australia's mining monthly - conveyor equipment and services feature - february 2014
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Conveyor Equipment & Services
PROUDLY sPOnsOReD bY
56 AMM February 2014 www.miningmonthly.com
CONVEYOR EQUIPMENT & SERVICESPROUDLY SPONSORED BY
Individually tensioned steel cords entering the cover consolidator.
Conveying con� denceThe completion of a $32 million expansion at its Australasian headquarters has set Veyance Belting up for a strong future Down Under. Tess Ingram reports from Melbourne
www.miningmonthly.com February 2014 AMM 57
Veyance Belting enjoyed 2013. It was a good year for the company.
Among the highlights were the unveiling of a $32 million
expansion at the conveyor belt manufacturer’s Australasian headquarters, new service centres established in Mackay and Karratha , and winning the Bulk Handling Supplier of the Year award.
Not a bad effort, during a year when most mining supply companies began cutting back and closing doors.
As a guest of Veyance at its expansion grand opening ceremony, I was impressed by the large turnout of customers, suppliers, staff and VIPs who travelled to Melbourne for the event.
A tribute to the strong relationships the company has across the industry, the opening of the $32m expansion became a diverse celebration of all things belting.
Victorian Premier Denis Napthine was on hand to celebrate the occasion, holding Veyance up as a great success story of advanced manufacturing in the state.
“These conveyor belts are absolutely vital to the growth of the economy right across Victoria and Australia,” Napthine said.
“There is a great future for manufacturing, but it’s of the type we’re talking about today - highly skilled, highly technical and the world’s best practice manufacturing.”
Veyance’s $32m spend at the Bayswater
manufacturing plant, just outside of Melbourne, has allowed it to double its Flexsteel belt manufacturing capacity and significantly increase its Glide underground fabric belting capacity.
To do this, the company improved three main components in its manufacturing process.
First, Veyance expanded its cranage
capacity, allowing it to supply long-length racetrack reels to reduce onsite installation time.
Second, and central to the doubling of production at the plant, was the installation of the new Siempelkemp steel cord press.
The press, combined with Veyance’s proprietary individual cord tensioning system, has the potential to increase production volumes of the next frontier of conveyor belts, the ST10,000 high-strength steel cord belts.
Veyance Belting general manager David Stone explained the press’s capabilities.
“The new line is capable of cord diameters
from around about 3.6mm all the way up to 14mm which is your ST10,000,” Stone said.
“Our ability on the old equipment was about up to an ST6500 and we are now one of three Veyance plants that can make ST10,000s.”
Stone said the ST10,000 belt is increasing in popularity, as the work that conveyors are required to do becomes more strenuous.
“At this point in time there are a number of projects around the world and in Australia that are looking at ST10,000s,” said Stone. “They will begin to become more and more evident in the industry.”
The third major component of the expansion is the new hot former calendaring operation.
“I would say the major benefit that the customer gets from it the hot former is the simple fact that it can produce one full cover, anything from about 200 meters to about 800m, in one roll without a cover join,” Stone explained.
“What that means is that it delivers
CONVEYOR EQUIPMENT & SERVICESPROUDLY SPONSORED BY
“These conveyor belts are absolutely vital to the growth of the economy right across Victoria and Australia.” – Victorian Premier Denis Napthine
A tour group inspecting the hot former.
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extreme bene� ts to the customer from a quality perspective.”
In an interview with Australia’s Mining Monthly a� er the opening ceremony, Stone and Veyance Technologies’ US-based president John Hamilton discussed the speci� cs of the investment.
“Of all the Veyance conveyor belt facilities that we completely own, this is the one that
produces the most steel cord belt and the most low-rolling resistance belts of anywhere in the world,” Hamilton said, adding that the company’s decision to install this highly technical technology here in Australia re� ected its faith in the market.
Stone echoed Hamilton’s sentiment.“Our installed capacity over the last 10
years has increased tenfold and so while we
are currently at one of those � at periods in terms of projects, the base installed capacity is there and we will continue to grow, especially in areas like iron ore,” Stone said.
“It is a long-term commitment to the Australian manufacturing base.”
Improving the lead time on its products was a huge driver for the investment, according to Stone.
He said: “If you look at the investment and the reason why we did it there, there’s not just one simple answer. It has probably reduced the lead time by around 30% to 40% compared to what it was in the past and that is a signi� cant improvement for our customers.”
� e 18-month expansion project was completed in what Stone called record time, provided 60 jobs during the construction phase and another 130 once fully operational.
Veyance’s service business also received a boost during 2013, with the establishment of service centres in Karratha and Mackay.
“Over the last 18 months, we have invested signi� cantly going into that services organisation so that we can go in, install and inspect the belts ourselves, repair them out in the � eld and provide a full service to our end-users,” Stone added. “It is part of our business going forward.”
• The $32m Bayswater expansion will double the site’s manufacturing capacity
• The hot former and the steel-tensioning system were both designed by Veyance
• When Veyance began work at Bayswater in 1990, it had a staff of just 15 people, now it has about 220.
• Veyance is the number one producer of belts in China, Brazil, US, South Africa, Canada and Australia
• Veyance’s customer list boasts companies such as BHP and FMG
AT A GLANCE
The Siempelkemp press and control panel.
60 AMM February 2014 www.miningmonthly.com
Within Fortescue Metals Group’s $US3.2 billion Solomon development sits the recently opened Kings mine.
When developing the 40 million tonne per annum Western Australian mine, FMG called across the country to Melbourne-based Veyance Belting to help fulfil its belting requirements.
In its recently expanded Bayswater headquarters, Veyance manufactured the 12km belt order from FMG. But that is only where the story begins.
Veyance installed the belt onsite through its recently established Veyance Conveyor Services.
Established in 2013, the company’s service centres in Karratha and Mackay aim to provide country-wide access to services in installation, repair, maintenance and training.
After being awarded the installation contract, Veyance’s Perth and Karratha offices had only four weeks to collaborate and complete the installation of the belting for three overland conveyors.
Over a period of four weeks of back-to-back 12-hour shifts, the first 7.1km of 1800mm ST3200 belt was installed on conveyor CV704.
Due to construction progress, installation of the belt needed to be undertaken starting
from the head, then pulling down the return strand around the tail of the conveyor and up the carry strand, back towards the head.
Specially engineered belt pulling plates were employed with large winches to pull the belt onto the conveyor structure, with line tension monitoring with in-line load link feedback.
Belt winders were also modified to accommodate special positioning requirements over the conveyor structure.
Technicians then installed 1400mm-wide
ST3400 belts onto conveyors CV123 and CV113, approximately 2.2km and 2.6km in length respectively. All belts were spliced using Goodyear Preform splice materials.
Veyance said although it was new to the service industry, the contract allowed it the opportunity to prove it had the capability of delivering engineered solutions to meet the requirements of customers within the mining and materials handling industries.
Veyance Asia Pacific region sales and marketing director Con Michaels said the objective of the new service arm of the business was to focus on belt installation, maintenance, condition monitoring and training.
“This is not just high-end value adding. It’s about local investment and training,” he said.
“We cover steel cord, textile reinforced fabric and PVC belts in both surface and underground applications.
“We offer belt installation, splicing, repairs, pulley lagging, scanning, full certified training and lots of ‘hands-on’ help for all belt owners.”
Michaels said the main objective was to help customers achieve lowest cost per tonne conveyed.
“We also provide belt survey audits, conveyor inspections and design and selection advice as required” he added.
Fit for a KingFrom the floor of a Melbourne factory to the red dirt of a Pilbara mine, Veyance Belting was contracted by Fortescue Metals Group to manufacture and install 12km of conveyor belting at the Kings mine. By Tess Ingram
CONVEYOR EQUIPMENT & SERVICESPROUDLY SPONSORED BY
Veyance Belting’s conveyor at Fortescue Metals Group’s Kings
mine in Western Australia.
“This is not just high-end value adding. It’s about local investment and training.” – Veyance Asia Pacific region sales and marketing director Con Michaels
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62 AMM February 2014 www.miningmonthly.com
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Safety and productivity are two of the most frequently used words in the mining industry vocabulary. And for good reason.
Reducing injuries and machine downtime is critical to ensuring an operation is achieving maximum productivity and providing a comfortable working environment for its employees.
Bulk materials-handling solutions provider Kinder & Co believes that asset management – of people and machinery – is a crucial part of the process.
“Millions of workers in this country are exposed each year to the very serious health threat known as silicosis,” Kinder & Co founder and CEO Neil Kinder explained.
“The most important step to protecting workers is to keep harmful silica dust out of the air.
“All machinery that could produce silica dust should contain the appropriate dust controls. These dust controls need to be well
maintained and monitored.”Kinder & Co provides a range of dust
-suppression products, including the K-Snap-Loc Dust Seal System and a range of conveyor hoods and covers.
“Our customers who have installed the K-Snap Loc Dust Seal System have found it very easy to mount,” Kinder said.
“Once it’s in place, the inherent memory set capabilities of the engineered polyurethane means that the skirting basically looks after itself, requiring very little adjustment and maintenance.
“This means that workers spend less time exposed to the dust around the dust-prone conveyor transfer point, which is a significant health benefit.”
When it comes to machines, environmental debris and particles can quickly destroy bearings, windings and brushes on expensive electric motors and add considerable expense to service, maintenance and repair bills.
“Maintaining a clean operating environment
seems the most obvious answer to optimising motor performance,” said Kinder.
“However, it is not always possible to keep electric motor drives dust-free as the nature of many bulk materials tasks and conveyor systems mean spillage and debris is virtually inevitable.
“Take, for instance, a belt conveyor high in the air. The wind may blow some of the dust off the motor, but dust underneath gets into very confined and hard to reach places. Any kind of spillage can easily block the motors.”
Kinder & Co’s K-MotorShield Motor Covers are simple, lightweight, easy to install and will keep motors debris-free and stop them from overheating.
“The bottom line is, if you maintain your machinery properly and protect it from dust exposure, you won’t have the motor problem,” Kinder added.
Kinder & Co are based in Braeside, Victoria.
Practical solutionProper asset management can protect your employees and bottom line.
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Conveyor hoods help to suppress hazardous silicosis particles.
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The demand for BLH Safety’s Conveyor & Machine Guarding Solutions range has grown rapidly and globally.
BLH Safety expanded its range of industry safety products to conveyor and machine guards in 2011 and has since seen it grow rapidly across the globe.
Developed through the evolution and integration of two of its other products, the BLH Conveyor & Machine Guarding Solutions range of frames and guards was designed as a � exible and easy to install alternative to existing solutions.
Fibreglass reinforced plastic (FRP), used in BLH’s hand-railing systems, has been combined with its patented BLH Stop Drop safety barricading system, which is designed to protect workers from falling objects.
“� ere is nothing like it in the world; it is
a patented product,” BLH Safety Solutions managing director Mark Austin said of the conveyor range.
According to Austin, one of BLH Guarding Solutions’ biggest advantages over current conveyor guarding methods for the mining industry is its durability in high-corrosive areas where steel is sometimes not an option.
“FRP works especially well for re� neries that use acids which can leach into metals or any project that is in a high-salinity area,” he said.
FRP is half the weight of steel of the same dimension and eliminates other issues related with steel, including complex and long duration installation involving the use of hot works.
Austin said that within the last year, BLH Safety has seen increased global demand for its Conveyor & Machine Guarding Solutions and
now has distributors in South America, Europe and Asia.
� e company set up an o� ce in Chile in late 2012 and has used the base to grow its footprint in that region.
“We have networked to increase distribution reach and have expanded globally, which is a really good thing,” Austin added.
“We are currently in negotiations with other countries and other distribution o� ces to look to expand further.”
For the mining industry, BLH has developed three design options; custom designed single hinge, single section pull out guarding and custom design hinged double guarding.
BLH Safety has a head o� ce in Beauty Point, Tasmania.
An increasingly mechanised world can escalate the number of hazards encountered in the workplace, creating the need for innovative safety solutions.
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Protecting people
BLH Safety’s Conveyor & Machine Guarding Solutions in action.
66 AMM February 2014 www.miningmonthly.com
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Alkane Resources’ Tomingley Gold Project has moved fairly quickly from approvals to production.
� e Central New South Wales project was granted a mining lease in February last year and with a scheduled production date of this month, the pressure was on for contractors to get everything constructed in a relatively short time.
Project EPCM contractors Mintrex had engaged Dyna Engineering on several other conveying projects in the past and invited managing director Graeme Greaves to submit a quote for the design, manufacture and supply of the componentry for the project in March.
Greaves said Dyna’s quote was approved that month and by mid-June, the job was completed.
“One of the things that we concentrate on is that when we have a commitment to deliver, we deliver on time.
“In the mining and bulk materials-handling sectors they have timelines and tight schedules ,and we need to be able to � t within with those,” Greaves said.
� e project consisted of three drive pulleys with ceramic lagging, 12 non-drive pulleys with hot vulcanised, diamond-groove rubber lagging, 480 idler sets (carry, transition, impact, return and trainers) and six hybrid impact beds.
A total of 515m of rubber conveyor belts were also supplied in three rolls for the three conveyors.
One of the unique parts of this job was the design of the hybrid impact beds.
Designed and manufactured at Dyna’s workshop in Bayswater, Western Australia, the beds combine ultra-high-molecular-weight polyethylene (UHMWPE) bars with impact rollers.
When coupled with the Dyna-Trac Flexiseal
Skirtboard system, the product provides impact resistance and skirt sealing.
“By using Flexiseal’s dynamic sealing system, dust is e� ectively reduced at the loading point and the skirting never needs adjustment to maintain a seal,” Greaves added.
All the pulleys underwent � nal assembly at Dyna’s Bayswater facility where bearings were � tted and rubber lagging completed.
Greaves said the company’s process has a lot to do with its fast completion time.
He added: “I was talking to one of the big engineering companies recently and I told them that we delivered this project in ten weeks and they said that they wouldn’t even have the complete list drawn up and approved in that time.
“We have high-quality products and good project management skills so we can always deliver on time and on budget.”
DeliveredDyna Engineering designed, manufactured and delivered 15 pulleys, 480 idlers sets, six impact beds and 515m of conveyor belt for the Tomingley Gold Project in just 10 weeks.
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480 carry, transition, impact, return and trainers idler sets were supplied for the Tomingley gold project.
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The GOODYEAR (and Winged Foot Design) trademark is used by Veyance Technologies, Inc. under license from The Goodyear Tire & Rubber Company.Goodyear Engineered Products are manufactured and sourced exclusively by Veyance Technologies, Inc. or its affi liates. ©2011 Veyance Technologies, Inc. All Rights Reserved.
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THE PEOPLE WHO MAKE THEBEST CONVEYOR BELTSNOW ALSOSERVICE THEM.
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www.miningmonthly.com February 2014 AMM 69
Proudly Made In Australia
An intelligent conveyor installation has been completed by the Ellton Group for Rio Tinto Coal Australia’s Coal and Allied Hunter Valley operations.
The 2km coal conveyor system includes an overland conveyor and a skyline stacker conveyor system, eliminating the previous need for heavy trucks to transfer coal from another load-out facility during peak production.
The unique conveyor design also overcomes numerous environmental and structural challenges as it traverses reclaimed and subsidence-prone land to deliver high volumes of coal to an existing stockpile facility through a cost-efficient design that incorporates recycled structures.
“One of the many unique aspects of the design was the complete incorporation of an existing skyline gantry system contained within the new structure,” Ellton Group managing director Mark Elliott said.
“The old gantry had a tripper running through it. We built our new, higher capacity structure around the existing tripper gantry, running the conveyor in the opposite direction but sharing a radically improved and strengthened structure that easily and safely handles higher conveyor loadings but is designed to minimise additional mass and wind loadings.”
To overcome the challenge of the reclaimed land, Ellton designed structures to carry the overland conveyor. The solution included trestle structures and roof sections that were not only structurally independent of each other but also independently adjustable in three dimensions if issues arose.
Elliott said he believed one of things that impressed Rio Tinto was that Ellton didn’t attempt to impose standard solutions on the project’s unique technical and site issues.
“Working in consultation with their operations staff and their consultants, we evolved numerous options that made good use of existing infrastructure while observing their rigorous safety and environmental standards,” he said.
Ellton repaired and strengthened existing trestles and piers to withstand new loads, providing a solution for less than half Rio’s expected price.
“That’s the sort of thing you can do as a younger, nimble and innovative supplier,” Elliott said.
“While we have had plenty of experience, particularly in the Hunter Valley, we are not bound to old ways of doing things or regimented thinking that says we have to tear down everything that’s already there and start again.
“I think Rio Tinto was impressed by our close attention to their wishes.
“We certainly had to submit a very competitive tender and pass thorough scrutiny of our credentials and experience but I believe one of our winning edges was the ability to introduce fresh thinking to issues facing mine operators.”
Green design
Designed to bypass reclaimed and subsidence-prone land and built utilising existing structures, could this be Australia’s most environmentally friendly conveyor?
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Refurbished and strengthened foundations and structures.
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