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PRODUCT News
50
MODERN MINING
March 2015
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,
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
Johnson completes heavy lift for mill change-out
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.
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
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
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
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