disruption to production, with the improvements to the ROM
stacker being implemented during the mine’s annual shut down
period of seven days in February this year,” says van de Vyver.
The boom stacker conveyor feeds from the primary crusher
to the stockpile, where the material is reclaimed to feed Le?tseng
Plants No 1 and No 2.
DemcoTECH was also appointed in 2014 to carry out the
conveyor design and layout for the expansion to the tailings
dump for Phase 3 of the Le?tseng Mine expansion and is currently
upgrading the tailings dump. This involves the installation of
additional conveyor equipment as well as relocating the main
extendable boom stacker conveyor and transfer towers. This
current work is aimed at enabling the tailings system to handle
higher capacities resulting from Le?tseng’s Project Kholo, which,
amongst other objectives, is aimed at increasing ore throughput.
Previous stockyard projects include the design, engineering,
procurement and construction management for the materials
handling portion of the expansion to Grindrod’s multi product
terminal at the port of Richards Bay in South Africa. The scope
of the contract was to provide the bulk materials handling
system conveying various materials, but mainly coal and rock
phosphate, from three Richards Bay terminal sites. The system
provided, which has been operating successfully since
commissioning, included receiving the coal from a tippler
discharging onto three belt conveyors, one of which fed an open
stockpile. The stockpile was equipped with mobile plant
reclaiming material via a Buffalo feeder.
DemcoTECH also completed an expansion to the manganese
export facility at Assmang Limited’s Cato Ridge Alloys plant in
KwaZulu-Natal, South Africa, working jointly with Kantey &
Templer Engineers. Part of the project focused on the supply of a
greenfields stockpile and reclaim facility and included an
automatic truck loading system.
The stockpile has a new elevated tripper feeding the stockpile
with a dust suppression system to provide a safe and
environmentally friendly operation. The wagon tippler was
supplied with a new side arm charger to eliminate the positioning
of rail wagons using a locomotive.
DemcoTECH Engineering is a specialist bulk materials
handling and niche process plant company, offering services from
concept design through to project completion to the power
generation, cement, mining, metallurgical, manufacturing and port
Phoenix Terminal Solutions: a new level
Founded in 1892, Phoenix Products Company Inc. designs and manufactures lighting fixtures for some of the world’s harshest environments, including bulk handling stockyards. One of its key markets is the bulk handling industry a critical link in the world’s supply chain. How a terminal utilizes the ever-changing technology available in this competitive industry can have a direct effect on the operator’s bottom line. For this reason, having integrated systems and concise information about them is crucial.
FILLING A VOID
For years, Phoenix has been observing the many unique characteristics of the terminal industry from the long buying cycles to the amount of capital investment required to remain competitive. The distribution channels are also unique. In many cases, the manufacturer, OEM and specifier are all located on separate continents, which often complicates the management of these projects.
Phoenix has responded to these distinguishing factors with an innovative new business model — Phoenix Terminal Solutions. It sells Phoenix’s lighting fixtures in addition to other industry- leading manufacturers’ of specialty equipment.
Prior to doing anything, Phoenix researched, interviewed and judged key market professionals’ reactions to its concept. The response was positive, and it was convinced it was the right thing to do for two predominant reasons:
- Trust: Phoenix is more than 123 years old. With its rich history and the credibility built over the decades, customers were confident they’d be presented with top-quality products from trusted suppliers.
- Efficiency: there was also a consensus that, with PTS bringing more products from more manufacturers, customers would learn more from a single sales call than they would by meeting with four or more separate vendors.
Phoenix has aggressively grown its presence in the terminal market for lights installed on equipment worldwide. Scott Fredrick, CEO of PTS and Phoenix explains, “A good deal of our
growth has been in LED technology and was leveraged when we established a specialized port sales team within Phoenix. Until then, we weren’t able to identify an alternate sales channel that would focus exclusively on the port market, be adaptable to the long buying cycle or have a multi-national presence required by the industry.”
In addition to Phoenix, PTS currently represents two premium manufacturers — LASE and Bright Light Systems. But this is only the beginning. Fredrick states that they plan to add
others possibly organizations based overseas that are looking to grow in the North American market. Plans also exists to partner with American companies looking to expand into international markets because its port sales team already has a strong presence in Europe, Latin America, and Asia.
In reference to LASE’s new partnership with PTS, Lars Ambrosy, CEO of the Germany-based manufacturer says, “LASE strengthens its presence by this partnership. Phoenix stands for quality as well as high-value products and services, which also reflects the philosophy of LASE.”
This increased presence means more information for port operators who may not have the exposure to these manufacturers due to time or geographical constraints.
Fredrick further explains,“PTS’ sales team had proven to be very effective. It includes credible, port industry veterans with a wealth of applicable knowledge.” This brings a wealth of resources and a new level of service to terminals worldwide.
PTS has been fully operational since January 2015. Thus far, the market response and overall performance of the newly formed, specialized company has exceeded expectations. The project opportunities are abundant, and appointments have been incredibly productive.
All in all, it’s been a very promising start for a company that is challenging the status quo and working to optimize distribution in the port industry.
Cat® M Series 966 and 972 wheel loaders offered with XE advanced powertrain
he 966M, 966M XE, 972M and 972M XE wheel loaders have EU Stage IV C9.3 ACERTTM engines equipped with a combination of proven electronic, fuel, air and aftertreatment components. Applying proven technologies systematically and strategically lets Caterpillar meet its customers’ high expectations for productivity, fuel efficiency, reliability and service life. Deep system integration results in reduced emissions, improved performance and improved fuel economy without interrupting machine performance making it seamless to operators.
PRODUCTIVITY AND FUEL EFFICIENCY
The XE advanced powertrain first introduced with the 966K XE continues with the 966M XE and the 972M XE. The XE technology results in 25% higher fuel efficiency on average compared with machines with traditional torque converters, and simplifies operation with a two pedal design while providing seemingly endless power.
The 966M and 972M powertrains have also been improved with the addition of lock-up clutch torque converters as standard. These new torque converters have also been matched with the engine power and hydraulics to improve performance and fuel efficiency and are another example of deep system integration. These rugged planetary transmissions also have a split-flow oil system and use new multi-viscosity oil which improves fuel economy. The deep system integration of the above features and further axle and hydraulic improvements below result in ten percent lower fuel consumption on average compared to the 966K and 972K. The new 966M and 972M are second only to the 966M XE and 972M XE which are the class leaders in fuel efficiency.
These models are used in dry bulk handling and where poor underfoot conditions make traction difficult slowing production and challenging job deadlines. By their ability to engage on-the-
go and to transfer 100% of the torque to the wheel with traction, the disc-type differential locks improve tractive ability in these applications thereby increasing productivity. All four models come standard with front axle differential locks which are manually activated by a switch on the floor. Optional fully automatic front and rear axle differential locks operate by measuring differences in axle speeds and require no operator intervention to activate. These disc-type differential locks will reduce tyre scuffing compared with other traction aids further reducing operating costs for customers.
The axles contribute to lower fuel consumption due to lower oil levels and bevel gear shrouds which reduce churning losses from rotating components. They also have external caliper disc parking brakes mounted to the input shaft of the front axles. Caliper parking brakes have higher capacity than the drum brakes used on the 966K and 972K. Since they are external, they do not have the inefficiencies of enclosed wet parking brakes due to brake discs running in oil nor is there any oil to change reducing fuel and maintenance costs. External caliper parking brakes are easily accessible for inspection and service.
The main hydraulic valve is a mono-block with an integrated ride control section. The mono-block design reduces weight, has forty percent fewer leak points and is common across all
M Series models. The ride control system now has two accumulators enabling it to be more effective over a greater payload range, increasing productivity and operator efficiency due to a better ride. Auxiliary third and fourth hydraulic functions can be easily added at the factory or in the field with the addition of a second remote valve.
Hydraulic implement pumps continuously and automatically balance hydraulic loads with the machine performance desired by the operator. The pumps have larger displacements for increased hydraulic flow at lower engine rpm thereby saving fuel.
A new ‘aggregate handler’ version of these models allows to increase payload by approximately 700kg in free-flowing material applications.
Improving operator efficiency remains a key design goal for the 966M, 966M XE, 972M and 972M XE. Ensuring operators are safe, confident in the control of their machines, have a clean, comfortable and quiet operating environment with controls that are intuitive and low effort, all contribute to reduced operator fatigue and better performance.
In the cab, the new door securely seals against the new roll formed ROPS posts and the lower glass panel has been extended several centimetres to improve visibility to the left side of the machine. Large convex mirrors improve visibility to the rear and integrated spot mirrors provide visibility close to both sides of the machine.
A new multipurpose colour touch screen display dramatically simplifies the operator interface; with machine controls, rear view camera and new fully integrated Cat Production Measurement
system. Intuitive navigation with in-language text enables operators to modify certain machine operating parameters and monitor machine conditions literally at the touch of their fingers. Some controls have been relocated to this new display eliminating the need for the second membrane switch pad further reducing cab clutter.
Operator sound pressure level & exterior sound power level remain unchanged for the 966M and 972M at respectively 69 dB(A) and 108 dB(A).The 966M XE & 972M XE operating at lower engine speed, benefit from reduced noise levels at respectively 67 dB(A) and 105 dB(A).
Cat Connect enables operators and managers to access machine operating data including total fuel consumption, average fuel rate, total idle time and fuel consumed at idle, total operating hours and several other machine data. The Caterpillar Production Measurement app option is integrated in the touch screen display providing payload information. These technologies and services provide an increasing ability for customers to monitor, manage and enhance operations, gain more control of their jobsites and reduce costs and increase profits.