Transnet, the largest port operator in South Africa, has made a fresh investment to boost productivity at its flagship bulk handling terminal by switching to innovative CleanScrape belt cleaners from Martin Engineering.
Transnet’s Richards Bay bulk minerals import-export line in KwaZulu-Natal on South Africa’s southeast coast handles 20-million tonnes of commodities every year – exporting magnetite, ferrochrome, bauxite and woodchips to destinations worldwide, and importing materials such as sulphur, coking coal and alumina.
With a network of around 30 conveyors moving materials in and out of the port, 24 hours a day, 7 days a week, an efficient operation is essential. Transfer times must be kept to a minimum so shipping remains on schedule – that means maximising speed and volume without running the risk of excess spillages, blockages and buildups which, if left unchecked, can lead to conveyor damage or total breakdown. The plant also has some of the highest conveyor discharge points for loading the cargo holds of massive dry bulk carriers, making maintenance access challenging if things do go wrong.
When the stakes are this high, only CleanScrape conveyor belt cleaners were capable of achieving the desired result, according to Transnet. Featuring unique patented technology, the system uses a matrix of tungsten carbide wear tips lightly tensioned across the discharge pulley in a three-dimensional helix shape.
Despite the low contact pressure between the cleaner and the belt, this arrangement is proven to remove as much as 95% of potential carryback material, not only delivering superior cleaning performance, but also lasting up to four times the service life of conventional blades – and in many cases much longer. Only occasional tension adjustment is needed after installation of CleanScrape, with minimal ongoing maintenance and a significant whole-life cost reduction.
Back in 2015, Transnet led the way as the first operator in South Africa to trial CleanScrape, keen to see if it could improve performance on the plant’s most challenging conveyor belts at Richards Bay. Conveyors of 1 350 mm and 1 500 mm width were experiencing excessive spillage in the discharge zones with fines adhering to belts and causing carryback to spill along the belt path and accumulate underneath the framework and out into walkways.
Following installation of CleanScrape by Martin’s experienced technicians, it was not long before the innovative design began proving its worth. Further installations followed on eight more conveyors, especially those at transfer points where access is difficult and space is limited, with no room for a conventional belt scraper and mainframe.
Cyril Dludla, Transnet’s technical supervisor, says: “There has been a huge improvement in terms of spillage since the new scrapers were installed, and as a result we will be installing more CleanScrape belt scrapers to improve on spillage across the entire plant in Richards Bay. We are grateful to the team from Martin Engineering who installed the system at the site and continue to monitor performance.”
Now, as part of a major plant overhaul, Transnet has followed through on its commitment with the installation of CleanScrape cleaners on a further 12 belts, meaning that all the plant’s key conveyors are fitted exclusively with CleanScrape primary cleaners.
Complementing the primary cleaners are Martin’s SQC2 (SC16 in Africa) secondary belt cleaners, which feature a unique installation and removal guide/cradle for safe and easy servicing. The SQC2’s are fitted with blades that can withstand the most abrasive bulk cargoes and, combined with CleanScrape primaries, keep the belts running with virtually no spillage.
Janco Shulze, Martin Engineering’s sales representative in KwaZulu-Natal, says: “We are grateful to the team at Transnet who put their faith in Martin Engineering and we are delighted to be working with them to achieve a clean and efficient operation. Thanks to the reliability and performance of CleanScrape, Transnet’s maintenance teams can be deployed to other critical areas in the plant, ensuring hassle-free continuous running of essential belts.”
Lindokuhle Qwabe, technical manager (Export), says the earlier CleanScrape installations not only outperformed conventional cleaners but also surpassed everyone’s expectations: “Some of the CleanScrape belt cleaners have been in place for over four years – they are adjusted or re-tensioned now and again, significantly reduced wear part costs and allowing us to keep production moving smoothly without frequent maintenance interruptions.”
Shulze adds: “We are confident that the latest CleanScrape installations will be a game-changer for Transnet’s total productivity, and the arrangement we have in place allows our service team to operate a robust inspection and maintenance regime – not that our belt cleaners need much attention! Martin Engineering is all about solving problems and, thanks to CleanScrape, we are preventing problems from arising in the first place.”
Designed with safety and efficiency in mind, Martin Engineering equipment is engineered to offer agnostic, retrofitted and customized solutions to accommodate any belt speed and material characteristics. The company installs and services conveyor equipment at numerous ports around the world and understands the everyday challenges that busy bulk handling operations at ports experience.
Improved performance, less spillage, longer equipment life, and easier maintenance all help reduce the labour needed for cleanup. Reducing workers’ exposure and access to conveyors means safer operations and allows Transnet to concentrate on other parts of the terminal, improving efficiency and lowering the cost of operation.
