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CPS Conveyor Products & Solutions Australia's leading conveyor roller manufacturer adds FRAS composite rollers to their range www.bulkhandlingreview.com Volume 22 No 2 | March/April 2017 Conveyors, belt scrapers, ancillaries Grain handling Container tippling To view full digital edition of ABHR click here

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Page 1: CPS Conveyor Products & Solutions article 2017.pdf · CPS Conveyor Products & Solutions Australia's leading conveyor roller manufacturer adds FRAS composite rollers to their range

CPS Conveyor Products & SolutionsAustralia's leading conveyor roller manufacturer adds FRAS composite rollers to their range

www.bulkhandlingreview.comVolume 22 No 2 | March/April 2017

Conveyors, beltscrapers, ancillaries

Grain handling

Container tippling

To view full digital edition of ABHR click here

Page 2: CPS Conveyor Products & Solutions article 2017.pdf · CPS Conveyor Products & Solutions Australia's leading conveyor roller manufacturer adds FRAS composite rollers to their range

6 Mohi Media is new owner of ABHR

8 Pelletising plant uses Kason circular fluid bed dryers

CONTAINER TIPPLING

12 Ray Lee of Portside Solutions on containerised bulk

14 Qube’s Rotabox at Galaxy Resources’ Mt Cattlin

16 CRS supplies system to Taiwan

18 Steinert, Hazemag & Allmineral combine in Australia

19 Loren Neil Peterson, Vortex founder, dies

CONVEYORS, BELT SCRAPERS, ANCILLARIES

20 Trials and commercialisation for Smart-Idler

24 Cover story: CPS’ FRAS composite roller

27 Kinder Australia’s K-Conlock Clamp System

28 Flexco on mechanical splicing vs vulcanising

32 CPS lauds its polyurethane rollers

33 Martin Engineering now manufacturing CleanScrape

34 CoBond disrupting conveyor repair kit market

36 MLT preaching benefits of its splice solutions

37 Minprovise to supply primary crusher for Silvergrass

38 Bumper $140m contract for Takraf in Africa

38 MaxiTrans’ new boss

39 NSW sales manager for Bonfiglioli

40 Metso to spend a million on Tomago service facility

41 Enerpac’s self-propelled modular transporter

42 Soto says advances in DEM boost analysis capabilities

44 Rockwell to the fore at Internet of Things conference

45 Flexicon’s sanitary high lift box tipper

46 Case study: Flexicon’s pneumatic conveying of silicon powder for batteries

48 Siemens modernises drive system for Chilean ore mills

49 Pfisterer’s hybrid diesel/renewable micro-grid

GRAIN HANDLING

50 Rabobank says ‘world awash with wheat’

50 ABARES on bumper winter crop

51 Brisk business for Quattro since formation

52 GrainCorp breaks harvest records

54 Newcastle Agri Terminal boss upbeat

56 Mega trains equate to grower savings

57 Gangbuster harvest sees CBH smash records

58 RAM Spreaders on containerised grain

60 Kotzur’s new maintenance business

62 Tubeveyor helps ARTC deliver first ‘direct from farm’ loading

61 FLSmidth wins EPC contract for Brazilian mine

64 Concetti bagging line for silica powder

65 Brendon Grylls burnt by mining lobby

66 Mobile conveying & transhipping: Green Coast Resources and Metro Mining direct ship bauxite

www.bulkhandling.com.au

EDITOR

Charles MacdonaldTel: 02 9080 4443Email: [email protected]

ADVERTISING SALES

Patrick RobertsLevel 18, 347 Kent St, Sydney, NSW 2000Tel: +61 2 9080 4015 Fax: +61 2 9299 4622Email: [email protected]

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PLEASE SEND ADVERTISING MATERIAL TO

Ronda McCallum Email: [email protected]: +61 2 9080 4354

PUBLISHING DIRECTORMichael MohiEmail: [email protected]

AUSTRALIAN BULK HANDLING REVIEW (ABHR) ispublished 7 times a year by Mohi Media Pty LtdACN: 611591210ABN: 436111591210PO Box 455Rozelle, NSW 2039

ISSN 1444-6308 Circulaton: 5,263 (audit period ending September 2015) Member Circulation Audit Bureau (Australia)

Copyright © 2017 Mohi Media Pty Ltd. All rights reserved. Reproduction of the editorial or pictorial content by any manner without written permission of the publisher is prohibited.While contributed articles to ABHR are welcome, return postage must accompany all manuscripts, drawings and photographs if they are to be returned and no responsibility can be assumed for unsolicited materials. All rights in letters submitted will be treated as unconditionally assigned for the publication. All products listed in this magazine are subject to manufacturer’s change without notice and the publisher assumes no responsibility for such changes.The publisher’s advertising terms and conditions are set out in the current Advertising Rate Card, which is available to read before placing any advertisements.

contents MARCH/APRIL 2017

CPS Conveyor Products & SolutionsAustralia's leading conveyor roller manufacturer adds FRAS composite rollers to their range

www.bulkhandlingreview.comVolume 22 No 2 | March/April 2017

Conveyors, belt scrapers, ancillaries

Grain handling

Container tippling

ABOUT THE COVER

Conveyor Products & Solutions (CPS) adds FRAS composite rollers to its rangeAfter exhaustive research and development, CPS, in late 2016, finalised development of the first non-metallic conveyor roller to satisfy all of the mandatory tests within clause 3.4 of MDG3608.

This means that underground coal mines can now enjoy the benefits of CPS’ composite rollers, such as low weight and noise, longer life and lower cost of failure.

CPS’ new roller is being marketed as High Tensile Composite or HTC. It features an innovative composite shell manufactured from a conductive thermoset resin with glass fibre reinforcement.

For the full story and details of CPS’ R&D, see page 24.

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CONTENTS

3Australian Bulk Handling Review: March/April 2017

For more information please call 1300 70 70 67C3, 20 Tarlton Crescent, Perth Airport, Western Australia, [email protected] | www.lorbrand.com.au

Idlers | Pulleys | Belt Cleaners | Conveyor Belting

Your specialist partner for the manufacture and supplyof heavy duty conveyor components.

Lorbrand_FP_MA17_4.indd 1 21/3/17 2:16 pm

Page 3: CPS Conveyor Products & Solutions article 2017.pdf · CPS Conveyor Products & Solutions Australia's leading conveyor roller manufacturer adds FRAS composite rollers to their range

Australian Bulk Handling Review: March/April 201724

Before the development of suitable conveyor belts in the early 20th century, coal was transported from the mine by

rail transport systems, but for decades coal transport has almost invariably been by conveyor systems which have presented a unique set of challenges for mine engineers and managers tasked with minimising risks. A new conveyor roller recently developed by Perth-based Company Conveyor Products and Solutions Pty Ltd (CPS) mitigates the risks associated with composite conveyor idlers in underground coal mines and reclaim tunnels through purpose-developed materials technology.

Previously, only steel rollers have been used for underground coal conveyors, despite the health, safety, and operational risk advantages that newer composite and polymer roller designs can achieve. This is primarily due to previous concerns with fire risks of polymer and composite compounds. Therefore, elimina-tion of these fire related risks has come into focus to allow the coal industry to benefit from composite and polymer roller de-signs underground.

In 2012 the Mines Safety Operations Branch of NSW Trade and Investment published a guideline for non-metallic materials for use in underground coal mines, MDG3608, which identifies the major risks presented by non-metallic conveyor idlers under-ground, such as: • Initiation of a fire due to friction• Initiation of a fire due to static electrical discharge• Initiation of a fire due to heating or melting of materials used

in the roller construction• Propagation of fire due to the quantity of non-metallic materials• Toxic emissions and smoke produced by products of

combustion• Manual handling injuries relating to manual lifting and instal-

lation of conveyor idlers• Elevated noise levels causing permanent hearing loss

CPS have since used the tests and requirements pertaining to the above points, given in MDG3608, as a baseline with which to de-velop materials that would allow non-metallic roller advantages to be used underground.

In late 2016 CPS finalised the development of the first non-me-tallic conveyor roller to satisfy the mandatory tests within clause 3.4 of MDG3608.

The new roller, marketed as “HTC” or “High Tensile Compos-ite” features an innovative composite shell manufactured from a conductive thermoset resin with glass fibre reinforcement and uti-lises a fire resistant, conductive version of the CPS patented CBH composite bearing housing and multi labyrinth seal with a fixed face flinger covering 80% of the roller end to prevent rock jams.

Reduction of ignition risk due to heat/static build-up One of the biggest challenges faced in the development of non-metallic conveyor rollers for use in underground coal mines re-lates to minimising the risk of initiating coal dust or explosive gas fires due to friction between a non-metallic material and an-other surface, static electrical discharge and heating or melting of non-metallic materials. Coal dust can ignite at temperatures above 150°C with an oxygen concentration greater than 21%2 and methane gas has a known auto ignition temperature of between 537°C - 600°C3.

To test the performance of the CPS HTC roller in relation to ignition of fires a project was established to test the ignitability and maximum surface temperature of an idler subject to friction as detailed in MDG3608 Appendix F: Non-metallic Conveyor Idler Tests, F2.1.6(a).

Increasing safety in underground coal conveyorsBy Ernest Lapornik, CPS Pty Ltd

CPS HT Composite “HTC” Conveyor Rollers.

Thermographic Image of HTC roller face during seized idler simulation.

Graph of seized idler simulation.

CONVEYORS, BELT SCRAPERS & ANCILLARIES

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Australian Bulk Handling Review: March/April 2017

Conducting the testing through TUNRA, the test apparatus consists of a belt loop (approximately 5m in length) that is in-stalled with a Fire Resistant Anti-Static (FRAS) rated belt 600mm wide joined with a metal clip as required by the guideline. The belt speed used for the test was 3m/s and the load placed on the idler was equivalent to 104kg per 900mm belt width. After a two hour stabilisation period and additional 2 hour run period to test completion the HTC roller never exceeded a maximum surface temperature of 131°C with a mean of 123°C as shown in the table.

In a conventional steel shell roller this maximum tempera-ture exceeds the baseline temperature for testing of 325°C with additional sparking due to the metal belt clip striking the steel shell observed. As such it can be concluded that the seized CPS HT Composite roller is less likely to initiate a fire than a conven-tional seized steel roller

When tested in accordance to AS1334.10 – 1994 a method to determine the ignitability and flame propagation characteristics of non-metallic materials to test the “Finger Burn” test detailed in MDG3608 3.4.4.3, and a test method outlined under ISO4589-2:1996 to determine the “Oxygen Index” was conducted. All non-metallic components of the roller were tested in this way and found to comply in the same way that FRAS conveyor belts are assessed.

Interestingly MDG3608 calls for conveyor rollers to be orders of magnitude more conductive than conveyor belts when tested under ISO2878:2011 with the pass/fail criteria being that there “must be no more than 1MΩ electrical resistance between any two points on the non-metallic idler and between the non-me-tallic idlers and ground”1. For conveyor belts this criteria is set to 300MΩ.

Control of combustion bi-productsAlong with heat, the burning of every combustible material pro-duces smoke – gases and aerosols that, in sufficiently high con-centration, present hazards to people in the vicinity. Products near those already burning may also contribute to the smoke as they decompose from exposure to the heat from the fire. Pre-dominant among the hazards, which generally occur simultane-ously, are the following:• Sensory irritation of the upper and/or lower respiratory tract,

which can affect speed of movement and the ability to negoti-ate escape and, at higher exposures, can lead to incapacita-tion or death

• Central nervous system depression resulting from inhalation of asphyxiant fire gases, which can, in ascending exposures, lead to impaired judgment, disorientation, loss of motor coor-dination, unconsciousness, and, ultimately, death

• Thermal effects, including hyperthermia and thermal burns of the skin and respiratory tract

Exposure to these hazards is often prolonged by eye irritation and diminished visibility due to smoke obscuration, which can affect the ability of occupants to see and negotiate escape routes efficiently. Survivors from a fire may also experience post ex-posure complications that can lead to delayed health effects or even death.4

MDG3608 mandates that the toxicity of non-metallic con-veyor idlers must be tested under the method outlined in IEC60695.7.50-2006 Fire hazard testing part 7.50: Toxicity of fire effluent – estimation of toxic potency-Apparatus and test method; Allied Fire Assessment Publication 3 (AFAP-3).

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CONVEYORS, BELT SCRAPERS & ANCILLARIES

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Australian Bulk Handling Review: March/April 201726

Under this protocol CO2, CO and NOx levels were tested on each component of the conveyor roller. In addition it was decided to conduct an experiment to determine the levels of O2, CO2, CO, NOx, and SO2 during the full scale fire under controlled condi-tions using a FRAS conveyor belt on steel rollers comparing the results against the HTC composite rollers. The HTC composite roller emitted measurably lower toxic by-products than the con-trol steel roller with the conclusion being that in the instance of an underground conveyor fire using HTC composite idlers is safer than using conventional steel idlers. Results can be viewed in the following tables noting that changes in SO2 levels were indeterminable on both samples.

This same experiment was used to determine the risk of flame propagation using a modified version of the standard “flame gal-lery” test described under AS1334.12-1996 with acceptance crite-ria being determined under clause 6.1.2 of AS4606-2012 fire resis-tant and anti-static requirements for conveyor belting used in underground coal mine. It was decided to standardise the exper-iment by testing steel rollers as a control and then comparing the results against the HTC roller. While both the steel and the HTC rollers passed the requirements in all instances it was observed that it took a considerably longer time for the steel rollers to dissi-pate any residual heat compared to the HT composite rollers. One implication derived from this observation relates to auto ignition of bearing grease which while observed after “flame-out” on all roller types was observed to persist longer in the steel rollers.

Reduction of manual handling risksManual handling injuries relating to physically handling and in-stalling suspended idlers on underground conveyors has long been an issue to mine operators. Statistics published by The Department of Natural Resources and Mines’ Queensland mines and quarries safety performance and health report for July 1, 2013, to June 30, 2014, shows there were 38 permanent incapacities reported

relating to conveyors for 2013-14, compared to 32 in 2012-13. Of these 13 were reported from underground coal mines.

In one well publicised case a former mining employee filed a suit for more than $2 million after he sustained a lower back injury while changing trough rollers. According to the claim, the former employee injured his back when he was replacing a trough roller on a 1.8m conveyor belt that he was fixing with two other men. While he was holding the trough roller behind his head and twisting his trunk he “felt a pop in his lower back and immediately experienced severe pain”. As a result of the alleged incident the former employee sustained “soft tissue and interver-tebral disc injuries” that required surgery and caused aggravated pain down the back of his leg.5

The CPS HT composite idler was originally conceived as a solution to this very issue. A measurable reduction in mass of 40% is achieved in practice using a common 3 roller suspended set with 127mm diameter rollers for a 1600mm wide conveyor belt as an example, the mass for steel rollers would be approxi-mately 29.5kg. For HTC rollers this would be reduced to 17.7kg resulting in an 11.8kg reduction in total idler mass.

Reduction of noise and risk of hearing lossOccupational noise-induced hearing loss (ONIHL) is a significant health and economic problem in Australia. Between July 2002 and June 2007 there were about 16,500 successful workers’ com-pensation claims for industrial deafness involving permanent im-pairment due to noise. The economic burden of ONIHL is borne by workers and their families, business owners and managers, and the wider society.

The National Standard for Occupational Noise NOHSC:1007-2000 sets the maximum daily occupational noise exposure level at an eight-hour equivalent continuous A-weight-ed sound pressure level (LAeq,8h) of 85 dB(A) and, for peak noise, a C-weighted peak sound pressure level (LC,peak) of 140 dB(C). In addition, a code of practice NOHSC: 2009-2004 out-lines the noise management program that workplaces need to implement when the National Standard is exceeded.

The preferred solution to excessive noise exposure is to com-pletely eliminate the source of the loud noise. When this is not possible or practical, the legal requirement is to minimise expo-sure through a hierarchy of controls such as the following: • substitute the noise source with quieter machinery or processes• isolate the noise source from workers• apply engineering solutions (e.g. fit mufflers, redesign the

noise source, and install noise guards or enclosures) • apply administrative solutions (e.g. schedule noisy work

for when fewest workers are present, provide signs and quiet areas for breaks), and when none of the above are reasonably practicable

• provide personal hearing protectors (e.g. ear muffs and plugs).

CPS HTC rollers at completion of “Gallery Test”.

CONVEYORS, BELT SCRAPERS & ANCILLARIES

Page 6: CPS Conveyor Products & Solutions article 2017.pdf · CPS Conveyor Products & Solutions Australia's leading conveyor roller manufacturer adds FRAS composite rollers to their range

Australian Bulk Handling Review: March/April 2017

Within this hierarchy, priority is given to the source of the noise, followed by the path of transmission and, as a last resort, the ex-posed worker. A comprehensive hearing conservation program or noise control program should include strict adherence to the hierarchy of controls as well as assessments of noise exposure and hearing; education with respect to risks, solutions and responsi-bilities; and training on noise control and personal protection.6

Non-metallic conveyor idlers can assist in reducing the over-all noise levels in an underground mine. AS 1055.1-1997, using TUNRA’s Acoustics-Description and measurement of environ-mental noise provides the most accurate repeatable test method for analysing conveyor roller noise. A typical non machined and balanced steel roller has a noise output of approximately 85dB(A) while non-metallic rollers are observed to have a noise output typically in the 75 – 80dB(A) range effectively mitigating the risk to below the 85dB(A) threshold outlined in NOHSC:1007-2000. In 2016 CPS tested a number of conveyor rollers to determine noise output with the results in the graph measuring raw noise as an ambient background noise measured at 49.7dB(A) and also with the background noise subtracted in the test.

Note: CPS designates plain rollers as R01, low noise rollers as R08.

Final result summaryAfter a significant material and mechanical engineering devel-opment process, in late 2016, Conveyor Products and Solutions Pty Ltd finalised the development of the first non-metallic con-veyor roller to satisfy all of the mandatory tests within clause 3.4 of MDG3608.

Through this technology that is now in place, it has become possible for the advantages of modern composite roller designs to be brought to underground coal mining, particularly with re-gards to their lower weight, lower noise, higher operating life-time and lower cost of failure.

In addition to the above benefits, CPS has managed to ex-ceed original requirements, and the new design has proven not just equivalent, but superior to conventional steel rollers in fire safety performance.

References1. MDG3608: Non-metallic materials for use in underground

coal mines. Mine Safety, Trade & Investment Department, NSW Government. August 2012.

2. Norman F, Berghmans J and Verplaetsen F, 2013, The mini-mum ignition energy of coal dust in an oxygen enriched at-mosphere, Chemical Engineeing Transactions, 31, 739-744 DOI: 10.3303/CET1331124

3. D.B. Smith London Research Station, British Gas Corpora-tion, Michael Road, London SW6 2AD United Kingdom Re-ceived 10 May 1983, Accepted 19 May 1983, Available online 29 August 2001

4. Richard G. Gann Nelson P. Bryner Combustion Products and Their Effects on Life Safety Chapter 2 Section 6

5. Madeline McDonald, Gladstone Observer, Employee suing Anglo for $2m, claiming back injury, published 3 Aug 2015

6. Dr Perri Timmins and Mr Oliver Granger, Occupational noise-induced hearing loss in Australia: Overcoming barriers to ef-fective noise control and hearing loss prevention, Safework Australia published August 2010

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Contact: www.cpsconveyors.com.au

Unlocking conveyor spillage and dust problemsIdentification of material spillage and dust containment at transfer points and load zones is important if sites are to operate efficiently and within health and safety regulations.

Conveyor component company Kinder Australia says that its internal conveyor transfer point wear liners, such as

K-Containment Seal, provide a sacrificial wearing point within the loading zone that will be worn away by the conveyed material. Internal liners are commonly used in applications where material is highly abrasive, and therefore there is a requirement for routine replacement.

The internal liners perform important functions apart from wear protection of the chute wall. The liners help to keep the material centralised therefore assisting belt tracking and ensuring the best life and function of the external skirting media.

As the internal skirting is a key component of the transfer point, reliability is dependent upon accessibility to maintain adjustment. Given that it can’t be seen during inspections, the effectiveness is often overlooked. Also, replacement and adjustment is difficult and requires confined space permits and procedures.

K-Conlock Clamp System allows external skirting and internal K-Containment Seal Skirting from outside the conveyor

transfer point. The wear and tear of skirting or sealing material will require the operator to provide continuous adjustment depending on the abrasive wear of the product, or the design and functionality of the transfer point.

If the skirting clamp is difficult to maintain then the necessary adjustment may not happen. Or, over adjustment can occur which results in excess pressure applied by the skirting seal thereby damaging the belt.

According to Kinder Australia “Performing in the same way as the K-Lock Wedge Skirting Clamp, the K-Conlock fulfils the practical requirement of a reliable and serviceable system that is free of complications and doesn’t rely on the need for special tools to maintain correct seal pressure. The K-Conlock incorporates a design modification to now allow access to the outer face of the slotted arrangement, which is one of the key features of K-Containment Seal’s simple installation adjustment functions.”

Contact: www.kinder.com.au

CONVEYORS, BELT SCRAPERS & ANCILLARIES