COST AND TIME CASE STUDY

ON GRADE PLANT FEED

CONVEYOR HEAD CHUTE –

CHUTE # 2278

TABLE OF CONTENTS

Contents

Introduction ______________________________________________________________________________________________ 1

Chute Details ______________________________________________________________________________________________________1

Analysis ___________________________________________________________________________________________________ 2

Solution ___________________________________________________________________________________________________ 3

Data Synopsis ____________________________________________________________________________________________ 4

Wear pattern ______________________________________________________________________________________________________4

Replacement frequency ___________________________________________________________________________________________8

Cost comparison ________________________________________________________________________________________ 11

Time saving ______________________________________________________________________________________________ 12

Company Information __________________________________________________________________________________ 14

INTRODUCTION

Page 1

Introduction

WEBA South Africa have supplied over 260 chutes at Khumani Iron Ore in the past ten years. 77 of

which have been fully or partially converted to Quick Release lips.

WEBA have decided to use chute 2278 - On Grade Plant Feed Conveyor Head Chute to conduct a case

study proving the cost and time saving when converting to Quick Release Lips.

CHUTE DETAILS

Chute #: 2278 Installation Date: 07th March 2011

Conveyor: PB 03CV75 – On Grade Plant Feed Conveyor

QRL Installation Date:

February 2016

Belt size: 1530mm Tonnes received since installation of QRL

1 243 088.38

Belt speed: 3.12m/s

Max Lump size: 150mm

Tonnes per hour 3600

ANALYSIS

Page 2

Analysis

WEBA identified some concern with the standard conventional lip. Through research and development, we have improved the Quick release lips system.

Problem

Conventional Lip

- It is necessary to replace the full lip segment when it is only partially worn

- Skilled Artisan required to replace lip

- Laborious and time consuming to remove and install the conventional lips

- Specialised tools to be used to remove lip

- Only 4 – 10 lips could be changed in a maintenance shift

- Safety Requirements

- Hot works permit required

Figure 1: WEBA Conventional Lip

Showing all four segments requires replacement even though only a small part of segments “A” and “D” are worn

SOLUTION

Page 3

Solution

Solution

Quick Release Lip

- Only replace the worn lips

- No skilled Artisan required to replace lip

- Quicker to install

- No specialised tools to be used to remove lip

- Reduced risk

- Interchangeable

- Cost reduction

Figure 2: WEBA QR Lips

Showing only the worn lips need replacement

DATA SYNOPSIS

Page 4

Data Synopsis

WEAR PATTERN

The wear pattern was established and the wear on each lip or segment documented. Leg “A”

and leg “B” will see 50% each of 1,243,088.38 tonnes over a period of 3 (three) months.

Figure 3: Sectioned Internal ISO View

Showing internal wear pattern

Legend

< 10%

< 20%

< 30%

Leg A

Leg B

DATA SYNOPSIS

Page 5

Wear Pattern Established Derived from Site Inspection

Legend

< 10%

< 20%

< 30%

Figure 4: Sectioned ISO View Showing internal wear pattern

DATA SYNOPSIS

Page 6

Ore Flow through the Chute

Figure 5

DATA SYNOPSIS

Page 7

Table 1 – Tonnes per month for both legs – received from Khumani Control Room

Mass Flow Column Labels

Row Labels

[31] On Grade W&S Fresh Feed

[32] On Grade W&S Total Feed

[130] Total On Grade Reclaimed from On/Off

[187] Total On W&S Feed

P 2016_02 75856 193428 52983.33 128839.33

P 2016_03 246742 451162 40379.53 287121.53

P 2016_04 482856 780523 1999.2 484855.2

P 2016_05 341856 598289 416.32 342272.32

Grand Total 1147310 2023402 95778.38 1243088.38

DATA SYNOPSIS

Page 8

REPLACEMENT FREQUENCY

The replacement frequency was determined by the wear pattern, derived from the inspection

report and the average % when new lips should be ordered and when they should be

replaced.

WEBA recommend New QRL’s must be ordered once the lips is 60% worn.

DATA SYNOPSIS

Page 9

Table 2 – Showing the current % wear of the QRL and replacement frequency in months

LIP

QT

Y. Q

R1

00

-25

QT

Y W

orn

% W

orn

Repla

cem

ent

Fre

quency (

mo

nth

s)

QT

Y. Q

RR

400

-25

QT

Y W

orn

% W

orn

Repla

cem

ent

Fre

quency (

mo

nth

s)

QT

Y. Q

RR

450

-25

QT

Y W

orn

% W

orn

Repla

cem

ent

Fre

quency (

mo

nth

s)

Section C

CDB1 17 3 10 23 12 0 0 0

Section D

DR4 (N/S) 8 8 15 14

DR4 (F/S) 8 8 15 14

DR5 (N/S) 8 8 15 14

DR5 (F/S) 8 8 15 14

Section E

E1DB2 13 1 10 23 12 6 10 23

E1DB3 11 1 10 23 12 6 10 23

Section F

F1DB2 11 7 10 23 12 12 10 23

F1DB3 11 7 10 23 12 12 10 23

F1DB4 11 7 10 23 12 12 10 23

F1DB5 11 7 10 23 12 12 10 23

Section G

G1R1 (N/S) 12 8 20 11.5

G1R1 (F/S) 12 8 20 11.5

G1R2 (N/S) 12 8 20 11.5

G1R2 (F/S) 12 8 20 11.5

G1DB2 12 1 10 23 10 10 10 23

DATA SYNOPSIS

Page 10

Table 3 – Section H - Showing the current % wear of the QRL and replacement frequency in

months

LIP

QT

Y. Q

R1

00

-25

QT

Y W

orn

% W

orn

Repla

cem

ent

Fre

quency

(month

s)

QT

Y. Q

RR

300

-25

QT

Y W

orn

% W

orn

Repla

cem

ent

Fre

quency

(month

s)

QT

Y. N

ON

ST

D

QR

-LIP

S

QT

Y. N

ON

ST

D

QT

Y W

orn

% W

orn

Repla

cem

ent

Fre

quency

(month

s)

Section H

H1DB2 14 14 10 23 8 8 10 23 2278-QR2-

25 1 1 10 23

H1DB3 12 6 30 7 8 4 30 7 2278-QR3-

25 1 1 15 14

6 15 14 8 4 15 14

H1DB4 12 12 30 7 8 8 30 7 2278-QR4-

25 1 1 30 7

H1DB5 12 6 20 11.5 8 4 20 11.5 2278-QR5-

25 1 1 20 11.5

H1DB6 14 7 15 14 8 4 10 23 2278-QR6-

25 1 1 10 23

COST COMPARISON

Page 11

Cost comparison

Cost of Replacing Wear Components

Year Conventional Lips Quick Release Lips

% Cost Saving

Year 1 R44 340.00 R35 982.00 18%

Year 2 R190 351.52 R59 740.00 68%

Year 3 R44 340.00 R35 982.00 18%

*Costs determine at 2016 steel prices and does not include inflation

Price for

Full Set Conventional Lips

R230 873.05

Initial Price to

Convert to Quick Release Lips

R284 482.40

TIME SAVING

Page 12

Time saving

Removing and replacing a conventional lip is time consuming. The area around the lip needs

to be cleaned and the bolts removed before the new lip can be installed.

Removal of a conventional lip:

Material first needs to be

cleared on the top and bottom

of the base plate, then the nuts

need to be removed by means

of a cutting torch

TIME SAVING

Page 13

COMPANY INFORMATION

Quick Release Lips:

The removal procedure is

conducive to self-cleaning.

CONVENTIONAL LIP REPLACEMENT TIME

20 minutes per running meter

QUICK RELEASE LIP REPLACEMENT TIME

6.33 minutes per running meter

66% Time Saving

COMPANY INFORMATION

Page 14

Company Information

ALWIN NIENABER

TECHNICAL DIRECTOR

TED CRUICKSHANK PROJECT MANAGER

Tel +2711 827 9372

Fax +2711 827 6132

Mobile +27 82 779 0156

Email alwin@webachutes.com

Tel +2711 827 9372

Fax +2711 827 6132

Mobile +27 82 334 9878

Email ted@webachutes.com

WEBA South Africa (Pty) Ltd

99 Nagington Road, Wadeville, Germiston, 1422

Tel 011 827 9372

Fax 011 827 6132

www.webachutes.com