Ken Bromfield, ARDBEL, Impumelelo Overland Conveyor

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


•  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


•  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

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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


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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


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Power Breakdown:


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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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•  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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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

Ken Bromfield, ARDBEL, Impumelelo Overland Conveyor

Engineering

Transcript of Ken Bromfield, ARDBEL, Impumelelo Overland Conveyor