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MODERN MINING
February 2014
PRODUCT News
In an effort to reduce the high instal-
lation costs incurred in Australia, FMG
(Fortesque Metals Group) requested Terra
Nova Technologies (TNT) to outsource the
assembly of its transfer chutes and towers
to overseas third party companies. As a
result, M&J Engineering was awarded the
contract to supply Weba Chute Systems to
FMG’s Solomon mine in Western Australia.
Solomon is part of FMG’s major expan-
sion in the mineral-rich Pilbara. The
Solomon Hub is located 120 kmwest of the
Chichester Hub and comprises the Firetail
mine and the Kings mine. More than three
billion tonnes of resources have been iden-
tified at Solomon, providing FMG with a
long term, low cost production strategy.
Early ear thworks commenced at
Solomon in late 2011, with significant
greenfields construction work undertaken
since to develop the 60 Mt/a operation.
The US$3,5 billion Solomon site has two
OPFs, three crushing hubs, a 125 MW
power station, its own airstrip and three
camps to house 30 000 people.
This was the second of three contracts
awarded by TNT to M&J Engineering.
The company recently supplied chutes
to Kisladag mine in Turkey and is in the
process of supplying eight chutes to the
Morenci opencast copper mine in south-
east Arizona in the Unites States.
“We have formed a mutually beneficial
relationship with TNT that allows us to
customise transfer chutes to suit specific
client requirements. TNT’s comprehensive
Pre-assembled transfer chutes shipped to Australia
The fully assembled transfer tower and Weba
Chute Systems loaded and en route to
Freemantle, Australia.
understanding of the engineering and
application benefits that are derived from
the Weba Chute Systems gives them the
confidence to propose their use in large-
scale projects,”says Mark Baller, MD of M&J
Engineering.
The seven Weba Chute Systems trans-
fer chutes were designed, engineered
and manufactured in South Africa by M&J
Engineering to precise specifications.
“We then trial assembled the chutes and
shipped them to the steel fabricator, Best
Tech & Engineering Limited in Thailand.
The steel fabricator was responsible for
pre-installation of the chutes into the
transfer towers which had been fabricated
by them,” Baller explains.
“Once the assembly was completed, the
transfer tower, together with the chute
and all ancillary equipment, was shipped
fully assembled toWestern Australia. It was
offloaded at the docks and transferred to
road trains for transportation to the mine.”
Four of the transfer chutes were specifi-
cally designed to cater for worst overrun
conditions, with a required storage capac-
ity of up to 30 m
3
of ore. “We achieved this
by utilising a sophisticated and unique
design, considered to be a first in transfer
chute technology. The chute was fitted
with an air cannon system to ensure that
bulk flow was achieved once the system
was restarted. By incorporating block
chute detectors in the chutes, we can
confirm that the chutes have completely
emptied before the incoming belts are
restarted,” Baller points out.
The remaining three chutes are normal
belt-to-belt transfer points that are capable
of handling tonnages varying from 4 500
up to 7 400 t/h on belt widths of 1 400 and
1 800 mm, travelling at speeds of 4,6 m/s.
Four of the chutes are fully operational and
the last three chutes are currently being
commissioned.
“Apart from the technical merits of the
Weba Chute Systems, the critical factor in
this project was the ability to provide a
product that could be remotely assembled
then shipped in its final configuration to a
destination on another continent. The cost
savings achieved by FMG by adopting this
philosophy are substantial and outline
M&J Engineering’s flexible approach to
design and engineering,” Baller concludes.
Mark Baller, M&J Engineering, tel (+27 11) 827-9372
Osborn secures ‘first ever’ order from China
While Chinese machines are pouring into
Africa, a South African mining equipment
manufacturer is quietly making its mark in
the People’s Republic. Johannesburg-based
Osborn has secured its first ever export
order to China for a modular plant to be uti-
lised in iron ore processing.
“This is a ground-breaking order,” says
Marketing Director Martin Botha. “It is an
exciting and significant turnaround to see
a South African machine shipped to China,
while machines from China are being
shipped to mines around Africa. It’s a reflec-
tion of the exceptional quality of Osborn’s
equipment.”
Osborn won this R20-million export order
amid stiff competition from leading global
players.
The Osborn modular plant – which Botha
says will replace a ‘locally-made kit’ at the
Chinese operation – comprises a primary
Osborn jaw crusher, a secondary cone
crusher, a screen and a tertiary cone crusher.
With a capacity of 300 t/h, the Osborn plant
will produce a nominal -12 mm product.
Osborn has partnered with a China-based
company that will undertake the manufac-
ture of the plant’s conveyors.
This order is the latest in a series of sales
that Osborn has netted – locally and fur-
ther afield – for its SA-designed and built
modular crushing and screening plants.
The company has recently supplied modu-
lar plants to several South African mines, as
well as operations in Lesotho, Mozambique,
Zambia, Burkina Faso, Guinea and Namibia,
Botha reveals.
Three plants are available, in different
sizes – a modular jaw
crushing plant (sizes 2540,
3042, 3055, 3648), a mod-
ular cone crushing plant
(sizes 38, 44, 52, 57) and a
modular screening plant
(sizes 6’, 7’ and 8’ double
and triple decks).
Charisse Fallows, Osborn Engineered
Products, tel (+27 11) 820-7600
A typical Osborn modular plant.
