Investigation & optimization of Greenside coal transfer points in order reduce maintenance

requirements

Ayanda Nhlapho

2nd Year University of Cape Town

Table of Contents Project Background

Problem Statement

Objectives

Methodology

Plant Information

Materials Used on Chutes

Table of Contents Wear Liners on Chutes - Wear Liner Selection - Wear Liner Solutions

Liner Results

Liner Solutions - Dead Box liners

Table of Contens Functions of an Effective Chute

Chutes

Conclusion

Recommendations

QUESTIONS

Project Background 4-Seam & 5-Seam Plant

Chutes in the Plant

Liners on Chutes

Investigation of Transfer Points.

Objectives Find a way to improve Transfer Points in order to

reduce maintenance requirements.

Minimize costs.

Increase safety.

Decrease labour hours & downtime.

Methodology Participate in daily maintenance activities

Research on chute & liners

Visits to consultants Martin Engineering & Seaton products

Compare costs of new systems to old systems

Plant

5-Seam5-Seam

4-Seam4-Seam

Crusher

Size Separation (Debmar screen)

Separation of coal & waste (Spiral)

Separation of coal & waste (Cyclone)

Overflow (Product)

Underflow (Discard)

Vortex Finder

Tangential Inlet

Separation of coal and waste (Drum)

Wear liner on chutes Wear liner is a material used on the interior of a

chute as a sacrificial surface. It serves as an easily replaceable sacrificial wear surface to protect the walls of the chute.

Materials used on chutes Mild steel (Chutes) -Low maintenance -Price is relatively low -It is neither brittle or Ductile -Corrosion resistance

Stainless Steel [304] (Liner material) - Abrasion resistance - Antibacterial - Passivation - High strength - Corrosion resistance

Materials used on chutes Ceramic Tiles (Liner material) - Corrosion resistant - Abrasion resistance - Low maintenance - Relatively inexpensive

Wear liner selection Friction Coefficient

Resistance to material adhesion

Resistance to abrasive wear

Resistance to impact

Wear liner selection Resistance to corrosion

Attachment method

Initial cost

Maintenance cost

Wear liner selection

Liners on chutes

Dead Box Liners

Dead Box liners

Liner results Greater Savings associated with using

Polyurethane

Installation & maintenance is very cheap

6 Times lighter Therefore very safe to work with

Lasts longer than stainless steel

Great reduction in noise levels

Decrease in downtime

Liner Results

Functions of an effective chute To feed the receiving conveyor in its direction of

travel

To centralize the material load

Functions of an effective chute To minimize the impact on the receiving belt and

material degradation

- Chute angles

- Material buffer

Grizzly Bars installed on Chutes

Functions of an effective chute To supply the stream of material at a speed as

close as possible to the speed of the receiving conveyor.

To minimize the generation of spillage and the release dust.

 

Functions of an effective chute Traditional chutes

Hood & Spoon

Hood & Spoon

Hood & spoon

Hood & Spoon Dust reduction

Conclusion Change all liners to polyurethane

Apply Hood & Spoon

Recommendations Seaton Products

Martin Engineering

Acknowledgements Staff in the training centre Staff working at the plant Underground staff

QUESTIONS?

Questions?

Questions?

Questions?