Conveying, Storage and

Handling of Bulk Solids

Introduction and Course Outline

2
Introduction

• Course Facilitators

• The University of Newcastle

• TUNRA Bulk Solids Handling Research Associates

• Course Outline

CBSPT University of Newcastle 1

 3
Course Facilitators

Bill McBride
William.McBride@newcastle.edu.au

Craig Wheeler
Craig.Wheeler@newcastle.edu.au

Australia is a Dry Country 4

This data is before the start

of the last drought.

Death of the Murray Darling Basin?…

CBSPT University of Newcastle 2

 5

Dryness
sometimes leads
t a littl
to little dust.
d t

…. of droughts and
flooding rains……
Banjo Paterson

Australia is a Dry Country, but…. 6

Newcastle occasionally has a bit of rain. The odd thing washes up on our
beaches …

CBSPT University of Newcastle 3

 When it rains it is often in the wrong spots! 7

Newcastle, Australia 8

• Australia’s 6th most populated city

• 2h
hours northth off S
Sydney
d
• Capital of the Hunter Region

CBSPT University of Newcastle 4

 Newcastle, Australia 9

Newcastle, Australia 10

Two Centuries of Coal

Loading at Newcastle

CBSPT University of Newcastle 5

 Newcastle, Australia 11

Newcastle has a long history of Coal exports

1797 Newcastle ‘Discovered’

Discovered
1799 Vessel "The Hunter" carries first export coal to Bengal via Sydney.
1913 Record 5.2 million tonnes of coal shipped from Newcastle. This volume of tonnage was not
achieved again until the 1960's

Currently >100Mt pa

Australian Mining 12

The Australian minerals sector is in the top five producers of most of the
world’s key minerals commodities including:

•the world’s leading producer of bauxite and alumina, ilmenite, rutile and
zircon, synthetic rutile and tantalum;

•the second largest producer of gold, iron ore, lead, uranium, diamonds (by
weight) and zinc;

•the third largest producer of silver and nickel;

•the
th fourth
f th largest
l t producer
d off black
bl k coall and
d manganese;

•and the fifth largest producer of aluminium, copper and lignite.

CBSPT University of Newcastle 6

 The University of Newcastle, Australia 13

• Established in 1965
• Innovative and comprehensive
approach to teaching and
learning
• Research intensive
• Campuses at Newcastle, Central
Coast, Port Macquarie and
Singapore
• Over 28,000 students

Newcastle Innovation 14

Newcastle Innovation Organisation and Resources

The University of Newcastle

Faculties and Schools Service Divisions and Units Controlled Entities

Newcastle Innovation Ltd

Board of Directors

CEO

Divisions Technology Administration Services

Transfer

Start-up Companies
& Listed Investments*
TUNRA Bulk Solids Probiotics Accounting
Hunter Occupational Health Viraltyics* Invoicing
TUNRA Clean Coal NUSEP* Employment
TUNRA Fine Particles Keystone
ANZ Breast Cancer Trial Group Innova Soil Technologies
Newstat

CBSPT University of Newcastle 7

 TUNRA Bulk Solids - Brief History 15

1975 Commencement of Research and Development work in Bulk

Solids Handling in association with TUNRA Ltd.
Formation of TUNRA Bulk Solids Handling Research
Associates as a Division of TUNRA
TUNRA.

1995 Key Centre for Teaching and Research established under the
Australian Research Council’s Research Centre’s Program
Funding period July 1995 - June 2001.

1999 Establishment of Chair of Bulk Solids Handling.

Staff: Supported by Centre and TBS Funding 20

Academic Staff linked to Centre 5
Post Graduate Students 15
Post Doctoral Fellows 4
Uniss Scholars 2

TUNRA Bulk Solids - Structure 16

TUNRA Bulk Solids Handling Research Associates

Research and Consulting Activities

Storage, Flow Instrumentation, Belt Conveying Industrial Fluid

and Handling Control Systems and and Mechanical Mechanics
Stress Analysis Handling

Belt Conveying

7 PhD Students
4 ARC Grants (>$2.5M)

CBSPT University of Newcastle 8

 TUNRA Bulk Solids - Facilities 17

Bulk Solids Flow Properties Test Laboratory 18

CBSPT University of Newcastle 9

 Flow Property Measurement 19

Pneumatic Conveying Test Facilities 20

CBSPT University of Newcastle 10

 Belt Conveying Test Facilities 21

Projects 22

Flow Property Testing of Iron Ore. Transmission Loss in Panels.

Four Tensile Tests on Belt Samples Supplied. Flow Property Testi ng of Cement. SG Testing
of Modified NHPH Coal Wagon Draft Gear Pocket. Tensile Testing f Conveyor
o Belt Test Pieces. Robe River Pannawonica Dump Hopper Model Testing.
Fine Ore Feed Stockpile Investigation. SG Testing of NHPH Coal agonW DG Pocket & Doors. Conveyor Surcharge Angle Measurements. lowFProperties of
Magnetite. Ash Flow Properties. SG Testing of NHPH Rail Wagon St ainless Section. Batau Hijau Project. Flow Properties of Activated Alumina. Flow
Properties of Lead & Zinc Concentrates. Research on Stockpile Loads. Screw Feeder Review. Review ofKruppReclaimer. Fluor Bin Modifications. Wall
Friction of Ilmenite. Train Loading Investigation at Newman. Flo
w Properties of Henderson Ore. Dustiness of Mesa J Iron Ore. Flo w Properties of Zinc
Concentrate. Fatigue Testing on Thai Bogie Sandbox. Lime Bin Scr ew Conveyor Analysis. Sandbox Mounting Bracket Strain Gauge Test . Belt Tension
Measurements. Properties of Nickel Concentrates. No.1 Primary usher
Cr Pocket Modifications. Chute Inspection. Review of Blue Cir cle Cement Hopper.

Approx. 150 Projects

Review of Yandi Dump Hopper Feeder. Flow Properties ofTalleringPeak Iron Ore. Handleabilityof Export Coals. Certification of Pool Enclosure. Flow
Properties of Nickel Ore. Strap Hanger Fatigue Testing. Comments
and Feeder for Huntly Project. Consulting Regarding Fly Ash Hand
Flow in Goliath Cement Rail Load Silos. Strain Gauge Testing of
on Strain Transducer Weighing Systems. Site Visit RE: Blocked
ling. Consulting Regarding Weipa Dump Hopper. Research and Devel
NHPH Coal Wagon Draft Gear Pocket. Panel Sound Transmission Test
Design. Flow Property Testing of Iron Ore. Transmission LossPanels.
in Four Tensile Tests on Belt Samples Supplied. Flow Proper
hute
C Problem. Hopper
opment. Cement
s. Screw Feeder
ty Testing of Cement. SG
Testing of Modified NHPH Coal Wagon Draft Gear Pocket. Tensileesting T of Conveyor Belt Test Pieces. Robe River Pannawonica Dump Hopper Model

Per Year
Testing. Fine Ore Feed Stockpile Investigation. SG Testing of NH
PH Coal Wagon DG Pocket & Doors. Conveyor Surcharge Angle Measur

Modifications. Wall Friction of Ilmenite. Train Loading Investig

ation at Newman. Flow Properties of Henderson Ore. Dustiness of
Properties of Zinc Concentrate. Fatigue Testing on Thai Bogiendbox.
Sa Lime Bin Screw Conveyor Analysis. Sandbox Mounting Bracke
ements. Flow
Properties of Magnetite. Ash Flow Properties. SG Testing of NHPH Rail Wagon Stainless Section. Batau Hijau Project. Flow Properties of Activated
Alumina. Flow Properties of Lead & Zinc Concentrates. Research on Stockpile Loads. Screw Feeder Review. Review of Krupp Reclaimer. Fluor Bin
Mesa J Iron Ore. Flow
t Strain Gauge Test.
Belt Tension Measurements. Properties of Nickel Concentrates. No .1 Primary Crusher Pocket Modifications. Chute Inspection. Revie w of Blue Circle
Cement Hopper. Review ofYandiDump Hopper Feeder. Flow Properties ofTalleringPeak Iron Ore. Handleabilityof Export Coals. Certification of Pool
Enclosure. Flow Properties of Nickel Ore. Strap Hanger Fatigue esting.
T Comments on Strain Transducer Weighing Systems. Site itVis RE: Blocked Chute
Problem. Hopper and Feeder for Huntly Project. Consulting Regard ing Fly Ash Handling. Consulting Regarding Weipa Dump Hopper. Re search and
Development. Cement Flow in Goliath Cement Rail Load Silos. Stra in Gauge Testing of NHPH Coal Wagon Draft Gear Pocket. Panel Sou nd Transmission
Tests. Screw Feeder Design.

CBSPT University of Newcastle 11

 Australia 23

Adelaide, Albury Wodonga, Argyle, Bowen Basin, Boddington, Brisbane, Bunbury, Dampier,
Devonport, Canarvon, Cape Lambert, Century, Cobar, Geraldton, Gladstone, Groote Eylandt,
Hobart, Hunter Valley, Kalgoorlie, Karratha, Katherine, Kwinana, Launceston, Leonora

Leigh Creek, Mackay, Marandoo, Melbourne, Mt Channar, Mt Gambier, Mt Isa, Mt Keith, Mt

Newman, Newcastle, Olympic Dam, Orange, Pannawonica, Paraburdoo, Perth, Pinjarra, Pt
Kembla, Portland, Port Hedland, Rockhampton, Sydney, Tom Price, Townsville, Wagerup,
Willowdale, Wollongong, Yandicoogina

BHP Mt Newman - Iron Ore Weipa - Bauxite 24

Bulk Solids Handling and Processing

ALCOA Pinjarra - Alumina Hunter Valley - Coal

CBSPT University of Newcastle 12

 Internationally 25

Argentina, Australia, Batu Haijau, Brazil, Bolivia, Bougainville, Canada, Chile, China, Czech Republic,
Denmark, England, France, Finland, Germany, Ghana, India, Indonesia

Ireland, Irian Jaya, Japan, Laos, Netherlands, New Caledonia, New Guinea, New Zealand, Norway, Peru,
Philippines, Singapore, South Africa, Saudi Arabia, Senegal, Thailand, Turkey, Vietnam, United Arab
Emirates, United States

26

Bulk Solids
from powders to particles
to rocks to…..

CBSPT University of Newcastle 13

 ….. “bundies”!! 27

Relevant Industries 28

• Mining and Minerals

• P
Power G
Generation
ti
• Chemicals
• Pharmaceuticals
• Agriculture
• Food
• Manufacturing

CBSPT University of Newcastle 14

 Research Areas 29

• Flow Property Determination

• H
Hopper, Sil
Silo and
d St
Stockpile
k il DDesign
i
• Feeders and Discharge Devices
• Mechanical Conveying
• Belt Conveying
• Pipeline Transport (Pneumatic/Hydraulic)
• Instrumentation

Course Outline 30

Day Time Topic Presenter

8:30 – 9:00 Registration
9:00 – 10:30  Introduction and Course BMc &
Overview CW
 Open and Closed Belt
Conveyors
10:30 – 11:00 Morning Tea
11:00 – 12:30  Open and Closed Belt CW
Conveyors (cont.)
1
 Overview of Static Design
Procedures
12:30 – 13:30 Lunch
13:30 – 15:00  Overview of Static Design CW
Procedures (cont.)
15:00 – 15:30 Afternoon Tea
5:30 – 17:00
15:30 7:00  Staticc Design
S es g Examplepe1 CW
 Tutorial 1 - Static Design

CBSPT University of Newcastle 15

 Course Outline 31

9:00 – 10:30  Belt Transitions and Vertical CW

Curves
 Static Design Example 2
10:30 – 11:00 Morning Tea
11:00 – 12:30  Tutorial 2 - Multigrade CW
Analysis
2
12:30 – 13:30 Lunch
13:30 – 15:00  Tutorial 2 - Multigrade CW
Analysis (cont.)
15:00 – 15:30 Afternoon Tea
15:30 – 17:00  Stopping and Starting GS
Characteristics

9:00 – 10:30  Main Resistances, Design CW

Optimisation and Dynamics
10:30 – 11:00 Morning Tea
11:00 – 12:30  Bulk Materials Characterisation BMc
3 12:30
:30 – 13:30
3:30 Lunch
u c
13:30 – 15:00  Bulk Materials Characterisation BMc
(cont.)
15:00 – 15:30 Afternoon Tea
15:30 – 17:00  Tutorial 3 - Data Conversion BMc

Course Outline 32

9:00 – 10:30  Bin Design BMc

10:30 – 11:00 Morning Tea
11:00 – 12:30  Tutorial 4 - Bin Design BMc
12:30 – 13:30 Lunch
4
13:30 – 15:00  Feeder Design including BMc
Flowrate
15:00 – 15:30 Afternoon Tea
15:30 – 17:00  Tutorial 5 - Feeder Design BMc

9:00 – 10:30  Tutorial 5 - Feeder Design BMc

(cont.)
10:30 – 11:00 Morning Tea
11:00 – 12:30  Elevation of Bulk Solids BMc
12:30 – 13:30 Lunch
5
13:30 – 14:30  Transfer Chute Design – CW
Continuum Approach
15:00 – 15:30 Afternoon Tea
15:30 – 17:00  Computational Methods CW &
(DEM and CFD) BMc

9:00 – 10:30  Review Questions for CW &

6 Assignment and Exam BMc
10:30 – 11:00 Morning Tea
11:00 – 12:30  Review Questions for CW &
Assignment and Exam BMc

CBSPT University of Newcastle 16