The Martin Engineering team invites attendees at the UK’s number one show for bulk material handling to stop by stand RA17 of the Hillhead 2018 Quarrying, Construction and Recycling Exhibition at the Hillhead Quarry in Derbyshire on 26-28 June.  The team will be on hand to meet current and potential customers and discuss common issues and unique problems affecting their operations.

“The UK and Scandinavia are centres of excellence when it comes to bulk material handling and processing,” said Robert Whetstone, Martin Engineering’s European Vice President.  “It’s exactly the kind of market that benefits from the innovations in products and services for which Martin Engineering is known.”

Since 1944, Martin Engineering has designed, engineered and manufactured heavy duty conveyor components and material flow aids with a focus on safety, efficiency and ease of service.  The company has had offices and manufacturing in the region for more than 30 years, and has established a reputation for premium quality equipment and expert service throughout Northern Europe in a wide range of industries, including heavy building products, mining, cement, steel production, fertiliser, power generation, recycling, food, railheads, ports and bulk storage industries.

Working from a purpose-built production facility, products including air cannons and belt cleaners will be manufactured at the new location.  Also housed there will be factory direct equipment and spares for Martin Engineering bulk handling solutions to be quickly dispatched to any area in the region to keep customer plants running efficiently and safely, while reducing expensive downtime.

Martin Engineering’s ability to deliver operational and safety training that is specific to the region’s strict occupational and workplace regulations is an important asset to bulk handlers in the region.  Using its Foundations™ reference book, now in its 4th edition, the firm’s experts train customer employees on the function, maintenance and safe operation of conveyor systems.  In addition, the company’s Foundations for Conveyor Safety presents more detailed concepts specifically focused on safety regulations and procedures.  The entire program is designed to maximise operators’ understanding of current equipment and technologies, help improve system performance, reduce downtime and minimise hazards.

Appointed as general manager to head up the team, Aaron Bartram is a UK native who has been part of Martin Engineering’s recent launch of the Mr. Blade^® program, a unique service which ensures clean conveyor belts at all times.  Mr. Bartram’s 30 years of experience running major production operations in the heavy building products sector will be invaluable to the success of the new endeavor.

Also bringing their experience to the team are customer service representative Richard Housechild and service engineer Wayne Crossland.  Housechild will be accommodating the growing sales demand of the UK market and Crossland will be on sites installing and servicing customer equipment.

“The expanded Martin team is already working with a number of customers in the region,” said Whetstone.  “Now that we’ve bolstered our staff and opened the new facility, we’re geared up to achieve our ambitious growth plans.”

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Transportadora Callao S.A., the logistics operator of a special cargo terminal in the port of Callao/Peru, relies on a BEUMER Group Pipe Conveyor for the transportation of zinc, copper and lead concentrates of different mining companies from the warehouse to the terminal. With its ability to navigate curves in three dimensions, the conveyor can be optimally adapted to its routing course of approx. 3000 metres. What is even more important: the conveying system prevents the concentrates from coming in contact with the environment and ensures dust-free transport to the ship’s holds. BEUMER Group was responsible for engineering and supply, including the steel structure, supervision of the installation and putting the Pipe Conveyor into operation.

Callao is located directly on the Pacific Ocean. With 877,000 inhabitants, it is one of the largest cities of Peru, with the largest airport in the country and one of the most important fishing and commercial ports in South America. A modern ship loading terminal for ore concentrates was built in this port and it is operated by Transportadora Callao S.A.

About 75 percent of the imports and exports of Peru, one of the most important mining countries world-wide, are handled in Callao. In order to satisfy the increasing demand for these valuable materials, the Peruvian government decided to expand the port. Besides additional storehouses, the plans also foresaw the largest, most modern ship loading terminal in the country. Peru also wanted to change the way the raw materials were transported to the ship loading areas. Before the construction of the special terminal, trucks were used to transport the concentrates from the warehouses to the port terminal. “Since Transportadora Callao started its operation, they could reduce the truck drives by 130,000 per year,” explains Victor Sam, CEO at Transportadora Callao S.A. The company, a consortium comprising five enterprises from the mining and port industries (manufacturers and warehouse logistics operators), obtained a license from the state of Peru for building and operating the necessary infrastructure.

PIPE CONVEYOR: DUST-FREE CONVEYING

The mines in central Peru transport their concentrates to the warehouses, approx. 3 kilometres from the port. This required an absolutely protected method for the transportation of material, to prevent particle emission into the atmosphere. Transportadora Callao opted for the BEUMER Group Pipe Conveyor. The direct contact person and project partner was Helmut Wolf from BEUMER Group Austria GmbH: “Together with the responsible persons from the customer, we developed a solution that is perfectly adapted to the routing and the ambient conditions.”

Due to its enclosed transport, the Pipe Conveyor not only protects the environment against harmful impacts during the transport of the lead concentrate, it also allows conveying over long distances and navigation through tight curve radii. Due to its ability to navigate curves, this belt conveyor requires a lot less or no transfer towers at all, depending on its length and the available curve radii. This results in substantial cost savings for the customer, and allows BEUMER Group to easily customise the system to the individual routing. Durable conveyor belts guaranteeing tensile strength are used. The engineers use different dimensioning programs to determine the ideal belt design. They use them to calculate tractive forces and forces that arise during acceleration and deceleration and also to determine possible curve radii. BEUMER Group provides tailor-made feasibility studies for each project. Another advantage is the reduced noise emission that the system provides. This is ensured by special idlers, as well as low-noise bearings and selecting the right conveying speed. “This improves the quality of the employees’ day-to-day work environment,” says BEUMER engineer Wolf. Victor Sams adds that the “noise measurements along the Pipe Conveyor resulted in values that are consistently far below the permitted limit values.”

Conveying capacity: 2,300 tons per hour

BEUMER Group supplied and installed a Pipe Conveyor with a centre distance of 3,195 metres. “Due to the system design and the required system capacity, we designed it with a diameter of 400 millimetres,” explains Helmut Wolf. “The conveyor transports 2,300 tons per hour, at a speed of 4.5 m/s and is driven by 3 motors with a capacity of 650 kW each. We equipped the system with filters, strippers, a dedusting unit and a control system.” BEUMER Group was responsible for engineering and automation, and supplied the steel structure and the necessary components. The site managers supervised the installation and put the system into operation.

The process is practically free of faults and, above all, safe: trucks or trains transport the mining commodities from the mines to the ore storages, from where they are transported to the open access station. Here, the concentrates are received by a feeding 43-m belt conveyor that transfers it to the Pipe Conveyor at a height of 6 metres. A dedusting unit ensures that no material is emitted during this process. “We equipped the feeding belt conveyor with a metal detector and an electric magnet,” explains Helmut Wolf. “This prevents damage of the downstream Pipe Conveyor by metal parts.” At the end of the route, the conveying system runs along the seaside in the naval port of Callao to the transfer tower. Here, the belt opens automatically. It transfers the material to another belt conveyor that conveys the ore to the ship loading system.

Victor Sam: “This modern system, in operation now for 17 months, caused a significant increase in speed by 500 % for loading concentrates and reduced the ship’s waiting time until loading by more than 80 %. These advantages lead to savings for the exporters and improve the competitiveness of the country’s mining industry.”

Trouble-free integration, challenges mastered

“A big challenge for us was integrating the Pipe Conveyor into the existing environment,” says Helmut Wolf. The BEUMER system is the connection between the individual belt conveyors from various manufacturers. “When managing the project we had to meet several official requirements,” reports Helmut Wolf. The project represents a concession by the state of Peru given to Transportadora Callao S.A., who commissioned Odebrecht Perú Ingeniería y Construcción with the execution, and Buenaventura Ingenieros S.A. with the supervision. Odebrecht commissioned BEUMER Group with the design of the entire line section onshore.

The onshore section starts at the “Open Access”, where the concentrate is transferred from the warehouses. The Pipe Conveyor then passes a refinery and a military area. “That was the specified routing that we had to observe,” explains Helmut Wolf. In the area of the refinery, the systems had to additionally be equipped with fire-proof covers.

Due to this impressive engineering work, Transportadora Callao is now able to handle ships for bulk products of up to 60,000 DWT without obstructing the work in the other terminals of the Callao port.

World-wide connected and brought to one point

BEUMER Group has bundled its comprehensive expertise spanning various industries and established different Centers of Competence in order to offer optimal support of their single-source solutions for companies like Odebrecht and Transportadora Callao. The Pipe Conveyor segment is one such Center of Competence. This center is responsible for sales and project management worldwide. It collects and prepares the know-how of each regional group company and passes it on to the group company’s global experts, such as Helmut Wolf and his team. “BEUMER’s technical team has proven its professionalism and stand-by duty, during construction and operation, and after 1.5 years in operation and more than 4 million tons of transported concentrates, we can attest that the set goals have been reached,” explains Victor Sam.

BEUMER Group’s extensive Customer Support ensures a high level of system availability after commissioning. Transportadora Callao just signed a teleservice contract with BEUMER Group, so that BEUMER specialists can eliminate possible malfunctions in the system. If necessary, the BEUMER Group service staff will go to Callao in order to make the necessary adjustments and prevent malfunctions and machine breakdowns, which would lead to long downtime.

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“Rather than fabricating the main frame from individual steel profiles welded together, the frame for the new design is roll formed out of a single piece of steel, which produces an extremely strong and durable component,” explained Paul Harrison, Director of the Conveyor Products Business Group.  “The process eliminates the time-consuming steps of having to weld any portion of the frame, which also contributes to the reduced purchase price.”

Described as one of the most comprehensive patents the company has ever been awarded, protection covers the main frame design, manufacturing process and attachment method.  The new cleaner features Martin Engineering’s unique “CARP” (Constant Angle Radial Pressure) technology to maintain the most efficient cleaning angle throughout service life, with a no-tool replacement process that can be performed safely by one person in less than five minutes.  It delivers outstanding performance and durability, while reducing the total cost of ownership.

“We’ve simplified the manufacturing process and also re-engineered the blade itself,” Harrison continued.  “The new profile is less complex to produce, and because it can be roll formed or manufactured on a press brake, it will be easier to source throughout the world from any Martin Engineering manufacturing site.”

The new design also features a special alignment system to facilitate extremely precise installation.  “One of the most common problems we see in the field is primary cleaners installed in the wrong position,” said Senior Product Specialist Dave Mueller.  “This cleaner was engineered for easy, accurate installation.”

The product announcement comes on the heels of Martin Engineering’s introduction of the company’s “Forever Guarantee,” which ensures lifetime no-cost replacement of tensioners and main frames for any belt cleaner assemblies that are exclusively fitted with the company’s replacement blades.

The Martin® QB1™ Cleaner HD is engineered to represent the next generation of belt cleaning technology, delivering the cleanest belt and longest blade life — at the lowest cost.  It can be retrofitted onto any existing Martin Engineering tensioners, as well as most competitive systems.

In addition to its cost advantages, the QB1 HD design features a square mainframe positioned to shed dust and spillage.  The urethane blade formulation can accommodate belt speeds of up to 900 fpm (4.6 m/sec) and service temperatures of -40° to 160°F (-40° to 70°C).

The QB1 HD is available in lengths of 18 to 96 inches (457 to 2438 mm) and can also be ordered in 10-foot (3.05 meter) sections, allowing distributors or customers to cut to length for increased versatility. The new design is one of the many belt cleaners covered by the company’s new Mr. Blade program, under which Martin Engineering’s mobile technicians provide fresh, factory-direct replacement blades, delivered and custom-fitted on-site — installed free of charge.

Founded in 1944, Martin Engineering is the world leader in making bulk materials handling cleaner, safer and more productive.  The company supplies flow aids and conveyor products around the world for a wide variety of bulk material applications, including coal, cement / clinker, rock / aggregate, biomass, grain, pharmaceuticals, food and other materials.  The firm is headquartered in Neponset, IL, offering manufacturing, sales and service from factory-owned business units in Brazil, China, France, Germany, Indonesia, Mexico, Peru, Russia, South Africa, Turkey, India and the UK, and under exclusive license with ESS Australia.

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The new technology can create a virtually unlimited array of shapes and sizes, including the DustBoss^® DB-R ring, which creates a curtain of mist around the cargo stream or specified area for outstanding containment of fugitive dust or odor.  The customized solution offers high-volume applications such as radial stackers, crushers and screeners more focused and reliable suppression, taking the technology beyond perforated hoses and basic spray nozzles.  The company has also developed the ability to supply custom spray bars and shapes under the DustBoss^® DB-B family of spray bar products.

“This capability was developed in response to several requests by clients seeking a viable area-specific solution,” said DCT President Laura Stiverson.  “We’ve found that the most effective dust suppression approach involves identifying where in the industrial process fugitive dust is produced and customizing a solution that contains it at the point of emission.”

Customers can request a virtual site assessment to determine the optimum size and shape of a customized ring, working with experienced personnel to design a tailored system.  The assessment includes such details as material properties and volume, width / length / speed of conveyors, pulley diameter and slope.  DCT can also produce customized shapes from customer drawings, depending on the size, geometry and complexity.

The objective in atomized mist technology for dust suppression is to induce as many collisions as possible between the dust particles and the droplets, causing an agglomeration effect that weighs down the solid particles and drives them to the ground.  As airborne dust particles and water droplets approach each other, the best chance for a collision is created when they are roughly the same size, avoiding a slipstream effect that can carry them past one another.

The force of the slipstream is relative to the size and speed of the droplet.  When smaller airborne particles encounter a large droplet, they can get caught in the slipstream, causing them to move around the droplet rather than being absorbed by it.  Because atomized mist technology creates similar-sized droplets that are able to travel with dust particles on natural air currents, the chances of collision and absorption are increased, allowing the collective weight to drive particles to the ground.

Customizing A Solution

At the core of the technology, water is pumped into a stainless steel manifold and atomized by a series of specially designed nozzles that fracture the water into a cascading mist.  The water can be supplied by standard municipal sources or a hydrant, feeding a hose sized for the application and connected directly to male pipe threads on the manifold.  To avoid premature clogging of misting nozzles, facilities that draw from non-potable water sources can employ additional filtration systems.

“Custom rings and spray bars can be equipped with a pump that is matched to the specific device and the service conditions under which it must operate,” said Stiverson.  “Options include a complete plug-and-play system with its own control panel, as well as the ability to tie in to a customer’s existing controls.  For applications that require surfactants, a dosing pump can be included in the design to precisely meter additives.”

No Two Applications Are Alike

Engineers at DCT have created custom systems for a variety of different industries, from aggregate to recycling to coal.  With the launch of the customization program, the company is equipped to engineer systems of nearly any size and configuration.

“This product family was created to fulfill unmet customer needs, but it also helps protect workers and the surrounding community from industrial dust and odor,” Stiverson concluded.  “We want all of our customers to have a solution that fits their individual needs, contributing to health and safety, good community relations and regulatory compliance.”

The company has positioned itself as a complete solutions provider for dust and odor control, able to deliver a level of customer service that is difficult to match from suppliers that provide a broad range of equipment.  By specializing in atomized mist technology for dust and odor control, DCT has built a reputation for outstanding customer service and industrial-strength equipment designs that address even the largest and most difficult applications.

Dust Control Technology is a global leader in dust and odor control solutions for coal, demolition, slag handling, landfills, recycling and many other applications.  The company designs and manufactures customized equipment utilizing atomized mist technology for dust suppression and odor management.  All of the firm’s R&D, experience and expertise is centered completely around those applications, and its staff helps customers analyze particle sizes, working environments and other factors to ensure effective performance under real-world conditions.  The units are far more effective and efficient than manual spraying, with some customers realizing payback in less than six months.  DCT equipment can be purchased outright or rented from an extensive fleet.

For editorial assistance:

Rick Felde

+1 (541) 306-4815

rickf@dustboss.com

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EDGE MS80 mobile stockpilers reduce the double handling of materials by providing the solution for the loading of haul trucks directly from a Sandvik QE440 Scapler screening petrified wood out from lignite in the United States.

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