Material Handling Solutions.

Transcription

1 Material Handling Solutions

2 Capability Over 40 years experience in providing material handling products and solutions has given us the knowledge to provide the support and know how to satisfy our customers. HMA Halley & Mellowes Material Handling Division is part of the HMA Group of Companies and specialises in the design, supply, installation and servicing of material handling equipment in a wide variety of industries. Commissioning Maintenance & Support We represent principals who are among the leaders in their fields including PICOR International, A.S.H., Mogensen UK and Carman Industries and combined with our own in-house engineering, drafting and project management resources enable us to provide an optimum material handling solution to fit our customers needs. Project Definition Process SCOPE Equipment LAYOUT Costing Timeline Our network of sales and support offices means you are never far away from a trained HMA representative who can assist you with any of your needs for new or existing equipment. Whether it is the supply of a single screen or chute design through to a multi element turnkey project, HMA Halley and Mellowes has the experience and resources to ensure our customers goals are met. Conceptual Design Installation Detailed Engineering 2 Logistics Manufacture & Procurement

3 Contents Engineering and Design... 4 Material Loading Systems... 6 Stockpiling... 8 Screening Vibratory Equipment Conveying Weighing Systems Chutes and Gates After Sales Support The HMA Group of Companies Formation Babcock & Wilcox Employee Owner Group Geotechnical Systems Australia 3

4 Engineering and Design At HMA Halley & Mellowes Material Handling Division we work with the client as early in a project as possible, taking their vision and ensuring that the full scope of the project is reviewed in detail to ensure that all aspects and options are considered. Engineering Services HMA Halley & Mellowes (MHD) engineering services is the heart of our operations bringing the project vision to reality through: Project definition Conceptual design Design engineering Detailed drafting Manufacture & procurement Shipping Installation Commissioning Maintenance & support While many of our products are focussed on material handling systems, our team has a wider range of experience including process, structural, mechanical and fluid power engineering all working together to provide an optimum solution. 4 At HMA Halley & Mellowes (MHD) we work with the client as early in a project as possible, taking their vision and ensuring that the full scope of the project is reviewed in detail to ensure that all aspects and options are considered. This is the most critical stage of a project to ensure that the most cost effective solution is arrived at. Our aim is to maximise the project function and minimising its cost. Subsequent activities can usually only maintain or increase the overall cost of a project, not decrease it. Our design engineering team utilise the latest in engineering and computer aided design (CAD) software to: Reduce equipment footprint and structural size leading to reduced capital and construction costs. Simplify design and on site construction requirements Minimise design time, reducing the time from concept to creation. Safety is an important consideration in all of our engineering services. We undertake HAZOP and HAZAN analysis of all our designs in house and where required with our clients looking at all elements in terms of construction, operation, maintenance and end of life. While the design of a facility is generally the main factor in influencing the overall project cost and timeline, the procurement and manufacture process must be managed to eliminate costly construction delays and errors in manufacture. Our team of project managers and engineers as well as administrators work for our clients to provide: Design integrity by liaising with the engineering team to ensure the concept become reality On Time and On Budget by continual tracking of costs and timelines

5 Safety is an important consideration in all our engineering services. Superior safety by ensuring compliance with the project safety management system Customer satisfaction by keeping in constant communication and ensuring all parties work as a team HMA Halley & Mellowes (MHD) are able to assist in ensuring that the equipment within a project continues to operate at its maximum. Services include: Equipment inspections Training of operators Supply and management of spare parts Our extensive network of sales and support offices means you are never far away from an HMA Halley & Mellowes (MHD) representative and are backed up by workshops that can provide on and off-site services. Our aim is to offer our customers an outstanding service that reduces operating costs and outages. Our engineering services team is capable of providing our clients with a design to suit their needs and aims from a single piece of equipment through to a full turnkey project. Controls system support Upgrades and retrofits 5

6 Material Loading Systems HMA Halley & Mellowes (MHD) can provide a full complement of services with material loading systems. HMA Halley & Mellowes has developed a reputation as being one of the leading suppliers of loading systems for bulk materials in the Australasian region. This has been built on a number of successful installations with the introduction of various innovations and the use of new technology. Loading systems are available to suit both truck and train applications with various loading methods including: Flood (Volumetric) Loading Single or Multi Batch Weighed Loading Our scope of involvement can be from the supply and commissioning of a loading system through to a full turnkey project allowing for customised design, facility installation and project management. Our preference is to be involved as much as we can ensuring that we minimising the risk for our customers and that the final product satisfies all parties. HMA Halley and Mellowes do not prescribe to the one size fits all approach, instead working with each of its customers from the conception of a project to ensure the final product is inline with the operational requirements whilst incorporating features required to meet each sites needs. 6

7 Examples of features that can be incorporated into a design include; Telescoping or traversing chutes Covered or uncovered wagons Control Room designs CCTV Camera systems Bin Lining options Material veneering systems Automatic or manual operation All of our designs are continually checked and modified to ensure they comply with the requirements of any relevant standards including but not limited to Australian Standards. System Upgrades Existing loading systems can be upgraded so that factors such as throughput, loading accuracy and operator safety can be increased. Using our knowledge, HMA Halley and Mellowes (MHD) can design an upgrade to met you needs from a simple change in chute design for better profiling through to complete overhaul of controls, operations and equipment including automation. With the focus on maximising capacities, we can upgrade a Flood (Volumetric) loading system to one that gives a real time indication of the weight of material as it is being loaded. This allows the operator to know accurately the amount of material that has been placed in a wagon (Standard deviation of 0.5 tonnes per wagon can be achieved), reducing the risk of overloading while ensuring the wagon is fully utilised. Total train accuracy of 0.25% from target is a typical result. The system requires no weigh hoppers and does not modify the structure at all. Installation can be achieved while loading operations continue and when combined with automatic control gives a cost effective loading solution. Precision Loading System HMA Halley and Mellowes revolutionised the manner in which product is loaded into trucks or trains by increasing the loading efficiency, maximising the utilisation of transport stock and decreasing the overall capital cost of constructing a new facility. This has been achieved by the introduction of the patented Precision Loading System (PLS). The PLS is a weighed loading system consisting of two bins a larger surge bin at the top of the facility and a smaller weigh bin at the bottom. The PLS uses a multi batch loading process, which allows the rail wagon or truck to be loaded with precisely weighed batches to maximum their capacity. Multi batch means the facility can be designed for one, two or three batch loading depending upon customer preference and what best fits the application. The size of the weigh bin is custom designed to suit the required batch size, whilst the surge bin is sized to suit the infeed rates from the reclaim or other downstream feeding systems. Loading in 2 or 3 batches allows the weigh bin size to be significantly reduced when compared to a single batch operation. The smaller weigh bin size allows a smaller surge bin to be used as the instantaneous capacity is not required. These features translate into an overall height reduction of as much as 10 m from traditional single batch systems. This smaller size yields many benefits in the installation and operation of the loading facility 1. A decrease in steel and foundation costs, reducing the capital cost of the loading facility. 2. Reduction in feed conveyor height and length requirements producing savings in capital costs as well as land requirements. 3. Reduction in conveyor power requirements of up to 125 kw providing significant operating cost savings. 4. Simplified structure design allows for a decreased installation time and cost. Overall the multi batch PLS is able to lower the total construction cost of your loading facility. 7

8 Stockpiling A key component of most bulk material handling systems is that of storage. It is not always feasible or indeed desirable to have material in continual movement which means that a form of storage is required. In terms of bulk materials this is usually done in the form of an on ground stockpile. When considering how material is to be stored there are a number of factors that need to be taken into account. Key among these is how big does a stockpile need to be, how is the material going to be placed onto the stockpile and how is material going to reclaimed. HMA Halley & Mellowes Material Handling Division are able to assist you in these areas to ensure a successful solution is put in place. Stockpile geometry HMA Halley & Mellowes (MHD) can assist in determining an optimum stockpile configuration and geometry to meet your process needs. Whether it is a linear, conical or radial style of stockpile, HMA Halley & Mellowes (MHD) can model a design to determine space requirements, available capacity, and reclaim volume. We work with our clients to ensure all scenarios are explored to provide an optimum solution. Stockpile generation There are many ways to generate a stockpile and it is important that the requirements and characteristics of each project be taken into account when selecting the method of loading material onto a stockpile. It is very important that the stockpile geometry and method of generation be worked together to ensure an optimum solution is arrived at. HMA Halley & Mellowes (MHD) can provide a number of equipment and process design solutions to meet the various stockpile generation methods. These include: Stackers Stationary Radial Overhead Fixed Tripper Travelling tripper As with all of our designs, these are customised to fit the project requirements. Stockpile reclaim HMA Halley & Mellowes (MHD) has extensive experience in the design, supply and installation of underground reclaim from stockpiles. Our Drawdown Hoppers are recognised around the world as being a leader in the field of stockpile activation. The design eliminates outdoor stockpile storage and reclaim problems including coring, bridging, and minimal active reclaim by using vibratory action to transmit energy directly into the stockpile, encouraging sloughing into the flow stream and maximizing active reclaim. Individually engineered for each application, the unique design of the Drawdown Hopper allows easy installation with the ruggedness to stay on-line. To ensure proper application, HMA Halley & Mellowes (MHD) engineers analyse the flow properties of your product and match the correct Drawdown Hopper to the project needs. 8

9 The Drawdown Hopper is only one element of the reclaim system. It is necessary to control the flow of the material from the Drawdown Hopper to the reclaim conveyor. HMA Halley & Mellowes (MHD) can provide a number of options for flow control including: Vibratory feeder Swing hopper flow control gate Low head room flow control gate The low head room flow control gate is the latest innovation bought to the market by HMA Halley & Mellowes (MHD). It provides good control over a wide range of flow rates, is low maintenance with its use of low friction polymer slide blocks and with a reduced height, allows reduced chamber and tunnel excavation and construction costs. HMA Halley & Mellowes (MHD) also provides design solutions for discharge chutes, conveyor skirting and maintenance access platforms to offer a complete reclaim system solution. The underground reclaim system is ideally matched with our PLS truck or train loader as it provides a high reclaim rate, consistency of feed and high level of control. These features allow the PLS design to be optimised and operate at its maximum potential. HMA Halley & Mellowes (MHD) are also able to supply the civil design for the underground tunnel as well as the reclaim conveyor as part of a turnkey package, which provides our clients of an assurance of design compatibility. 9

10 Screening HMA Halley and Mellowes Material Handling Division has a range of products that are able to assist you in your screening and sizing applications. We have a standard equipment range that have been used successfully in many applications or can custom modify our equipment with our engineering and design department to suit your requirements. Divergator The Divergator is a patented high capacity non binding and self-cleaning static grizzly. It contains no moving parts and the bars are individually and easily replaceable. The unit can be sized to suit most applications in widths varying from 0.5 to 5 m and placed in series for an increased separation area. Typical applications for the Divergator are: Crusher protection ( i.e. remove fines which do not need to be crushed) A shedder plate for conveyor belt protection To segregate products inexpensively when sharp separations are not required Feed to the Divergator can be either by conveyor, feeder, shovel or truck. slopes from the top to the bottom. Coarse mesh apertures result in a screening system that has increased resistance to pegging and blockages, but with very high specific throughput rates and with excellent screening efficiency and recovery figures. The Sizer is fully enclosed and dust proof, and available in widths from 0.5m to 3m with a choice of six, five or three decks depending on the screening duty. All machines are supplied with quick-change, end tensioned meshes. Options include: Electric deck heating for sticky materials Automatic deck cleaning Stainless steel or abrasion-resistant construction Choice of mesh material and aperture Comprehensive selection of product chute configurations Rubber, polyurethane, metallic and ceramic wear-resistant linings Backed by the strong reputation and experience of Mogensen, the sizer is ideal for applications such as fertilizer, mineral sands, ceramics and stone. HMA Halley & Mellowes (MHD) can design the structure or chute to contain the Divergator and integrate it into your plant. Sizer The Mogensen sizer has become synonymous with high capacity screening applications around the world due to its robust and unique design. The concept is based on multiple mesh decks arranged one above the other at increasingly steep 10

11 Vibratory Equipment HMA Halley and Mellowes (MHD) are able to supply a wide range of vibratory process equipment through our principal partners Carman and Mogensen as well as our own design and engineering resources. No matter what the application, HMA Halley and Mellowes (MHD) are capable of providing a solution to your needs. Examples of equipment available are: Bin dischargers Vibratory bin dischargers eliminate hopper flow problems including bridging and ratholing by using vibratory action to improve bin flow and easily discharge virtually any material. Individually engineered for each application, the unique design of the HMA Halley and Mellowes (MHD) vibratory bin discharger allows easy installation with the ruggedness to stay on-line. A large number of options are available to suit any number of industries and applications including: Food Hydrated lime Foundries Chemicals Glass and plastic Grain and wood Feeders and grizzlies HMA Halley and Mellowes (MHD) have a range of standard designs for vibratory feeders suitable for feed rates up 1800 tph. The vibration is generated by vibrator motors mounted either below or above the unit to provide options for installation. Grizzlies can be included in the design to provide a size separation with the one unit. Fluid bed processors A vibrating fluid bed processor is the ideal method to heat, cool, dry, or moisturise bulk solid materials. By passing controlled process air up through the material bed of the vibrating processor, the material is percolated like a gently boiling fluid. The solid particles undergo intensive intermixing as process air surrounds each particle, permitting direct heat and/or moisture transfer between the air and the particles. It is this intimate contact between air and material particles which makes a fluidised bed the most efficient convection heat and moisture transfer process for use in food, mineral sands, chemical and many other industries. Conveyors Vibratory conveyors can solve your most difficult material handling problems. The versatility of our vibratory conveyors means your bulk materials can be moved at the speed you want, in the volume you need. The vibratory conveyors have proven to be highly effective in so many industries due to the number of processes which can be accomplished along with movement. In addition, you ll get efficient flow rates, lower power use and minimum maintenance demands. Vibratory conveyors find applications in moving foods, chemicals, mined materials, wood products, glass, recycled materials, foundry materials, metals... virtually any bulk material you can name. No matter what the application, HMA Halley & Mellowes (MHD) are capable of providing a solution to your needs. 11

12 Conveying Belt Cleaners The Dirtwhacker conveyor belt cleaner system supplied by HMA Halley & Mellowes (MHD) is recognised worldwide for its effectiveness, durability and belt-friendliness. The design makes use of a proven parallelogram system, ensuring that the blade-to-belt angle will always function at the optimum angle. Available in both primary and secondary form (the secondary can be used as a tertiary) the Dirtwhacker range is designed to provide the industry with a conveyor belt cleaning solution on the conveyor belt top cover as it returns from the head pulley. The units are highly effective in removing carry back material from the face of the belts and yet, the conveyor belt top cover is exposed to minimal wear. The innovative parallelogram design maintains the optimal belt blade angle irrespective of blade wear The air bladder system sustains even blade-to-belt pressure for each blade segment over the full cleaner width The blade design is compatible with the majority of mechanical belt fasteners The unit requires no mechanical adjustment in-between blade changes There is a visual indication of belt to blade pressure at all times The belt-to-blade pressure can be adjusted from a suitable remote location Belt Trackers Belt alignment problems can be resolved by using HMA Halley & Mellowes (MHD) supplied Hallitrak belt equipment. The Hallitrak is a fully assembled idler frame style belt tracker that is designed to accept stock rollers making maintenance easy. It is available in a range of sizes to suit all belt widths and roller configurations including return idlers. The guide rollers are fully adjustable and made from stainless steel for a long life. Drop forged and round link chain HMA Halley & Mellowes (MHD) are able to assist with the supply of chain, flights and other items associated with bucket elevators, chain feeders, chain conveyors and enmasse conveyors. All of our chains and flights are manufactured to the highest standards in quality endorsed locations ensuring the reliability and longevity of the equipment supplied. We make items to suit most standard machines but also have a design service to match an existing installed unit. 12

13 Belt conveyors HMA Halley & Mellowes (MHD) can supply belt conveyors to satisfy any of our customers needs, whether it is a conveyor matched to our stockpile reclaim and train loading systems or a smaller unit to feed into a Mogensen Sizer. We are also able to supply: Radial stackers Belt feeders Ship loaders Mobile conveyors Pipe conveyors Pipe conveyors have considerable environmental and economic advantages in the transport of bulk materials. Minimal dust generation and protection from outside contamination Up to 50% increase in incline over conventional belt conveyors giving reduction in overall conveyor lengths and plant foot print. Narrower than conventional belt for same capacity Can be used to transport material on the return section of the belting. Shape enables the pipe to be curved horizontally as well as vertically enabling several conventional belts to be replaced leading to reduced transfer points, power requirements and particle degradation. The pipe conveyors can be supplied in a range of materials to suit most bulk material applications with capacity equivalent to the standard belt widths. HMA Halley & Mellowes (MHD) can offer a design, supply and installation service that can deliver costs effective innovative solutions to complex transportation problems that are environmentally beneficial. Chain conveyors, feeders and bucket elevators HMA Halley & Mellowes (MHD) can supply chain conveyors, feeders and bucket elevators to suit a range of applications. These can be supplied either on their own or as part of a larger package incorporating other design elements. Designs and materials of construction are available to suit most bulk materials in a wide band of capacities. 13

14 Gates and Feeders Loading, Isolation and Flow Control Gates We have a large selection of standard design bulk material isolation and flow control gates available suitable for all industries such as mining, quarrying, food etc. We have extensive experience in gate design with numerous installations handling materials such as Coal, Iron ore and grain. We can also custom design gates to suit your particular application based on our materials handling knowledge. Gate types including Slide, Bi Parting, Clamshell, Undercut, Isolating and swing styles with any type of actuation such as Hydraulic, Pneumatic or Electro - Mechanical Reclaim, Chain and Apron Feeders We design & manufacture a range of Reclaim and Apron Feeders for use primarily in mining industry to reclaim ROM and Product coal at mines or from the coal stockpiles at shipping terminals and power stations. Our Feeders are designed to be fed by either truck or dozer without the need for large dump hoppers and are suited to smaller operations with lower feed rate requirements. HMA Reclaim and Apron feeders are an efficient way of reclaiming or feeding material in a wide variety of applications. Each feeder can be custom designed to suit the application and the feeding needs of our clients. 14

15 Chutes and Support Telescoping chutes Chute designs are available for a variety of applications including train and truck loading. They can be manufactured to telescope up and down to maintain the correct filling location, traverse sideways to move out of the way of high objects or a combination of the two. Switches and position indicators can be included to provide feedback to the operator or be part of an automatic control system. Material transfer chutes Using our years of experience, HMA Halley & Mellowes (MHD) can design material transfer chutes to suit any application to minimise wear and promote material flow. Existing installations can be improved by making an analysis of problem areas and designing them out. New installations are carefully analysed using flow modelling programs to maximise the design effectiveness. If required the chutes can be lined with any material from HMA Greenbank s range. After Sales Support HMA Halley & Mellowes (MHD) can provide after sales support for all of the equipment it designs and installs or supplied by others. This support includes: Operator and maintenance staff training Troubleshooting Design review and improvement Spare parts Field service Facility management Workshop repairs and overhauls Re-commissioning Our service engineers are qualified trades personnel, trained in-house as well as attending specialised external training. Service work is supported by reports which clearly detail inspections, measurements and other repair work done giving our clients a history on their equipment. HMA have a history of supporting our customers through long term service contracts that are designed to be provide measureable benefit and a lower cost of ownership. 15

16 Superior Ceramic Solutions Design, manufacture and installation of ceramic lined pipework and equipment Ceramic lined pipework Pipescan- Pipe wear monitoring Alumina shapes & tiles Site Installation & maintenance Basalt linings Eriez magnetics Sitech ceramic components Cyclone design, manufacture & overhaul Mining and Rail Equipment Solutions Jet slingers and telescopic chutes Trippers Belt feeders Rail maintenance equipment Vehicle wash systems Specialised design and prototypes

17 Keeping our customer s people, plant & environment SAFE Fire & Gas Detection & Protection Igniters & Flame Detectors for Boiler Control Industrial Explosion & Overpressure Protection Oil in Water Detection Analysers & Engineered Systems Offshore, Marine & Power Industry Solutions Clean Energy Solutions Power Generation Pulp & Paper Petrochemical Heavy Industry Large & small Boilers Custom designs & Engineering

18 Industrial Valve Suppliers & Engineers Supplying valves and control solutions to Australasia for over 30 years. Butterfly valves Ball valves Check valves Automatic control valves Sluice valves Knifegate valves Slurry valves Actuators Air valves Superior Measurement Systems Supplying Innovative Instrumentation and control solutions to industry Level Flow Viscosity Boiler level Process indicators 2D/3D solids measurement Nucleonic source disposal Solutions engineering Pressure Density Temperature Radiometric Density Alarm annunciators Coal analysers Material weighing Service & commissioning

19 Geotechnical Systems Australia Specialists in Geotechnical Instrumentation Our portfolio is extensive and provides the following products and solutions for geotechnical, mining and structural engineering applications. Pressure Monitoring Stress Monitoring Displacement Monitoring Inclination Monitoring Custom Instrumentation Datalogging and Telemetry Communication Systems Comprehensive Field Installation and Supervision Project Management and Turnkey Services Workshop Repairs, Service and Calibration Short and long term hire Instrumentation Evaluation of existing systems and installations Power Division Supplying state of the art equipment to the power industry for 50 years On-Line Condenser Tube Cleaning systems Self-cleaning filter systems Acoustic leak detection systems Extensive range of filter bags and accessories Waste water remediation technologies Finned -Tube heat exchanger components

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