Scaw has produced these products for the mining industry since 1921 and is a
• Double drum winder ropes technological leader in this field and manufactures to national and international
• Koepe / Friction winder ropes standards.
• Shaft sinking ropes
• Mine hoist ropes Scaw provides a full range of customer support services. A team of qualified
• Scraper and haulage ropes engineers with extensive experience in all aspects of steel wire ropes, chain and
• Dragline and hoist- and drag-ropes cast products are available to advise on the selection, handling, installation and
• Face shovel ropes maintenance of products as well as provide on-site inspection of products and
Chain Products: equipment.
• Round link welded chain and chain fittings in
grades 3 to grade 8 to national and Scaw supplies globally and also offers nationwide distribution in South Africa
international standards. through its strategically located branches throughout the country.
Cast Products:
• Mantles and bowl liners Haggie® Steel Wire Rope: Tel: +27 11 620-0000 • Fax: +27 11 620-0009
• Mill liners Chain Products: Tel: +27 16 428-6000 • Fax: +27 16 428-1212 / 1089
• Rope sockets Eclipse East Foundry: Tel: +27 11 747-5000 • Fax: +27 11 421-4943
• Track shoes Cast Products: Tel: +27 11 749-3600 (GET) • Tel: +27 11 842-9303 (Other)
• Dragline parts Fax:+27 11 421-8032 (GET) • Fax: +27 11 842-9710 (Other)
• Ground engaging tools (GET)
Website: www.scaw.co.za

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BULK HANDLING TODAY Feb 2010 

 BULK HANDLING TODAY Feb 2010

Featured on the cover: Contents

The monthly circulation Proprietor and Publisher: Advertising Sales:

BULK HANDLING TODAY Feb 2010 

From the Chairman’s Desk

 BULK HANDLING TODAY Feb 2010

Movers and Shakers ...

BULK HANDLING TODAY Feb 2010 

applications throughout the world. “Advantages

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“The skirt wing is yet another innovation and is

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Tarkwa Unlocking potential

Northam Cerro Verde Mogalakwena

Local service and customer support

Shane Beattie of Crushrite

The semi-mobile impactor

BULK HANDLING TODAY Feb 2010 

A VSI impactor under construction

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The First Line of Defence

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problems can also be identified.”

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Mining Dust Control

Only to let most of it escape again along the way

“If you look at the collection of fine dust in bag

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energy being thrown around. opportunity to introduce our technologies,” says

A reduction in energy consumption of at

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Figure 2: The principle of operation of an electrical motor

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Item Description teristics are shown in Table 2.

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characteristics from its

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Figure 3: Connections for three-phase systems

/ 0.7 = 143 kW. The

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Graph 4: The relationship between speed and torque

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Magnetic flux weakens

The theory behind this does not

Figure 3 Peak voltage

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Beating the Costs

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Conveyors, giving P&H access to

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‘Bulk Handling Today’

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Enhancing the cost of ownership

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Contact Surita Marx on Tel: (011) 781-1401,

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BULK HANDLING TODAY Feb 2010

BULK HANDLING TODAY Feb 2010

BULK HANDLING TODAY Feb 2010

BULK HANDLING TODAY Feb 2010

BULK HANDLING TODAY Feb 2010

BULK HANDLING TODAY Feb 2010

BULK HANDLING TODAY Feb 2010

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