ken bromfield, ardbel, impumelelo overland conveyor
DESCRIPTION
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/bulkmaterials14TRANSCRIPT
Engineered to Deliver
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BULK MATERIALS HANDLING PERTH
28 – 29 April 2014
IMPUMELELO OVERLAND CONVEYOR
Presented by Ken Bromfield Pr Eng
2 better 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 better 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 better 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 better together, one team – One Sasol confidential - copyright reserved, 2013, department, company
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Project Loca+on
Sasol Secunda
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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.
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• The Impumelelo Mine is located approximately 30 km from SECUNDA in SOUTH AFRICA.
Mine Loca+on
Impumelelo Mine
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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
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Horizontal Profile:
Conveyor CV2301: Overland Conveyor
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Conveyor Vertical Profile
Conveyor CV2301: Overland Conveyor
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Proposed Solution: One elastic band 54 kilometres long
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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)
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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
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Power Breakdown:
Conveyor CV2301: Overland Conveyor
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Brief overview of project scope
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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
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td • 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
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Overland Conveyor: Mine Incline
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td • 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
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Impumelelo overview
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15000 ton Bunker and throw-‐out stockpile overview
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Bunkers: Precast Elements
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15000 ton Bunker under Construction
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North end of 15000 ton bunker
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Reclaim Transfer on Overland Conveyor overview
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Conveyor CV2301: Overland Conveyor – Belt Turnover Tail End
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Start of Conveyor
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Towards the Plant
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• 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
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• 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
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Structural Work at SCS Bunker
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4000 ton Bunker at SCS
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Belt Delivery: 1 km per roll; 33 ton, 6m wide x 4m high
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Media Coverage
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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