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Ken Bromfield, ARDBEL, Impumelelo Overland Conveyor

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Ken Bromfield delivered the presentation at 2014 Bulk Materials Handling Conference. …

Ken Bromfield delivered the presentation at 2014 Bulk Materials Handling Conference.

The 11th annual Bulk Materials Handling Conference is an expert led forum focusing on the engineering behind the latest expansions and upgrades of bulk materials facilities. This conference will evaluate the latest engineering feats that are creating record levels of throughput whilst minimising downtime.

For more information about the event, please visit: http://www.informa.com.au/bulkmaterials14

More in: Engineering , Business
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  • 1. Engineered  to  Deliver   ©2012ELBEngineeringServices(PTY)Ltd  BULK  MATERIALS  HANDLING   PERTH   28  –  29  April  2014     IMPUMELELO  OVERLAND  CONVEYOR   Presented by Ken Bromfield Pr Eng
  • 2. 2better together, one team – One Sasol confidential - copyright reserved, 2013, department, company The  Client:  Sasol  (Synfuels)   •  Founded  in  1950   •  Employees  over  35000  people   •  Operates  in  37  Countries   •  Listed  on  JSE  and  NYSE  
  • 3. 3better together, one team – One Sasol confidential - copyright reserved, 2013, department, company •  Integrated  Energy  and  Chemicals   company   •  Develops  and  commercialises  energy   related  technologies   •  Builds  and  Operates  world  scale  faciliYes   •  Produces  Liquid  Fuels,  Hi-­‐value   Chemicals  and  Low  Carbon  Energy  
  • 4. 4better together, one team – One Sasol confidential - copyright reserved, 2013, department, company •  World’s  only  commercial  viable  Coal-­‐ based  Synfuels  manufacturing  plant   was  pioneered  by  Sasol   •  World  leader  in  Gas  to  Liquid  and  Coal   to  Liquid  Technologies   •  Operates  one  of  the  world’s  largest   underground  coal  mining  complexes   •  Top  10  most    valuable  company  on  JSE    
  • 5. 5better together, one team – One Sasol confidential - copyright reserved, 2013, department, company
  • 6. ©2012ELBEngineeringServices(PTY)Ltd Project  Loca+on   Sasol Secunda
  • 7. ©2012ELBEngineeringServices(PTY)Ltd Sasol  Coal  Mines:  Secunda   Current Underground mining operations are: •  Bosjesspruit, •  Brandspruit, •  Middelbult, •  Syferfontein •  Twistdraai / Thubelisha •  and Sigma near Sasolburg. •  As some of these mines are approaching the end of their useful lives, new developments are underway to ensure continued coal supply. •  The Impumelelo mine will replace the Brandspruit operation. It will be ramped up to produce 8,5 mtpa, which could later be upgraded to 10,5 mtpa. •  This coal will be used exclusively by the Sasol Synfuels’ plant.
  • 8. ©2012ELBEngineeringServices(PTY)Ltd •  The  Impumelelo  Mine  is  located  approximately  30  km  from  SECUNDA  in     SOUTH  AFRICA.   Mine  Loca+on   Impumelelo Mine
  • 9. ©2012ELBEngineeringServices(PTY)Ltd
  • 10. ©2012ELBEngineeringServices(PTY)Ltd The Challenges •  The Impumelelo mine 30 kilometres from the plant • The Mine is planned to initially supply 8.5Mtpa of coal, expandable to 10.5Mtpa • The incline conveyor is designed for 3350 t/hr and will operate at 2900 t/hr. • The overland conveyor is designed for 2400 t/hr and operate at 2000 t/hr. • 5 Horizontal curves with a minimum radius of 4500m • Undulating terrain • 65 m vertical difference • Day / Night temperature variation -6°C to 36°C. • Two Flight overland conveyor system? • EPC Contract
  • 11. ©2012ELBEngineeringServices(PTY)Ltd
  • 12. ©2012ELBEngineeringServices(PTY)Ltd Horizontal  Profile:   Conveyor CV2301: Overland Conveyor
  • 13. ©2012ELBEngineeringServices(PTY)Ltd Conveyor Vertical Profile Conveyor CV2301: Overland Conveyor
  • 14. ©2012ELBEngineeringServices(PTY)Ltd Proposed Solution: One elastic band 54 kilometres long
  • 15. ©2012ELBEngineeringServices(PTY)Ltd RISKS AND BENEFITS – 2 x flights vs 1 x flight as offered by ELB ITEM   SINGLE  FLIGHT   TWO  FLIGHTS     RISKS   BENEFITS   RISKS   BENEFITS   BELTING   OLC  conveyor  length   exceeds  20km   Increased   opportunities  to   maximise  efficiency       Belts  known  to   operate  at  these   lengths     Belt  breaks  complete   system  stops   Reduced  belt  flexure   results  in  improved   splice  and  belt  life   Increased  number   of  pulleys  –   reduced  belt  and   splice  life     Can  off-­‐load  at   intermediate   transfer  point     Belt  wear  due  to   transfer   Minimum  height  of   transfer  results  in   softer  loading   Belt  Wear  due  to   transfer       Increased  belt  wear   due  to  wider  idler   spacing  –  idler   spacing  confirmed  to   not  affect  belt  life.   (Cover  selection)         DRIVES   None  –  Conveyor  can   run  at  slightly   reduced  capacity   even  with  one  drive   out.   Opportunity  to  reduce   number  of  drive  packs     Inefficiencies  due   to  separate  drive   systems   One  conveyor   can  be  kept   running   IDLERS   Perceived  increased   idler  failure  rate  due   to  wide  spacing  –   proved  untrue  by   design  comparison   Reduced  Initial  Cost   and  reduced   operating  cost  –  both   in  maintenance  as   well  as  power   consumption     Reduced  idler   spacing  –   apparent   reduction  in   idler  failures   (confirmed  not   true)  
  • 16. ©2012ELBEngineeringServices(PTY)Ltd     General  SpecificaYons:   •  Horizontal  pulley  centres:      26  962m   •  Ver+cal  liP:        -­‐63m   •  Installed  power:      4  x  1000kW,  2  x  450kW   •  Belt  Width:        1  200mm   •  Belt  class:        ST2000,  7/5  LRR   •  Belt  Speed:        6.5m/s   •  Design  Capacity:      2  400ph   •  Start-­‐up  on  full  load:      Yes   •  SoP  Start:        VSD  670  sec   •  Take-­‐up  type:        Ver+cal  gravity   •  Holdback:        Park  Brakes  on  high  speed     •  Normal  Stop  100  sec      Emergency  stop  67  sec   Conveyor CV2301: Overland Conveyor
  • 17. ©2012ELBEngineeringServices(PTY)Ltd Power Breakdown: Conveyor CV2301: Overland Conveyor
  • 18. ©2012ELBEngineeringServices(PTY)Ltd Brief  overview  of  project  scope  
  • 19. ©2012ELBEngineeringServices(PTY)Ltd Conveyor CV2301: Overland Conveyor (tension sensors) Head Pulley– Drive 3 Gravity Take-up with Capstan Brake Drive 4 Head-end Turnover 1. Head Arrangement Drive 1 Drive 2 Drive 5 & Brake Winch Controlled Belt Storage Loop Belt Tension Measurement System for Booster Drive Control Tripper Chute Skirt boards 2. Booster Drive Station Tail - Drive 6 & Brake Tail-end Turnover Tail Loading Chute Skirt boards Belt Tension Measurement System for Tail & Return Drive Control 3. Tail Arrangement
  • 20. ©2012ELBEngineeringServices(PTY)Ltd •  The  underground  surge  bunker   •  surge  facility  1500  ton.   •  two  vibra+ng  feeders,     •  chute  work,  plate  work,  suppor+ng  steelwork,  feeding  arrangement  onto  the  single  incline  conveyor.     •  A  single  1800  mm  incline  conveyor  with  a  design  capacity  of  3  350  tph.   •  Horizontal  pulley  centres:    1086m   •  Ver+cal  liP:      265m   •  Installed  power:      3  x  1000  kW   •  Belt  width:      1800mm   •  Belt  class:      ST3150   •  Belt  speed:      4.7m/s   •  A  single  1800  mm  Tripper  conveyor   •  Low  profile  tripper  car  with  a  design  capacity  of  3  500  tph.     Brief  overview  of  project  scope:  Mine  end  
  • 21. ©2012ELBEngineeringServices(PTY)Ltd Overland  Conveyor:  Mine  Incline  
  • 22. ©2012ELBEngineeringServices(PTY)Ltd •  A  15  000t  live  capacity  surface  surge  bunker  (SSB)     •  10  luffing  chutes  to  discharge  onto  the  reclaim  conveyor.     •  A  9000t  surge  stockpile  and  100  000t  throw-­‐out  stockpile     •  4  luffing  chutes  for  reclaiming  from  the  stockpile.   •  A  1800  mm    reclaim  conveyor,  design  capacity  of  2  400  tph   •  two  Multotech  magnets   •  two  four  idler  Process  automa+on  weigh  scales   •  A  par+cle  size  distribu+on  ash  and  moisture  sampling  plant  on  the     surface  bunker  reclaim  conveyor.     Brief  overview  of  project  scope:  Bunker  and  Stockpile  
  • 23. ©2012ELBEngineeringServices(PTY)Ltd Impumelelo  overview  
  • 24. ©2012ELBEngineeringServices(PTY)Ltd 15000  ton  Bunker  and  throw-­‐ out  stockpile  overview  
  • 25. ©2012ELBEngineeringServices(PTY)Ltd Bunkers: Precast Elements
  • 26. ©2012ELBEngineeringServices(PTY)Ltd 15000 ton Bunker under Construction
  • 27. ©2012ELBEngineeringServices(PTY)Ltd North end of 15000 ton bunker
  • 28. ©2012ELBEngineeringServices(PTY)Ltd Reclaim  Transfer  on  Overland   Conveyor  overview  
  • 29. ©2012ELBEngineeringServices(PTY)Ltd Conveyor CV2301: Overland Conveyor – Belt Turnover Tail End
  • 30. ©2012ELBEngineeringServices(PTY)Ltd Start of Conveyor
  • 31. ©2012ELBEngineeringServices(PTY)Ltd Towards the Plant
  • 32. ©2012ELBEngineeringServices(PTY)Ltd •  Surge  bin  /  large  transfer  chute  for  the  long  overland   conveyor  discharge  end   •  A  4000t  live  capacity  SCS  surface  bunker  without  a  throw-­‐ out  facility,     •  3  luffing  chutes  to  discharge  onto  the  reclaim  conveyor.   •  A  single  SCS  surface  bunker  tripper  conveyor  and  a  moving   head  with  a  1500  mm  belt  width  and  a  design  capacity  of   2400  tph.   •  An  SCS  surface  bunker  reclaim  conveyor  with  a  1800  mm   belt  width  and  a  design  capacity  of  2400  tph  feeding  directly   into  the  SCS  crusher  house.   Brief  overview  of  project  scope:  Plant  (SCS)   End  
  • 33. ©2012ELBEngineeringServices(PTY)Ltd •  An  interconnec+ng  conveyor  with  a  design  capacity  of  2400  tph   between  the  SCS  surface  bunker  reclaim  conveyor  transfer  point   and  the  current  Brandspruit  conveyor  transfer  tower  feeding  SCS.   Brief  overview  of  project  scope:  Plant  End  
  • 34. ©2012ELBEngineeringServices(PTY)Ltd Structural Work at SCS Bunker
  • 35. ©2012ELBEngineeringServices(PTY)Ltd 4000 ton Bunker at SCS
  • 36. ©2012ELBEngineeringServices(PTY)Ltd Belt Delivery: 1 km per roll; 33 ton, 6m wide x 4m high
  • 37. ©2012ELBEngineeringServices(PTY)Ltd Media  Coverage  
  • 38. ©2012ELBEngineeringServices(PTY)Ltd Acknowledgements   -  SASOL Mining - Client -  EPCM - RSV-ENCO Goba / Hatch -  EPC - ELB Engineering Services -  Lyonell Fliss & Associated – Bunker design -  Conveyor Dynamics, Inc. (CDi)- Conveyor design -  Tasman Warajay - Chutes -  Conveyor Belt Technology – Belt Installation Procedures -  CONCOR- Civils Contractor -  ELBCON – Erection Contractor -  Veyance (Goodyear) – Belt Supplier