BB Design Report

Functional Design Report
Sishen Iron Ore B&B Plant

BSFSA-518
Bulk Solids Flow SA cc

No. 4 Timbavati Place PO Box 10119 Tel : 011-979-4770
Cnr. 7th & Witstinkhout Ave Aston Manor Fax : 086-726-1299
Glen Marais Extensions 1630 Cell : 082-601-6455
Kempton Park Republic of South Africa E-mail : bsfsa@mweb.co.za
REPORT BSFSA-518
SISHEN IRON ORE, BEDDING & BLENDING PLANT, FUNCTIONAL DESIGN
By: Wouter A H Deijs Date : 11 October 2011
1.0 INTRODUCTION
Bulk Solids Flow SA [BSFSA] was approached by Anglo American Sishen Iron Ore
Company for the functional re-design of 7 bi-directional transfer chutes located in the
bedding and blending plant.
2.0 TESTS
No bulk solids flow tests were carried out for this project and therefore, the entire
functional design is based on data bank information derived from test work carried out for
the ship loading facility at the Saldanha harbour. A copy of the data bank information is
attached to this report.
3.0 FUNCTIONAL DESIGN
3.1 HEAD CHUTE CONVEYOR F886 G4000

[Sketch BSFSA-518-SK-01]
This sketch shows the general arrangement of the F886 G4000 conveyor head
chute with the new diverter plate.
Material: Maximum particle size is -31.5 mm

-4mm material fraction is High
Design bulk density is 2.50 T/m3
Solids density is 3.50 T/m3
F886 G4000: Capacity is 4000 TPH

Belt speed is 4.50 m/sec
Belt width is 1200 mm
Head pulley diameter is 1150 mm
Belt inclination angle is 15 degrees

Throughing angle is 35 degrees

1
Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Pressure 2.1 kPa Friction angle 50 deg.
Liner: Pressure 0.0 kPa Friction angle 35 deg.

Liners : All transfer chute sliding surfaces shall be lined with ultra smooth
Rio Carb liners, Linox SF tiles, or any other liners with identical or
better friction characteristics. The chute side plates in contact with
sliding material shall be lined ultra smooth Rio Carb liners, smooth
ceramic liners, or any other liners with identical or better friction
characteristics. All indicated dimensions to be inside liners.
The velocities, impact pressures and required areas are as follows :
Point A Material velocity before impact is 4.50 m/sec.

Material stream pressure is 4.77 kPa.
Material velocity after impact is 1.74 m/sec.
Required material section is 0.2555 m2.
Point B Material velocity is 1.15 m/sec.
Point C Material velocity is 1.22 m/sec.
Point D Material velocity is 1.49 m/sec.
Point E Material velocity is 1.81 m/sec.
Point F Material velocity is 2.12 m/sec.
Point G Material velocity is 2.82 m/sec.
Point H Material velocity is 5.20 m/sec.
3.2 SHUTTLE CAR in TRANSFER F886 G4000 to F886 G5000

This sketch shows the general arrangement of the shuttle car in the transfer from
conveyor F886 G4000 to conveyor F886 G5000.
2






3

Material: Maximum particle size is -31.5mm






4

3.4 TRANSFER CHUTE F886 G4000 to F886 G5000

This sketch shows the general arrangement of the transfer chute from the shuttle
car situated below the conveyor F886 G4000, to conveyor F886 G5000.






5

The stream pressure on the receiving belt is 7.83 kPa. The material velocity in the
direction of the belt is 3.13 m/sec. The required material section where it directly
lands on the belt is 0.1420 m2.




6




7




Throughing angle is 35/45 degrees
Belt inclination angle is 1.33 degrees



better friction characteristics.
8
The chute side plates in contact with sliding material shall be lined
ultra smooth Rio Carb liners, smooth ceramic liners, or any other
liners with identical or better friction characteristics. All indicated
dimensions to be inside liners.





9






10






11






12
lands on the belt is 0.1394 m2






13




14


Throughing angle is 35/45grees



15







16







17






18




19






20






21

Point D Material velocity before impact is 4.75 m/sec.

Point I Material velocity is 2.88 m/sec.
Point J Material velocity is 3.00 m/sec.
Point K Material velocity is 3.45 m/sec.

This sketch shows the general arrangement of the transfer chute between the head
chute of conveyor F883 G4400 and conveyor F886 G5000.

22





23







24





25



26






27

aterial velocity after impact is 1.80 m/sec.





28




29





30







31





32




33






34






35




36




37
5.0 LIABILITY
Bulk Solids Flow SA cc undertakes to exercise all reasonable care, skill and diligence in
the performance of its services.
Bulk Solids Flow SA cc cannot however, be liable to the client or any third party directly
or indirectly, for errors or omissions committed in good faith in whole or in part, to
inaccuracies or assumptions contained in any material, information or data furnished by
the client or other third party.
We do not accept liability for any consequential damages and limit our liability to the
repetition and correction of errors in our scope and this shall not exceed 50 percent of the
amount of Bulk Solids Flow SA’s total compensation for the project in question.
6.0 GENERAL
In order to eliminate any problems related to the flow of material in any area, minimum
requirements for constant gravity flow conditions as outlined in this report should be
followed.
Please note that a minimum knowledge of bulk solids flow technology is required to
understand all decisions and design approaches which are required to design all plant
areas successfully.
In the event that there are any queries, please do not hesitate to contact me.
Bulk Solids Flow SA cc
_______________________
Wouter A H Deijs Pr Eng.
Bulk Solids Flow Consultant
38
Please Note !!!
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Data Bank Information
MATERIAL : FINE IRON ORE [30% -080MM, 80% +0.80MM – 4MM]
CLIENT : TRANSNET, SALDANHA
MC (%) 4 4 4.75 4.75 5.5 5.5
ST (hrs) 0 48 0 48 0 48
BC (m) 0.060 0.260 0.200 0.300 0.280 0.500
BP (m) 0.030 0.130 0.100 0.150 0.140 0.250
Phi (deg) 48 48 48 48 50 50
Delta (deg) 50 50 49 49 51 51
Liner VRN-500 VRN-500 VRN-500 VRN-500 VRN-500 VRN-500
Theta-c/p (deg) 4/14 6/16 2/12 4/14 1/11 4/14
Liner CERAMIC CERAMIC CERAMIC CERAMIC CERAMIC CERAMIC
Theta-c/p (deg) 4/14 6/16 2/12 4/14 1/11 4/14
Liner LINOX-SF LINOX-SF LINOX-SF LINOX-SF LINOX-SF LINOX-SF
Theta-c/p (deg) 11/21 12/22 10/20 11/21 13/23 14/24
BF (m) 0.050 0.160 0.120 0.190 0.170 0.300

EH (m) 5 5 5 5 5 5
DF (m) 2.040 3.090 2.460 3.430 2.850 3.910
EH (m) 10 10 10 10 10 10
DF (m) 3.670 5.420 4.330 6.000 4.950 6.720
EH (m) 15 15 15 15 15 15
DF (m) 4.960 7.260 5.800 8.030 6.600 8.930
NOMENCLATURE :
MC = Moisture content
ST = Storage time
BC = Minimum diameter of a circular outlet of a mass flow bin
BP = Minimum width of a slot opening of a mass flow bin
Phi = Angle of internal friction
Delta = Effective angle of internal friction
Theta-c = Maximum hopper angle, from the vertical, for mass flow conical hoppers and end walls
of transition hoppers
Theta-p = Maximum hopper angle, from the vertical, for mass flow side walls of a transition hopper
BF = Minimum width of a slot opening of a funnel flow bin
EH = Effective head of consolidation
DF = Critical piping dimension for funnel flow
MATERIAL : FINE IRON ORE [MC = 4%]
LINER PHI-1 PHI-2 PHI-3 PHI-4 GAMMA-1 GAMMA-2
3CR12 34 36 38 40 31.4 26.1
VRN-500 34 36 38 40
Arcoplate 29 31 32 34
Arcoplate HB 31 33 34 36
Ceramic Tiles 33 35 37 39
Linox-SF 30 32 34 36
MATERIAL : FINE IRON ORE [MC = 4.75%]

3CR12 34 36 37 39 30.6 25.8
VRN-500 34 36 37 39
Linox-SF 27 28 29 30
MATERIAL : FINE IRON ORE [MC = 5.5%]

3CR12 36 39 41 43 29.8 26.2
VRN-500 34 37 39 41
Linox-SF 30 33 35 38
NOTES : Gamma-1 = Maximum measured density [kN/m^3]

Gamma-2 = Minimum measured density [kN/m^3]
Phi-1 = Friction angle after impact pressure of 0.00 kPa [deg.]
MATERIAL : IRON ORE FINAL PRODUCT
CLIENT : SENET, SAPO SALDANHA PHASE 1B PROJECT
MC (%) 4 4 4.75 4.75 5.5 5.5
ST (hrs) 0 48 0 48 0 48
BC (m) 0.060 0.220 0.180 0.280 0.300 0.520
BP (m) 0.030 0.110 0.090 0.140 0.150 0.260
Phi (deg) 44 44 45 45 43 43
Delta (deg) 48 48 49 49 48 48
Liner VRN-500 VRN-500 VRN-500 VRN-500 VRN-500 VRN-500
Theta-c/p (deg) 6/16 7/17 7/17 8/18 10/20 11/21
Liner CERAMIC CERAMIC CERAMIC CERAMIC CERAMIC CERAMIC
Theta-c/p (deg) 6/16 7/17 7/17 8/18 10/20 11/21
Liner LINOX-SF LINOX-SF LINOX-SF LINOX-SF LINOX-SF LINOX-SF
Theta-c/p (deg) 13/23 13/23 13/23 14/24 19/29 20/30
BF (m) 0.050 0.150 0.130 0.210 0.190 0.340

EH (m) 5 5 5 5 5 5
DF (m) 1.750 2.770 2.440 3.390 2.550 4.200
EH (m) 10 10 10 10 10 10
DF (m) 3.150 4.870 4.300 5.960 4.410 7.250
EH (m) 15 15 15 15 15 15
DF (m) 4.250 6.520 5.770 7.990 5.880 9.650
NOMENCLATURE :
MC = Moisture content
ST = Storage time
BC = Minimum diameter of a circular outlet of a mass flow bin
BP = Minimum width of a slot opening of a mass flow bin
Phi = Angle of internal friction
Delta = Effective angle of internal friction
Theta-c = Maximum hopper angle, from the vertical, for mass flow conical hoppers and end walls
of transition hoppers
Theta-p = Maximum hopper angle, from the vertical, for mass flow side walls of a transition hopper
BF = Minimum width of a slot opening of a funnel flow bin
EH = Effective head of consolidation
DF = Critical piping dimension for funnel flow
MATERIAL : IRON ORE FINAL PRODUCT [MC = 4%]
3CR12 32 36 38 39 27.9 24.7
VRN-500 32 36 37 38
Linox-SF 25 28 29 31
MATERIAL : IRON ORE FINAL PRODUCT [MC = 4.75%]

3CR12 33 36 37 39 31.0 26.6
VRN-500 33 36 38 40
Linox-SF 27 30 32 34
MATERIAL : IRON ORE FINAL PRODUCT [MC = 5.5%]

3CR12 35 38 40 42 28.5 26.9
VRN-500 33 36 38 40
Linox-SF 29 32 34 37
NOTES : Gamma-1 = Maximum measured density [kN/m^3]

Gamma-2 = Minimum measured density [kN/m^3]

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Functional Design Report

Sishen Iron Ore B&B Plant

Bulk Solids Flow SA cc

SISHEN IRON ORE, BEDDING & BLENDING PLANT, FUNCTIONAL DESIGN

By: Wouter A H Deijs Date : 11 October 2011

3.0 FUNCTIONAL DESIGN

3.1 HEAD CHUTE CONVEYOR F886 G4000

Material: Maximum particle size is -31.5 mm

F886 G4000: Capacity is 4000 TPH

F883 G5500: Capacity is 2000 TPH

F886 G5000: Capacity is 4000 TPH

Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Liner: Pressure 0.0 kPa Friction angle 35 deg.

The velocities, impact pressures and required areas are as follows :

Point A Material velocity before impact is 4.50 m/sec.

3.2 SHUTTLE CAR in TRANSFER F886 G4000 to F886 G5000

F886 G4000: Capacity is 4000 TPH

F883 G5500: Capacity is 2000 TPH

F886 G5000: Capacity is 4000 TPH

Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Liner: Pressure 0.0 kPa Friction angle 35 deg.

The velocities, impact pressures and required areas are as follows :

Point A Material velocity before impact is 8.23 m/sec.

3.3 SHUTTLE CAR in TRANSFER F886 G4000 to F883 G5500

Material: Maximum particle size is -31.5mm

F886 G4000: Capacity is 4000 TPH

F883 G5500: Capacity is 2000 TPH

F886 G5000: Capacity is 4000 TPH

Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Liner: Pressure 0.0 kPa Friction angle 35 deg.

Point A Material velocity before impact is 8.23 m/sec.

3.4 TRANSFER CHUTE F886 G4000 to F886 G5000

Material: Maximum particle size is -31.5 mm

F886 G4000: Capacity is 4000 TPH

F883 G5500: Capacity is 2000 TPH

F886 G5000: Capacity is 4000 TPH

Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Liner: Pressure 0.0 kPa Friction angle 35 deg.

The velocities, impact pressures and required areas are as follows :

Point A Material velocity before impact is 2.86 m/sec.

3.5 TRANSFER CHUTE F886 G4000 to F883 G5500

Material: Maximum particle size is -31.5 mm

F886 G4000: Capacity is 4000 TPH

F883 G5500: Capacity is 2000 TPH

F886 G5000: Capacity is 4000 TPH

Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Liner: Pressure 0.0 kPa Friction angle 35 deg.

The velocities, impact pressures and required areas are as follows :

Point A Material velocity before impact is 2.86 m/sec.

3.6 HEAD CHUTE CONVEYOR F886 G5000

Material: Maximum particle size is -31.5 mm

F886 G5000: Capacity is 4000 TPH

F883 G8500: Capacity is 5280 TPH

F886 G6000: Capacity is 4000 TPH

Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Liner: Pressure 0.0 kPa Friction angle 35 deg.

The velocities, impact pressures and required areas are as follows :

Point A Material velocity before impact is 5.00 m/sec.

3.7 SHUTTLE CAR in TRANSFER F886 G5000 to F886 G6000

Material: Maximum particle size is -31.5 mm

F886 G5000: Capacity is 4000 TPH

F883 G8500: Capacity is 5280 TPH

Friction Angles : Deadbox: Pressure 0.0 kPa Friction angle 46 deg.

Liner: Pressure 0.0 kPa Friction angle 35 deg.