Modern Mining March 2015

PRODUCT News

Johnson completes heavy lift for mill change-out

FLSmidth, explains that as the OEM, FLSmidth supplied the replacement shell of the new semi-autogenous grinding mill in sections for assembly on-site. “At the point where it was ready for installa- tion, the complete mill was lifted by the 600-t crane directly into its final position. We worked very closely with the Johnson Crane Hire team during this process.” Domain comments that what differenti- ated this project was the fact that the mill shell was essentially pre-assembled on site and then lifted into place as a single unit. “Normally what we do is simply build the shell on the foundations, where the bear- ings are located. However, in this instance we had to adopt a modular approach in order to cater for the production and thus time constraints. This meant a great degree of upfront planning was involved.” Zimplats Holdings Limited is 87-% owned by Implats. At present it operates four shallow mechanised underground mines and a concentrator at Ngezi. The SMC, located some 77 km north of the mine, comprises a concentrator and a smelter. Zimplats’ Phase 2 expansion pro­ ject is expected to increase production to 270 000 ounces of platinum in matte in 2015. Peter Yaman, Johnson Crane Hire, tel (+27 11) 455-9242 rely on diesel power. They are far cheaper to operate and can still be relocated quite easily.” Scherf says that the Original Equipment Manufacturer (OEM) market in Africa is still quite depressed, which has meant a renewed focus on customer service and aftermarket support. Dyer comments: “We have always been close to our customers, from a technical service and aftermarket point of view, and that is unlikely to change with our agreement to acquire Trio.” Pilot Crushtec International will still source products from Trio Engineered Products of the US. “Trio has a longstand- ing relationship with Pilot Crushtec which has successfully taken the Trio products to market in Southern Africa,”says Mike Burke, former owner of Trio Engineered Products. “I have no doubt that this acquisition will position Weir Minerals to offer compre- hensive solutions to comminution clients, whether aggregate or ultimately mining.” Rene Calitz, Weir Minerals Africa, tel (+27 11) 929-2622

and to replace it with a new one weighing 170 t,” says Grant Parker, Project Manager at Johnson Crane Hire. The successful completion of the project marked the cul- mination of two years of detailed planning and engineering. Johnson Crane Hire used a 250-t crawler crane – on site at the SMC since the begin- ning of September 2014 – to assemble the new mill. The components weighed about 60 t to 70 t each. “We then brought in a LR 1600/2 600 t crawler crane from Europe to take off the gears and remove the old mill and install the new one, as we were concerned our LR 1750 Liebherr crawler crane was not going to finish on time at a project at Nacala in Mozambique,” Parker explains. Johnson Crane Hire had a tight window from 29 September to 22 October 2014 to complete the heavy lift project, which was when the SMC had a shutdown period. The 600-t crawler crane completed the lift on 13 October, well within the timeframe. “The entire project went off very smoothly and we managed to hand the new mill over ahead of time. It was a tremendous team effort in conjunction with our client as well as the mechanical installation crew,” Parker comments. Kurt Domain, Project Engineer at Minerals and Pilot Crushtec International in accessing new market opportunities and utilising their specific engineering excel- lence and expertise. “Modular systems comprise quick and easily available mod- ules that can be on site and operational within a day or two. This methodology is being adopted by the entire market, cer- tainly in the crushing and screening sector,” says Sandro Scherf, MD of Pilot Crushtec International. Another advantage of modular plants is that, in terms of any potential process changes, these can be slotted in easily. “Sometimes the requirements change, as with the aggregate sector when another product fraction is called for. Tracked mobile plants are the easiest in terms of mobility, but due to high capital and opera- tional costs, these are not always the best option. Semi-mobile modular plants have a lower capital cost, as they usually do not

Johnson Crane Hire’s Heavy Lift Division has completed a major heavy lift proj- ect at Zimplats’ Selous Metallurgical Complex (SMC) in Zimbabwe for client FLSmidth. The mechanical contractor was Competitive Construction Services (CCS) of Vanderbijlpark, Gauteng. The project was completed without any Lost Time Injuries (LTIs) due to the close working relation- ship between the professional team and a strong focus on health and safety. “We were contracted to remove an old mill weighing 225 t, with a radius of 31 m, Johnson Crane Hire brought in a LR 1600/2 600 t crawler crane from Europe to take off the gears, remove the old mills and install the new one at Zimplats’ Selous Metal- lurgical Complex in Zimbabwe for client FLSmidth.

Weir Group strengthens its comminution capability The latest trend in the mining and miner- als industry is a move towards the design and construction of modular plants, says Gavin Dyer, Regional Managing Director, Weir Minerals Middle East and Africa. In support of a strengthened comminution offering, The Weir Group has acquired Trio Engineered Products of the US. This further improvesWeir Group’s position to capitalise on the modular plant trend and to increase its market presence in the sand and aggre- gate sector.

Trio’s range of products is currently dis- tributed in South Africa by Pilot Crushtec International, a relationship that will remain intact after the acquisition. Trio designs and manufactures a range of crushers, screens, feeders, washers and materials handling solutions for the aggregate and minerals sector. The agreement to acquire Trio will lever- age significant opportunities for both Weir

50  MODERN MINING  March 2015