HANDLING • TRANSPORT • STORAGE • DISTRIBUTION • PROCESSING MARCH/APRIL 2012

CONTENTSNEWS

Exxaro moves into Congo 2A step forward for Guinea? 3New Oz ports closer 4Wagons roll for CBH 5

ITALY REVIEW

A grain of hope for Pagnam 6

CHINA REVIEW

New trade platform 7Energy transformation 8

SOUTHERN AFRICA REVIEW

Broadening the appeal 9

CARGO HANDLING

Bulking up 11Roll out the rubber carpet 14Driving front end loaders 15M&A increase optimism 17

COMMODITY FOCUS

Coal 18

Exxaro Resources has re-vealed that the shareholders inRichards Bay Coal Terminal(RBCT) are considering fur-ther expansion of South Afri-ca’s main coal terminal.

The Phase V expansion ofthe terminal boosted annualhandling capacity to 91 mt butthe lack of rail capacity on therailway from the Mpumalangamines to RBCT has preventedexports from exceeding 65mtpa. However, rail operatorTransnet Freight Rail (TFR)has announced major newinfrastructural investment andperformance on the railwayhas improved in recentmonths. The terminal exported

6.09 mt in February, whichwould give an annualised rateof exports of 73 mt.

Exxaro’s executive generalmanager of coal, MxolisiMgojo, commented: “Thepressure is back on us as RBCTshareholders to say, beyond 91million tonnes what can we do?We need to get to at least 100million tonnes.”

Unlike on the Phase V ex-pansion project, the RBCTshareholders – which includethe country’s biggest coalmining companies – willprobably not invest in newcapacity until TFR has begunthe development of a plannednew railway through

Swaziland and the purchase ofnew rolling stock.

It remains to be seenwhether new rail capacity willbe developed from the emerg-ing second centre of SouthAfrican coal production, theWaterberg Basin, in the northof the country. The Basin hasbeen largely untapped to datebecause of the lack of conven-ient rail access but decliningproduction in the Mpum-alanga mines has persuadedinvestors to look to Waterberg.The big question, however, iswhether the new mines willexport coal via RBCT orMatola Coal Terminal in Mo-zambique.

Phase VI for RBCT?A new initiative aimed at pre-venting non-compliant andpotentially unsafe machinery,including handling equip-ment, entering the Europeanmarket, was launched recentlyin Brussels at a conferencehosted by the European Com-mission.

Chairing a discussion on'Market surveillance to protectinnovation,' John Meale, man-aging director of mobile yardramp and dock loader special-ist Thorworld Industries,stated: “We are all familiarwith the concept of illegalconsumer goods that do notcomply with regulations, andwe are aware of the hard workdone by the authorities to pre-vent such products from be-ing sold.

“But why, if there is suchrobust market surveillance forconsumer goods, is there nota corresponding level of pro-tection for commercial equip-ment and machinery?"

“Too often, market surveil-lance for materials handlingequipment is reactive ratherthan preventative, whichmeans that it is then too latefor reputable suppliers whohave been undercut by unscru-pulous manufacturers, or forthe workers who face injuryor even death," Meale said.

There is also a major prob-lem of job losses within theEuropean community as a re-

European marketsurveillance initiative

Demag Cranes has establishedan International Dry BulkCompetence Centre in theUK, further expanding its ac-tivities in this sector.

The centre is located inBanbury and offers customersa complete bulk-handlingproduct family, ranging frommobile harbour cranes, por-tal harbour cranes and float-ing cranes to hoppers, con-veyors, grabs and drivecomponents.

The centre also providescustomers with state-of-the-art software tailored to bulkhandling applications, expertconsultancy services and serv-ice packages provided byqualified professionals.

The International Dry BulkCompetence Centre is headedby Mark Reardon and serves

Demag Cranes centralises bulkmaterials handling activities

Demag's Dry Bulk Competence Centre serves bulk terminalslooking to expand or upgrade their facilities

bulk terminals seeking to ex-pand or upgrade their facili-ties or material flows.

“Many terminals are cur-rently sourcing equipmentfrom a disparate range of sup-pliers, configuring their ownsystems using different ele-ments”, explains Reardon.

“Under the name of ourleading brand, GottwaldPort Technology, togetherwith our software specialistsubsidiary, DBIS, and aproven network of partners,we are ideally placed to pro-vide optimum solutionsfrom a single source.”

The Competence Centredemonstrates a major commit-ment by Demag Cranes in thedevelopment of its long-termbulk handling strategy, posi-tioning Gottwald as a leading

brand in this rapidly expand-ing market.

“Dry bulk is the largestseaborne commodity, drivenby increasing demand forenergy and food, resultingfrom continuing growth inglobal population,” saysGiuseppe Di Lisa, seniorvice president, port &intermodal cranes.

“Our Dry Bulk Compe-tence Centre will help termi-nals to master the challengestriggered by this growth,quickly and sustainably.”

sult of non-conforming prod-ucts reaching the Europeanmarket place, which are pro-duced to much lower stand-ards outside of Europe andhence are much cheaper toproduce. If this situation is notaddressed then many additionaljobs will be lost in Europe.

Market Surveillance is apartnership between sevenmajor European trade organi-sations, representing the con-struction, machine tools,weighing, agricultural ma-chinery, plastics and rubbermachinery industries, as wellas Orgalime, the EuropeanEngineering Industries Asso-ciation, and FEM, the Euro-pean Materials Handling Fed-eration, whose membershipincludes crane and lift truckOEMs, and bulk conveyor andstockyard handling equipmentsuppliers.

The conference was at-tended also by customs offi-cials, EU commissioners andMEPs and staff from a numberof national standards organi-sations.

Concerns about “good cur-rency being driven out by thebad” have been growing.Trelleborg Marine Systems,for example, has been vocif-erous in its condemnation ofsub-standard fendering sys-tems being selected purely onprice grounds, compromisingefficiency and safety.

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BMI March/April 20122

News

Renold Couplings preventcostly plant breakdowns

When a large equipmentmanufacturer needed a long-term solution to protectagainst costly coupling failureon its excavators, it turned toRenold Hi-Tec Couplings ofHalifax, England.

According to Renold, theexcavator company had beenusing rubber-in-shear cou-plings which were failing after4000 hours of operation. Eachtime a coupling failed, the ex-cavator had to be stripped downand the coupling replaced. Thiswas proving costly as the ex-cavator runs 24 hours a day,seven days a week and any un-planned downtime means thatthe cost per tonnage of mate-rial excavated increases.

Features of the HTB-GS excavator coupling include severeshock load protection properties

The coupling is fitted be-tween the diesel engine andthe gearbox, which has threeoutputs which drive three hy-draulic pumps that in turndrive all the motions on theexcavator.

As these excavators areused on demanding applica-tions, good coupling life isvery important. Renold there-fore recommended the HTB-GS rubber-in-compressioncoupling.

“Its intrinsically fail safe,maintenance free and severeshock load protection proper-ties, coupled with its high tem-perature capability of 200-degC, made it the ideal choice,”said Renold.

China’s Qingdao Port Group(QPG) expects to start opera-tions at its 400,000t iron oreterminal at Dongjiakou portthis year.

But according to thegroup’s chairman ChangDechuan, the company has notbeen approached by Vale re-garding access for the Brazil-ian miner’s giant vessels.

The terminal, which has alength of 510m and annual ca-pacity of 1.6 mt, is specificallydesigned to handle 400,000 dwtore carriers. However, the gov-ernment’s unease with giantvessels has meant that its nomi-nal capacity approved by Chi-na’s National Development andReform Commission is only300,000 dwt.

QPG said it has invested3.8B yuan (US$602M) in the

Qingdao eyes 2012 startfor 400,000t ore terminal

terminal and another smallerone capable of handling200,000 dwt vessels atDongjiakou.

When completed, theDongjiakou terminal will havea capacity of 40 mtpa and willbe the first Chinese port withthe technical capacity to re-ceive Vale’s huge dry bulkships, known as Valemaxes.

Other major ports whichhave the potential to handleValemaxes include Dalian,which earlier said it had up-graded facilities at its 300,000tiron ore berth to meet “the re-quirements for large-sized ves-sels to dock as well as the needsfor transhipment.”

However, Chang said Valehad not approached the com-pany regarding access for its400,000 dwt iron ore carriers.

In January, China bannedits ports from receiving bigvessels that exceed their ap-proved capacity, effectivelybarring Vale from sending anymore Valemaxes to its biggestiron ore customer. The movecame after heavy lobbyingfrom Chinese shipowners wor-ried that Vale’s fleet of ultra-large carriers would bringfierce competition in already-weak markets.

QPG plans to invest 30Byuan (US$4.76B) inDongjiakou port between2011-2015 to tap growing de-mand for coal, oil and iron ore.It aims to increase its totalthroughput to 400 mt this yearfrom 370 mt in 2011, includ-ing a 130 mt capacity for ironore, marking a 30% increasefrom last year, Chang said.

Congestion at the Port ofSantos could be substantiallyrelieved within the next threeyears following the expan-sion of Terminal Marítimoda Ultrafértil (TUF), ownedby CVRD (Vale).

According to TUF’s man-aging director RicardoButeri, the environmentalimpact assessment shouldallow work to be concludedby the second half of 2014.The environmental licenceshould, if everything goesaccording to plan, be issuedin April, with the availablearea handed over in Septem-ber. Work on converting thiswill commence by the end ofthe year. The expansion willenlarge TUF from 185,000m2 to 800,000 m2.

Buteri stresses that one ofthe most important aspectsof the project will be the raillink, which will transportmainly sugar and ethanol.Road haulage will be limitedto the transport of importedfertiliser. The expectation isthat rail will be used for allexport agribulk. Road willcontinue to handle fertiliser,given the short distance[around 7 km] between theterminal and the factory fa-cilities at Pólo de Cubatão.

To avoid trucks cloggingthe roads as demand for fer-tiliser rises, a parking areawill be provided within theterminal itself, thus allowingflow of traffic on the mainPiaçaguera-Guarujá high-way to remain unimpeded.

TUF to relieveSantos bottlenecks

Fertiliser volume is forecastto more than double in themedium term, from 2.5 mtpato almost 6 mtpa.

Export consignmentswill use the existing rail linkbetween the port of Santosand the states of São Pauloand Minas Gerais. The ac-quisition of 148 new loco-motives and 2680 wagons ata cost of US$700M will bethe biggest outlay involvedin the project, with FerroviaCentro-Atlântica being therail service provider. To ac-commodate this increase inblock trains, a further10,600m of track will be laidwithin the terminal itself.

“The intention is to inte-grate everything from theproducer to the port,” com-mented Buteri.

The number of berths inthe terminal will increasefrom one to three, with oneof the two new installationsbeing given over wholly todry bulk, thereby relievingpressure on existing facili-ties at Santos, which Buterisays are unable to upgradetheir own installations.

CVRD will also under-take maintenance dredgingof the Piaçaguera Canal toreturn it to a depth of 12m,which is regarded as beingsufficient for the moment, al-though the terminal does notrule out deepening this to15m if traffic requires it. Thiswould be the same depth asin the navigation channelleading to the port of Santos.

Exxaro Resources has taken86% equity in Australian firmAfrican Iron, which holds twoiron ore concessions in Congo-Brazzaville. The South Africanfirm secured the stake afterbuying out the 20.5% shareheld by Equatorial Resources,which will continue to controlan adjacent concession.

African Iron aims to export5 mtpa from the Mayokoproject next year and predictsoutput of up to 40 mtpa in thelonger term.

Exxaro must now decidehow to fund construction of a20 km spur railway to the mine,the required rolling stock and anew iron ore terminal at PointeNoire. Congo-Brazzaville andneighbouring states are emerg-ing as a major new iron orefrontier but Central Africa’stransport infrastructure must beupgraded to cope with in-creased demand.

Exxaro movesinto Congo

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News

Russia increases grain export forecastRussia has increased its grain ex-port forecast for this marketingyear (1 July 2011 – 1 July 2012)from 25 mtpa to 28 mtpa. Thecountry’s agriculture ministry haschanged its export forecast in viewof the improved harvest expected,94 mtpa instead of the forecast of90-92 mtpa, said agriculture min-ister Yelena Skrynnik.

In late February this yearSkrynnik stated that Russia’s grainexports had reached 20 mt since 1July 2011. Speaking about future

plans for the country’s grain exports,she declared her country’s readinessto expand its annual export volumeto 40 mtpa by 2020.

However, the forecast of 28 mtpais seen as a drop in exports by someRussian media, who cite sources inthe agriculture ministry as saying thatthe grain export forecast for this mar-keting year was initially set at 30 mtpa.

According to these mediasources, the reality is such that grainreserves close to the seaports havebeen virtually exhausted. As a result,

grain cost around US$246/t atNovorossiysk, US$232/t atKrasnodar and US$203/t atStavropol in late February 2012. Atthe same time, it took more thanUS$100 (or roughly half its FOBprice) to export a tonne of Siberiangrain via Novorossiysk. The situationwas aggravated by the ongoingstrengthening of the rouble and weak-ening of Russia’s position in its tradi-tional markets, such as Egypt.

Private traders of the RussianGrain Union are said by its president

Arkadiy Zlochevsky to be deter-mined to export 1 mt of grain to theAsia-Pacific markets (APM) this sea-son and so keep within the boundsforecast by the Union at the very be-ginning of the marketing year.

Russia’s grain exports to APMin 2010 were interrupted from Au-gust for about ten months by theRussian government’s grain exportembargo.

According to Zlochevsky, Rus-sia could potentially be able to ex-port up to 5 mtpa of grain to APM,upon the due development of theFast East export corridor.

The delayed Guinean general elec-tion will now be held on 8 July, hope-fully heralding the introduction of acivilian government and the settle-ment of iron ore, bauxite and railprojects in the country.

International financial organisa-tions, donors and mining companieshave been reluctant to invest in thecountry because of the lack of a sta-ble government but the EuropeanUnion and other organisations haveindicated that they will resume fullco-operation with the country if freeand fair polls are held.

Guinea is already the world’s big-gest bauxite exporter and possessesvast, largely untapped iron ore re-serves. Even during the height ofpolitical uncertainty after the fall ofthe country’s long governing militaryjunta, Guinea’s bauxite exports man-aged to increase by 9% last year to17.59 mt. Alumina exports fromRUSAL’s Friguia refinery increasedby 3% to 631,000t but this was lessthan expected.

A spokesperson for the financeministry explained: “The reason forthe [slower growth] in the aluminasector is the many production out-ages at Friguia and also the declin-ing demand for this product on theinternational market.”

However, government threats towithdraw mining licences continueto unnerve investors. Speaking at theMining Indaba conference in CapeTown in February, the Guinean min-ister of mines Mohamed LamineFofana said that his country was notsecuring the benefit from its naturalresources that it deserved.

The government is also consider-ing reducing newly imposed taxes onmining production.

One step forwardfor Guinea?

The government of Mozambique hasblocked plans to use the River Zam-bezi for coal transport on environmen-tal grounds, in the short term at least.

Coal production in northwesternTete Province is expected to increasefrom virtually nothing to up to 100mtpa within a decade. The Sena rail-way from Tete to the port of Beirahas been upgraded but is unlikely toprovide sufficient transport capacityto carry coal from all of the plannedmining projects to the coast for ex-port. Other transport corridors willtherefore be required and Rio Tintohad carried out a feasibility study intousing barges on the River Zambezi.

However, the deputy environmentminister, Abdul Razak, announced inearly March: “For now, according tothe information passed on by Micoa[the ministry of the environment], itis not possible to use the river to ex-port coal. It is because of the ecosys-tem: more studies need to be done.”

A range of rare flora and fauna livein the river system, particularly in theZambezi Delta. In addition, the gov-ernment argues that dredging the riverwould exacerbate flooding problems.

Transport minister Paulo Zuculatold journalists: “We can assure eve-rybody that we will build enough railcapacity to carry their coal…By theend of this year we will reach 10million tonnes of capacity on theSena line; next year we will start re-habilitating Nacala and build twonew railways. Coal is a developmentproject for us, so we are a most in-terested party. ”

Maputo rejectsZambezi plan

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Tough application,ingenious solution Exactly

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ISSN 0955-3754ISSUE NO:135

Schade Lagertechnik is sched-uled to deliver a portal scraperfor chrome ore to JSC TNKKazchrome in 1Q 2012.

The system has a rail tracklength of 48m and conveyingcapacity of 500t/h and will beused in Aktobe near the Rus-sian border, in north-westKazakhstan.

Kazchrome is part of theENRC Group and is a majorferrochrome producer, operat-ing several large ferrochromeplants in Kazakhstan.

The new portal scraperspans the stockpiled ore andtravels back and forth longi-tudinally over the stockpile. Inthis instance, and owing to theabrasivity of the material,Schade is employing a scraperchain furnished with a wingroller, the bearing being ar-ranged directly on the shaft.The latter was especially de-veloped for highly abrasivebulk materials.

Schade Lagertechnikto supply portalscraper to Kazakhstan

The drag link conveyorchain will be used in particu-lar where chain lubrication isnot permitted. It is furnishedwith hardened bolts and bush-ings which keep the wear fac-tor at a low level.

Each link of the bushedchain is additionally equippedwith bearings and wing rollerswhich run in the chain guide.The rollers are furnished withbearings and special seals. Anautomatic chain tensioning de-vice also ensures a low main-tenance requirement.

The portal scraper trans-ports the bulk material awayin layers from the side slopeand guides it over a concreteramp onto a belt conveyorwhich is arranged longitudi-nally adjacent to the stockpile.Reclamation takes place auto-matically, with the cutting andgrading of the stockpile to beusually performed manuallyby the operators in Aktobe.

The high price of importediron ore and China’s sluggishsteel market will prompt do-mestic companies to investheavily in overseas miningoperations, according to asenior official with the ChinaIron and Steel Association.

“It is estimated that Chi-nese-invested overseassources will bring in 100 mtto 200 mt of iron ore annu-ally in the coming three tofive years,” said associationchairman Zhu Jimin.

He said an over-relianceon high-priced imports ofthe mineral is squeezingprofits at Chinese steel mills,piling further pressure on anindustry that’s already expe-riencing a decline in domes-tic demand.

In 2011, China imported686 mt of iron ore, equal to60% of the domestic steel in-dustry’s consumption during

Chinese steel makers eyeoverseas investments

the year. The majority of theimports came from Australia,Brazil and India.

China is the world’s larg-est steel maker and the biggestconsumer of iron ore, but Chi-nese companies currently ownless than 10% of the importedore, said Li Xinchuang,deputy secretary-general ofthe association.

The heavy dependence onoverseas supplies has madelife tough for China’s steelmakers, who saw the indus-try’s average profit margin re-duced to less than 3% in 2011.

Meanwhile, India, theworld’s third-largest supplierof iron ore, raised its exportduty on the mineral at the endof 2011, a move that was cop-ied by Vietnam in February.

Australia, the largest over-seas provider of iron ore toChina, shipping 297 mt in2011, will also introduce its

Minerals Resources RentTax on 1 July. That’s likelyto drive the price of iron oreimports higher in the comingyears as producers pass on theextra costs to purchasers.

The high prices set byoverseas suppliers will pushmore Chinese companies toinvest overseas in the hopeof relieving the pressures ofshrinking profit margins,Zhu said.

Zhu, who is also chair-man of Shougang Corp, oneof the largest steel compa-nies in China, said the com-pany will invest heavily inoverseas mining operationsto improve its self-suffi-ciency in iron ore.

He said 25% of the ironore used by the company in2011 was produced throughits overseas investment.That figure is set to increaseto 60% by 2015.

Lomar Corporation, a subsidi-ary of the Libra Group, hassigned an order with China’sCOSCO Group for up to sixUltramax bulk carriers.

Scheduled for deliverystarting from early 2014, the‘Dolphin’ 64,000 dwt vesselshave been designed by lead-ing Chinese design instituteSDARI (Shanghai MerchantShip Design and Research In-stitute) and meet the higheststandards for fuel efficiencyand environmental compli-ance, including the latestIACS Common StructuralRules (CSR).

“These new vessels are thelatest in design and effi-ciency,” said Achim Boehme,CEO of Lomar.

“They complement our ex-isting bulk carrier portfolioand allow us to stay competi-tive in the dry bulk markets.Our substantial investmentdemonstrates real commit-ment to operating a modern,fuel-efficient fleet.”

Lomar says that the invest-ment restates its dedication tothe dry bulk sector with re-

Lomar orders new Ultramaxvessels from China’s COSCO

newals and additions to thefleet which can carry a widerange of bulk cargoes and ben-efit from the latest eco-friendly,fuel-efficient designs.

The order takes Lomar’scurrent fleet to over 40 ves-sels. The new Ultramax bulkcarriers have been designed tocarry up to 11% more cargothan conventional Supr-amaxes while consumingaround 13% less fuel.

The fuel-efficient design of the new 64,000 dwt vesselsmeans that they will consume around 13% less fuel thanconventional Supramaxes

Lomar already has alongstanding relationship withCOSCO Group for ship repairand dry docking works andlooks forward to working withthe group on newbuildings.

Between 2004 and 2007Lomar sold 69 vessels, re-en-tering the market in 2009 withthe US$325M acquisition ofAllocean and its entire fleet of26 ships.

The Spencer Gulf Port Link’sproposal for a large new bulkcommodities export facility atPort Bonython has taken astep forward after the SouthAustralian Governmentgranted major project status.

Port Bonython is plannedas a Capesize-capable facility,featuring a 3 km jetty reachinginto deep water. The ship-loader will be served by fullyenclosed conveyors. SGPLsays the final design is “de-pendent on a range of issues,”including geotechnical condi-tions, environmental controls,a wide range of approvals, andfinancing.

New Oz ports closerPlanned initial capacity is

20 mtpa of iron ore, with firstloading in 2015. Eventualthroughput, driven by devel-opment of a number of pro-posed mining ventures, couldreach 60 mtpa through incre-mental expansion.

South Australia had earliergranted major project status toanother development chasingiron ore trade, Centrex’s PortSpencer proposal.

The government hasmoved to relieve pressure atanother SA bulk port,Thevenard, on the state’s farwest coast near Ceduna. Jointstate/federal funding of over

A$10M will be allocated tothe construction of a newcommercial fishing harbournear the Thevenard Slipway atBosenquet Bay. The new fa-cility will eliminate over-crowding at the existing port,which handled over 3 mt ofgypsum, mineral sands, salt,seeds and grains exports andfertiliser imports in 2010-11.

� In Queensland, engineeringcompany John Holland haswon a A$220M contract tobuild the first stage of stock-yard works for the WigginsIsland Coal Export Terminal.Stage 1 of the coal industry-owned WICET has a con-tracted annual coal throughputexport capacity of 27 mt.

Algoma Central Corporation,which owns and operates thelargest Canadian flag fleet ofdry and liquid bulk carriersoperating on the Great Lakes- St. Lawrence Waterway, isto install fresh water, exhaustgas scrubbers on six new ves-sels that will remove 97% ofsulphur oxides emissions gen-erated by vessel engines.

The St. Catharines, On-tario-based company hassigned a contract withWärtsilä Ship Power for thesupply of the systems for itsEquinox Class vessels, whichare currently being built byChinese shipbuilder NantongMingde Heavy Industry Co.Ltd. The total supply and in-stallation cost of the six scrub-ber systems is US$12M.

The two gearless bulk car-riers and four self-unloadingbulk carriers are designed spe-cifically for Great Lakes serv-ice. These ships have beendesigned with high efficiencyhulls that will require lesshorsepower to achieve higherspeeds than any previousGreat Lakes design and thusachieve the lowest fuel con-sumption and emissions pertonne/kilometre of cargocarried.

The first Equinox Classvessel will arrive in Canada inthe first half of 2013.

The Algoma order is thefirst for Wärtsilä’s new, inte-grated, fresh water, exhaustgas scrubber design. Thescrubbers are designed toclean the exhaust gases of thevessels’ main and auxiliaryengines as well as the oil-firedboiler and will meet morestringent environmental regu-lations taking effect over thenext three years.

These scrubber systemswill allow shipowners to uselower cost, heavy fuel oilswhile, at the same time, meetthe new Emission ControlArea sulphur limits estab-lished by the InternationalMaritime Organisation(IMO) and adopted byCanada and the UnitedStates for the Great Lakesand coastal waters.

Without scrubber technol-ogy, shipowners will be forcedto convert vessels to burnmore expensive diesel oil.

“The installation of scrub-ber units on our Equinox Classvessels fits with our statedstrategic objective of improv-ing the efficiency of our fleetwhile at the same time reduc-ing our environmental foot-print” says Greg Wight, presi-dent and CEO, Algoma Cen-tral Corporation.

“These are truly importantvessels as they will set newstandards for environmentallysustainable shipping on theGreat Lakes and for cargo ves-sels in general,” said JuhaniHupli, vice president, shippower technology at WärtsiläShip Power.

AlgomachosesWärtsiläscrubbers

04_BMI_Mar_Apr_2012.indd 1 15/05/2012 11:47:03

BMI March/April 2012 5

News

Western Australia’s CBHGroup has marked an all-timerecord grain harvest with thearrival of the first shipment ofits new rolling stock and fac-tory roll-out of its first newlocomotive.

A pre-harvest forecast of13.5 mt was well and trulyexceeded when a truckload ofwheat delivered to CBHGroup’s Pingrup receivalsite in the Albany zone inearly February pushed totalgrain receivals in WA past15 mt for the first time inhistory.

A month earlier statewideproduction surpassed theprevious record set in 2003-04 of 14,695,321 mt.

CBH then went on to breakthe record for the most amountof grain shipped in the monthof February with more than1.29 mt departing WesternAustralian ports for interna-tional markets. The previousrecord of 1.174 mt was set

Wagons roll for CBH

The Ukrainian port ofMariupol (MMTP), the gate-way to the Donetsk coal ba-sin on the Sea of Azov, is forg-ing ahead with its improve-ment project.

Last year it announced thatit had invested around US$8Mto replenish its handling facili-ties and machinery. In thecourse of the year, the port ac-quired a total of 16 forklifttrucks, including seven with a5t lifting capacity, three 16 tlcmodels manufactured by Yale,one 25 tlc and one 28 tlc madeby Kalmar, and two 32 tlc andtwo 37 tlc produced by SMV.

It bought three wheel load-ers each with a bucket capac-ity of 2.5 m3 and two bulldoz-ers from Liebherr and pur-chased an Aichi wheeledboom lift. Finally, MMTP re-plenished its motor pool with11 lorries including a fire truck.

In 2012, the port is plan-ning to buy a Ukrainian-madeMark 362 portal crane, 16more forklifts, two marinetractors, three roll trailers, anempty container handler, atelehandler and a tractor withremovable equipment.

As far as the port’sberthing structures are con-cerned, MMTP recently post-poned completion of the re-construction of its berth No. 8(bulk cargoes) from the end of2012 to the end of 2013.

Work started last year andwill include deepening of thedepth alongside the 226m-long berth to 9.75m in orderto increase its handling capac-ity to 1 mtpa.

MMTP is one of the fivebiggest harbours in Ukraineand features the country’s larg-est dedicated coal terminalwhich has a handling capacityof up to 5 mtpa. Apart from do-mestically-produced coal, theport handles Russian coal too.

Mariupolcontinuesupgrade

Cementa AB’s new cementimport terminal at Swe-den’s Malmö Northern Har-bour has been officially in-augurated.

IBAU Hamburg com-pleted the EPC-contract, in-cluding piling works, civilworks, steel structure supplyand erection as well as elec-trical and mechanical supplyand erection.

The Cementa-ownedships can discharge at the ter-minal at a rate of up to 1,000t/h. The cement is fed to themulticompartment storagesilo which has a height of90m, a diameter of 26m, sixchambers and a capacity of30,000t. Distribution takesplace via three combinedtruck/wagon loading lanes,each with a capacity of 250t/h. The terminal can be op-

New cement importterminal opens in Malmö

erated automatically 365days/year and 24 hrs/day.

Cementa AB is part of theHeidelbergCement group ofcompanies.

The storage silo has acapacity of 30,000t

The Chris Corrigan-ledQube Logistics has ex-panded further into the Aus-tralian mine-to-port logisticssector with the acquisition ofWestern Australia-basedGiacci Holdings for aroundA$119M.

From Bunbury Giacci hasexpanded operationsthroughout Western Aus-tralia, South Australia,Queensland and the North-ern Territory and now em-ploys 350 people across tenstrategic sites that include22,000 square metres ofmineral storage sheds.

Qube said Giacci, whoseMD and co-owner PeterGiacci has agreed to staywith the company for at leasttwo years, had built its corebusiness in the mining indus-try, specifically in mineralhaulage and handling, pro-viding mine to port solutionsfor the majority of its cus-tomers and in most in-stances, assuming full re-sponsibility for the supplychain.

It operates a fleet of bulkhandling equipment, withkey strategic partnershipsand joint ventures incorpo-rating shipping and rail,managing in excess of 17mtpa of bulk products.

Qube will fund the acqui-sition through the issue ofA$20M of new Qube sharesto the vendor at an issueprice of A$1.4749 per sharewith the balance of the pur-chase price funded fromQube’s available cash anddebt facilities.

The acquisition will becompleted during March2012 and the business willform part of Qube’s Ports &Bulk division.

MD Maurice James saidthe acquisition would enableQube to provide a completemine-to-port logistics solu-tion covering transport,stockpile management andstevedoring.

“The enhanced logisticscapability should providesignificant opportunities toexpand the range of servicesoffered by the Qube group,”James said.

In its first result after con-version to a conventionalcorporate structure, on 1March Qube reported a 37%increase in operating reviewand a 45% increase in profitafter tax.

Among other milestonesQube noted that two yearsafter it began as operator ofPort Hedland’s Utah Pointcommon user bulk terminal,throughput at the facility hasreached its nameplate rate ofover 10 mtpa.

in 2004. February’s ship-ments took the total exportedsince 1 November 2011 to4.18 mt.

On 9 February theOldendorff-operated multi-purpose ship PACIFIC FIGHTERarrived at Kwinana to dis-charge the first 50 of a totalorder of 574 aluminium-bod-ied grain wagons, loaded in theport of Lianyungang in north-eastern China.

CBH ordered 446 stand-ard gauge and 128 narrowgauge wagons from Austral-ian company Bradken,which is building the stockat its Xuzhou factory.

CBH GM Operations ColinTutt said this was a milestonefor the CBH Group and a sign2012 was the year rail would berevitalised in WA.

“The lightweight alu-minium body allows us to loadmore grain into each wagon,

around 10t per wagon morecapacity than the currentsteel wagons. This of coursemeans more tonnes to portper train movement and amore efficient rail systemfor everyone.

“The wagons are also in-credibly safer than the oneswe use currently; there will besignificantly less direct inter-action with wagons with theinstallation of auto hatch anddischarge doors as well asscanning technology,” Tuttsaid.

Subsequently at the end ofFebruary the first of 22 new2700hp and 3200hp locomo-tives came off the produc-tion line in Boise, Idaho inthe United States and is ex-pected to arrive in WA inmid-May. CBH is investinga total of A$175M in thenew wagons and locomo-tives.

QubeminesOz portlogisticschain

05_BMI_Mar_Apr_2012.indd 1 15/05/2012 11:49:42

BMI March/April 20126

Area Focus: Italy

Pagnam, the “distressed” companyspecialising in shipping grain andother agri-bulks by barge fromChioggia (near Venice) on the Ponavigation system to various desti-nations in the Pianura Padana,could yet acquire a buyer and re-main a going concern.

U.S.-based multinational graintrader Cargill, which acquiredPagnam in 2006, recently stated thatthe Italian company would cease trad-ing as it was not economicallyviable.However, a mixed public/

prviate enterprise, Allibo AdriaticaSpA, based in Rovigo and with a capi-tal base of €0.7M, has been formed totake over Pagnam’s activities.

Clear interestAllibo’s shareholders are all compa-nies or public sector bodies with anclear interest in Pagnam’s survival:Ship Service Srl of Venice, with24.5%; tug operator Cam RimorcheSrl (14%); the tug companyRimorchiatori Panfido di Venezia Srl(14%); the Venice Chamber of Com-

merce (10.5%); Chioggia Shipyard(10.5%); Interporto di Rovigo(10.5%); flour shipper Grandi MoliniItaliani SpA (5%); ViglienzoneAdriatica SpA (5%); New PortMenela Srl (3%); and Veronesi Hold-ing SpA (3%).

“Our objective is to take overfrom Cargill Srl all its assets in thePort of Chioggia, specifically thelightering of seagoing bulk vessels andsimultaneous transhipment to bargesbound for Porto Marghera (Venice)and inland ports on the Po navigation

system, Rovigo Interporto, Mantovaand Cremona,” said Allibo.

A key target is ROMANO P, a 100mlong, 20m wide transhipper equippedwith a Sobemai balance crane andspecifically designed for lighteringoperations in the Venice Lagoon. Ca-pacity is up to 15,000 tpd (1200 tph)and the annual service capability isequivalent to 15,000-18,000 truckloads.

Coal boostElsewhere in Italy, coal industry as-

Following the commissioning ofORE FABRICA for Vale, Logmarinhas commissioned a secondnew transhipment lighter vessel,FC BLITZ, for Indonesian shippingline PT MBSS. Flying theIndonesian flag, the 4490 grt,91m-long floating terminal wasbuilt by Keppel Shipyard inSubic Bay and is classed byRINA. The vessel will operatealongside PRINCESSE CHLOE, apreviously-delivered Logmarinfloating transhipment terminal,off the east coast of Kalimantan,handling coal. The vessel isequipped with two Liebherrfixed pedestal cranes and canwork colliers up to Capesize at25,000 tpd. �

sociation Assocarboni has called forthe country to boost its use of coal.The solid fuel has just a 12% shareof the energy mix, compared to theEuropean average of 33%.

Speaking at the recentAssocarboni National Congress inRome, Andrea Clavarino, the asso-ciation’s chairman, urged the govern-ment to address the country’s needfor a new national energy strategy,saying it was a key driver for thecountry’s economic revival. Italy isthe only country in the world to de-pend on natural gas for more than60% of its electricity production,Clavarino said.

“With no nuclear power and re-newable energy still being too expen-sive – it will cost Italian taxpayers€9 billion in incentives per annum –the situation is clearly unsustainableas it undermines the competitivenessof the Italian manufacturing indus-try, which in Europe is second onlyto that of Germany,” he warned.

Last year, Italy imported 17 mt ofsteam coal, in line with 2010, and 7mt of coking coal and PCI, up 27%over previous year. Petroleum cokeconsumption, used in the cement in-dustry, was in line with 2010 figure(2.3 mt) according to Assocarbonidata.

Planned CCT“In the last few years Italian coaloperators have shown an extraordi-nary ability to focus on innovationand fostered significant investmentsin new clean coal technologies, ena-bling the environmentally sustain-able use of coal,” said Clavarino.

He said that this was evident inplanned projects worth €5.5B, relat-ing to new coal plants and unitsequipped with cutting edge cleancoal technologies able to enhanceefficiencies by up to 46%.

The projects include the state-of-the-art SEI project in Saline Joniche(1,320 MW), the oil to coal conver-sion of ENEL plant in Porto Tolle(1,908 MW) with installation of CCStechnology and the requalification ofthe Tirreno power plant in VadoLigure with the construction of a newhigh-efficiency coal unit (460 MW).

“These are all good reasons toboost the role of coal in the nationalenergy mix,” Clavarino said. �

Allibo offers a grain of hope for Pagnam

Logmarin commissionsnew vessel FC BLITZ

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06_BMI_Mar_Apr_2012.indd 1 15/05/2012 11:53:19

BMI March/April 2012 7

Area Focus: China

Iron ore trade platform ‘willimprove price transparency’China is hoping that its first ironore spot trading platform will helpthe nation gain more influence inglobal pricing. It is the world’slargest user and importer of thecommodity.

The China Beijing InternationalMining Exchange (CBMX)launched the online platform in Janu-ary together with the China Iron &Steel Association (CISA) and theChina Chamber of Commerce ofMetals, Minerals & Chemicals Im-porters & Exporters.

“The iron ore market should bedetermined by and reflect real sup-ply and demand. However, mo-nopoly practices and price manipu-lation have exerted a big impact onprices,” said Wang Xiaoqi, vice-chairman of CISA.

Public platformChina accounts for 60% of the glo-bal iron ore trading market. The na-tion’s iron ore sources increasedfrom 48 countries in 2010 to 67 in2011, and there was a marked expan-sion in physical transactions.

Steel companies and iron ore trad-ers from China, Japan and SouthKorea largely regard other widely-used iron ore indices with some scep-ticism as to their transparency andfairness according to Wang.

“It is very important to build apublic platform in China to improvethe development of the industry,” hesaid.

CBMX is also publishing a newiron ore pricing index in an attemptto better reflect supply and demand,as well as reduce price volatility.

The GlobalOre trading exchange,backed by the mining giant BHPBilliton and based in Singapore, willface a threat from the new Chineseplatform. According to one Chinesetrader, many big domestic iron oresuppliers and steel producers havestopped trading on GlobalOne orhalted moves to join it.

According to CBMX, China’smajor steel companies - includingBaosteel Group Corporation,Hebei Iron & Steel Group, WuhanIron and Steel Group, ShougangGroup, Angang Steel Co and ChinaNational Minerals Co - haveagreed to become members of thenew platform.

To avoid speculation, financialorganisations and banks aren’t al-lowed to participate in the plat-form, CMBX president DongChaobin said.

Greater accuracyDong said shareholders of the plat-form are the China Beijing Equity

Exchange, Aluminum Corporationof China and China EverbrightGroup. The price index is based onactual transactions at domestic andforeign ports, which Dong suggestedwas fairer and more accurate thanother methods of calculation.

The online platform posts pricesof completed trades online without

identifying either the buyer or theseller, a move meant to improvethe accuracy and reliability ofprice statistics.

Liang Ruodong, vice-presidentof the exchange, said many over-seas steelmakers had shown an in-terest in the platform and mightjoin the system.

According to CISA, China im-ported 686 mt of iron ore in 2011, up10.9% year-on-year.Total crude steelproduction in China last year was680 mt, up 8.6%. Cast iron produc-tion was 630 mt, up 6%.

Japanese steelAccording to Toshihiko Emi, direc-

China is increasingly investing inoverseas mines in a move toguarantee supply of thecommodities it needs for itscontinued growth and development

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07_BMI_Mar_Apr_2012.indd 1 15/05/2012 11:56:50

BMI March/April 20128

Area Focus: China

tor of the Institute of Researchof Iron and Steel (Shasteel),Chinese steel companies arerapidly catching up with theirJapanese counterparts inmanufacturing high-qualityproducts.

The difference between thetwo steel industries is narrow-ing month by month, saidEmi, who also acts as assist-ant to the chairman of China’sJiangsu Shagang Group.

The Japanese steel indus-try has a longer history andbetter technology than its Chi-nese counterpart, but Emi saidChina now has some advan-tages in development.

“The major Japanese steelcompanies suffered a loss lastyear because of the risingvalue of the Yen, tripled la-bour costs and rising prices forraw materials,” he said.

“But China, because of itshigh import levels, can buyiron ore and coal at relativelylower prices with a discount.”

Investment overseasTo support domestic produc-tion, China also has been seek-ing to invest in mines in coun-tries such as Australia, Canadaand several in Africa.

Last year, the China Ironand Steel Association forecastthat China would need to im-port half of its iron ore needsby 2015. A large percentagewould be sourced from Westand Central Africa, it said.

“In addition, China has asteadily growing domesticmarket for steel products,while the Japanese steel indus-try depends highly on exports,which adds to its difficultiesin sales,” he said.

Iron ore prices have beenincreasing and steel prices havebeen falling in recent months,resulting in big losses for manyChinese steel companies.

But Emi believes this isdue to the depressed interna-tional market and will not con-tinue for long.

EU investigationIn addition to falling steelprices there is another causefor concern for China’s steelindustry. At a time when the

European Union has begun ananti-subsidy investigation intoChina’s exports of steel prod-ucts, Chinese companies arehaving to contend with anoversupply of such productsin their domestic market.

Analysts say that manyChinese companies have cometo depend on overseas sales andtherefore are at risk of beingharmed by the trade dispute.

In February, the EU offi-cially began investigatingwhether Chinese makers oforganic coated steel,usedmainly in home appliances,construction materials andheating equipment, had re-ceived government subsidies.To protect European produc-ers, the organisation threat-ened to impose tariffs on Chi-nese imports of the metal.

Europe is the main exportdestination for Chinese pro-ducers of organic coated steel,which would be vulnerable toharm if Europe decided to taketough actions against Chinesemanufacturers, said XuXiangchun, senior analyst atMysteel.com, a steel industrywebsite and consultancy.

He said China’s exports ofthis kind of steel to Europehave grown quickly in the pastthree years, pushed both by anincrease in the country’s pro-duction capacity and an over-supply in the market.

According to China Ironand Steel Association statis-tics, China produced 5.54 mtof organic coated steel in2010, of which 3.05 mt were

for export.In the first tenmonths of 2011, the countryexported 4.56 mt of organiccoated steel, 49.5% more thanthe total amount for the previ-ous year.

‘Too early’Xu said it was too early to es-timate how badly Chinese pro-ducers will be harmed if thepunitive tariffs are imposed,adding that China should avoidbecoming too dependent onoverseas markets.

He said the China Iron andSteel Association is helpingthe steel companies that willbe affected by the EU’s inves-

Coal-rich Inner Mongoliain northern China is seekingto process some of its vastreserves of coal into diesel orelectricity to add value to theresources and assist with thepressing issue of environmen-tal protection in the region.

“The resources will dry upone day no matter how manywe have now,” said HuChunhua, Communist Partychief of Inner Mongolia.

“We must find ways to freeourselves from the reliance onresources for our sustainabledevelopment.”

Inner Mongolia, with esti-mated 700 bt of coal reserves,is China’s burgeoning coalbase, producing more than onequarter of the country’s coaloutput.

Transport challengesIn 2011, over 60% of its 1 btof coal production was trans-ported over land to energy-thirsty areas like northeasternand central China.

The difficult task of mov-ing coal out of Inner Mongo-lia has posed a challenge forland transportation. In Sep-tember 2010, the Beijing-Tibethighway experienced trafficjams of up to 100km as the roadwas clogged by huge numbersof coal-hauling vehicles.

“It is inefficient to trans-port coal to all over the coun-try with diesel-driven trucks.So we must convert the coalto high-efficiency energyforms before sending it out,”said Liang Tiecheng, director ofthe Inner Mongolia Develop-ment and Reform Commission.

The government has de-cided to develop Inner Mon-golia into an “energy base”and a “new-type chemical in-dustry base” so as to give fullplay to its advantages in coaland non-ferrous metals and re-alise the transformation of itslow-efficiency resources tomore efficient forms like die-sel or electricity locally.

New technologiesWang Rungang, a NationalPeople’s Congress (NPC)deputy from Inner Mongolia-based Shenhua Wuhai CoalGroup, said his company car-ried out a coal-chemical ex-periment programme, ena-bling it to master the technolo-gies involved in turning coalto diesel with an annual capac-ity of 1.2 mt.

The value of diesel proc-essed from coal is eight to 12times that of the original ma-terial, Wang said.

Liang said the new tech-nologies are different fromthose used in upgrading primi-tive coal processing. Instead,it is an integration of multiplecoal-chemical technologiesto enable multilevel use ofcoal.

Moreover, Inner Mongoliawill develop a high value-

added economic and industrialchain that is composed of itsadvantageous resources in-cluding coal, iron and steel,and polysilicon, said Liang.

The development of itscoal sector will be a strategicmeasure to ensure the coun-try’s energy security, he said.

It is thought that foreigninvestment in Mongolia’smining sector will be encour-aged in a move to increasecoal production and availabil-ity and improve mine effi-ciency.

In 2011, China’s net coalimports reached a record 160mt. Improved availability ofMongolian coal would helpChina reduce its reliance onimports.

Mine overhaulBut growing interest in Mon-golian coal has resulted in il-legal mines being set up.

In an attempt to improvework conditions and safety aswell as the environmental im-pact of the mining sector, In-ner Mongolia has halted 467illegal mining projects in a re-gion-wide overhaul.

The regional land and re-sources bureau checked about9,000 mining projects in theoverhaul last year, halting 467illegal projects, ordering 887mines to suspend operationsand shutting down 73.

Officials said the mineswere unlicensed, upset localresidents or failed to properlycompensate for the use ofgrassland.

In a bid to build “harmoni-ous mines” the governmentdefused 100 disputes betweenlocal herders and mining com-panies last year while estab-lishing an effective mecha-nism to settle disputes throughdialogue, it said.

Inner Mongolia ordered anoverhaul of the mining sector,originally scheduled for onemonth but which was ex-tended after protests againstgrassland mining broke out inthe wake of the death of aMongolian herder during adispute with miners.

The regional coal mineindustry bureau then orderedlocal work safety watchdogs tostrengthen supervision of coalmines to ensure safe productionpractices, protection of the en-vironment, and attention to thewelfare of residents.

Inner Mongolia holds thecountry’s largest coal reserves- 770.3 bt at the end of 2011 -and rich deposits of other min-erals such as iron ore and rareearth metals.

A mining boom in recentyears has brought prosperityto the region but concernshave been raised about theecological damage that min-ing might cause to a regionbetter known for its vastgrassland and unique herd-ing culture. �

China’s energybase seekstransformation

tigation prepare for the ap-proaching legal process.

Chen Xinmiao, another in-dustry analyst, said that if theEU imposes tariffs on Chineseexports of the steel, Chinesecompanies must seek out newmarkets for the product.

Meanwhile, the economicgrowth that is occurring inSoutheast Asia is not likely toproceed quickly enough togive rise to the demandneeded to soak up China’soversupply of organic coatedsteel in the short term.

The EU therefore remainsan indispensable market forChinese producers.�

Brazilian miner Vale has saidthat it expects to win permis-sion “within months” to un-load its Very Large Ore Car-riers (VLOCs) at Chineseports. To date, only oneVLOC, the BERGE EVEREST,has been granted permissionto unload at a Chinese port.

“The big vessels are hereto stay, this is a technicalthing and we are just wait-ing for the ports to beadapted to receive ourships,” Tito Martins, Vale’schief financial officer, toldReuters.

“It’s going to happensoon.”

As previously reported,China has been reluctant to

allow the vessels to berth,accusing the miner of look-ing to monopolise the ship-ment of iron ore out of Bra-zil and warning that the com-pany would ‘practically con-trol’ movement of the com-modity between the twocountries.

Vale subsequently issuedclarification that its vessels,capable of transporting400,000t of iron ore andowned by itself or chartered,will only dock at Chineseports in total accordance withthe country’s legislation.

It said that it needs theships in order to remain com-petitive against Australianproducers. �

China to approveVLOCs soon, says Vale

China imported 686 mt of iron ore in 2011, an increase of 10.9% year-on-year

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08_BMI_Mar_Apr_2012.indd 1 15/05/2012 11:59:52

BMI March/April 2012 9

Area Focus: Southern Africa

Broadening Southern African appealUntil relatively recently, dry bulktransportation in Southern Africameant just one thing: South Africa.Principally South African coal butalso iron ore and, to a lesser extent,manganese.

Interest in the rest of the regionwas limited but over the past fewyears Mozambique has become ofincreasing importance and now Bot-swana too is on the radar of mostanalysts. This year, for the first time,developments in Mozambique areperhaps of equal importance to thosein South Africa, even in a year whenrail operator Transnet will begin toenact some important decisions.

Three projectsSouth African state-owned firmTransnet Freight Rail (TFR) hasmade three long-awaited investmentdecisions over the past few months.Firstly, it has decided to develop itsnew manganese export terminal atthe new port of Ngqura in the East-ern Cape rather than at the estab-lished iron ore port of Saldanha onthe Atlantic coast.

Ngqura was originally designedwith a planned aluminium smelter asits anchor tenant but the smelter wasnever built and Transnet has beenforced to find alternative uses forboth the facility and the adjacentCoega Industrial Zone.

A new transhipment container ter-minal has already been developedand now it will act as the country’sdesignated manganese port, replac-ing nearby Port Elizabeth, which hadpreviously fulfilled that role. A newrail corridor will have to be devel-oped from mines in the NorthernCape to the port.

The other two projects both con-cern the coal sector. Although thePhase V expansion of Richards BayCoal Terminal (RBCT) took the fa-cility’s handling capacity up to 91mtpa, TFR has been unable to railmore than 65 mtpa to the facility be-cause of vandalism on the line, acci-dents and a general lack of capacity.Mining companies have campaignedfor increased rail capacity butTransnet had previously failed tomake any concrete promises unlessmining companies signed long termuse agreements.

However, the company has nowdecided to develop a new railwayfrom the traditional centre of theSouth African mining industry inMpumalanga Province, throughSwaziland and then into South Afri-ca’s KwaZulu-Natal Province. Theline should be of some use toSwaziland but will mostly be used totransport freight from one part ofSouth Africa to another. TFR hopesthat it can transfer freight from theexisting Mpumalanga-RBCT line tothe new railway, freeing up capacityon the coal line for additional exports.

The new Transnet line throughSwaziland could also be used totransport coal to Matola Coal Termi-nal (MCT) next to the port of Maputoin southern Mozambique. OperatorGrindrod of South Africa has ex-panded MCT’s handling capacity to6 mt/y and is contemplating increas-ing this further to 20 mtpa. In Janu-ary, Vitol of Switzerland agreed tobuy a 35% stake in the project forUS$67.7M and this should help tofinance the expansion programme.

In addition, a new railway fromis to be developed from theWaterberg Basin in Limpopo Prov-ince to RBCT. It is expected that theWaterberg will provide much of the

new coal mining capacity developedin South Africa over the coming dec-ade, compensating for falling outputin some parts of Mpumalanga.

Shipment boost Demand for South African coal isrising in India and China and so thecoal mining firms that own RBCThope to maximise their output in or-der to take advantage of these grow-ing overseas markets.

Moreover, the South African gov-ernment hopes that the various black

empowerment mining companiesthat have been allocated capacity atRichard’s Bay will be able to boosttheir own shipments in order to ex-ploit higher international prices forcoal.

Despite severe problems on theRichards Bay rail line during the firsthalf of the year, the South Africandry bulk sector as a whole enjoyed asatisfactory year in 2011. The totalvolume of exports increased 6.6% to141.49 mt for the year, of whichRichards Bay handled 76 mt and

Saldanha 53.2 mt. South Africa ex-ported 39% more manganese in 2011than in 2010, while the coal sectorrecorded a small rise of 3.3% inturnover to 65.5 mt.

However, iron ore exports in-creased by 44.3% to R62.63bn($8.2bn) in 2011 in comparison withthe previous year, while actuallyproduction rose 26% in January2012 from the same month oneyear earlier.

With or without sustained highinternational prices for iron ore, TFR

is committed to boosting transportcapacity on the iron ore line from theSishen mines to Saldanha.

Botswanan optionsAside from South African exports,Mozambique could also handleBotswanan coal exports. Botswanalifted its moratorium on coal explo-ration licences at the end of January.It had been imposed to give the gov-ernment time to assess is resourcesand introduce a new regulatoryframework designed to allow onlycompanies with sufficient experi-ence and finance to secure miningconcessions.

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BMI March/April 201210

Area Focus: Southern Africa

recently completed studyhighlighted a number of areaswhich require immediate at-tention for Botswana to de-velop her coal resources. Withthese amendments to the li-censing regime the morato-rium imposed is lifted withimmediate effect.”

Several mine projects areawaiting development, includ-ing CIC Energy Corporation’sMmamabula combined coaland coal bed methane schemein the southeast of the country.The Canadian company is stilllooking for a larger partner fol-lowing the collapse of its pro-posed takeover by JSW Energyof India. The government be-lieves that production of up to90 mtpa is feasible but that re-mains to be proved.

Rail projectsThere is no spare coal haul-age capacity on the South Af-rican rail network to cope withBotswanan exports, while ex-isting rail links with SouthAfrica use narrow gauge track

that is not designed for carry-ing large coal trains.

Two new railway projectshave been proposed to trans-port Botswanan coal to over-seas markets: one to the west,to the Namibian port of WalvisBay, which would also pro-vide port access to smaller, un-tapped Namibian coal mines.The other would run east-wards to a new terminal atTechobanine in the far southof Mozambique. This couldalso be used to handle SouthAfrican coal from theWaterberg Basin.

Feasibility studies intoboth options are currentlyunderway but despiteGaborone’s hope that bothlines can be developed, onlyone multi-billion dollarscheme is likely to be financedfor the foreseeable future.

From Tete to the seaHowever, it is in Mozambiqueitself that most new coal min-ing production is expected tobe brought on stream over the

next decade and beyond.Maputo consistently forecaststhat the country could even-tually produce 100 mtpa, mostof which would be exported,and the country is currently oncourse to export 46 mtpa as

soon as 2015, all of from TeteProvince in the northwest ofthe country.

Given that Mozambicantransport infrastructure wasdevastated during the country’slong civil war and that it was

never designed to handle coalin the first place, massive in-vestment is being made in rail,road and port infrastructure.

The main investors inTete’s Moatize Basin atpresent are Brazilian firm Valeand Riversdale of Australia,which is now owned by RioTinto, but more than 100 coalmining concessions have beensigned and a variety of othercompanies plan to start export-ing coal in the medium term.

In January, Ncondezi Coalsigned an agreement with RioTinto for access to 10 mtpa ofport and rail coal capacity,suggesting the latter will bedirectly involved in develop-ing transport capacity.Ncondezi chief executiveGraham Mascall said: “RioTinto has significant experi-ence in developing rail andport infrastructure projectsaround the world, and I be-lieve that it is best placed tolead and implement thisproject in Mozambique.”

Coal export terminals areplanned at the existing portsof Beira and Nacala, whilenew terminals have been pro-posed at the mouth of RiverZambezi and at the town ofQuelimane to the north.

Nacala terminalIn February, the prime minis-ter of Mozambique, Aires Aly,announced that the construc-tion of a new US$4.4B coalterminal at the port of Nacalawould begin within a fewmonths. Handling capacity of18 mtpa is expected at both theport and on the planned 912km railway that will connectthe Moatize mines withNacala, although this is ex-pected to be expanded in asecond phase development.

Sources in Mozambiquesuggest that Vale will developthe project, although the Japa-nese government has funded afeasibility study into how bestto upgrade the port. Some formof support from international fi-nancial organisations is likely.

The Quelimane projectwould have handling capacityof about 20 mtpa, the samevolume planned for Beira andNacala, and would require theconstruction of a new 500 kmrailway from the port to themines. The site at the mouthof the Zambezi would havethe advantage of being a natu-ral deepwater harbour withdirect access for Capesize ves-sels. There is a lack of exist-ing infrastructure at both lo-cations but this could be anadvantage in terms of provid-ing terminals and railways fitfor purpose.

Spur lines In order to complement all ofthe independent and isolatedwest to east railway lines, thegovernment has announcedplans for a north-south railwaythat would act as a spine con-necting all existing lines in thecountry. This could enablecoal from Tete to be exportedfrom any or all of the plannedcoal export terminals.

As in most African coun-tries, the existing rail networkwas designed during the colo-nial era to move raw materialsout of the country and not to

enable trade within the countryor with neighbouring territories.

Spur lines that could servethe export of other commodi-ties are also to be rehabili-tated. The minister of trans-port, Paulo Zucula, said: “Thegovernment has not aban-doned these railways as somepeople claim. They will be re-built with greater capacity…but with modernising featuresand connected to the north-south line and to the existingports and new ports that willbe built.”

Despite the government’searlier commitment to priva-tisation, it remains to be seenhow much of this new infra-structure will be managed byprivate sector operators. InDecember, Maputo revokedRicon’s concession to operatea railway network in centralMozambique, including theline from Tete Province to theport of Beira. The concessionhad been held by Companhiados Caminhos de Ferro daBeira, in which Ricon – a jointventure of state owned Indianfirms Rites and Ircon Interna-tional – held a majority stake.

The ministry of transportand communications com-plained that the consortiumhad not completed rehabilita-tion work according to thepreviously agreed timetable.The railway will now be op-erated by Mozambican staterail and port company, Portose Caminhos de Ferro deMoçambique (CFM), whichalso manages other pieces oftransport infrastructure thathave been brought back understate control.

OutlookWith a total of five new coalterminals planned in Mozam-bique – to handle Mozam-bican, Botswanan and SouthAfrican coal – much remainsto be decided in the transportof dry bulk materials in South-ern Africa.

In an ideal world, all fivewould be constructed, aswould both railways out ofBotswana and the Mozam-bican rail spine project. Thisnew infrastructure would pro-vide plenty of options for min-ing firms and would also cre-ate the transport infrastructurerequired to assist in the furtherdevelopment of some of Sub-Saharan Africa’s most suc-cessful economies.

In practice, however, sucha grand vision cannot be im-posed from above. It must bedeveloped on a piece by piecebasis, with each part of the jig-saw required to be commer-cially viable in its own right.

In the case of Mozam-bique’s Tete Province, at least40 mtpa of coal rail and porthandling capacity is requiredrelatively quickly to meet thedemands placed by the coalboom in the Moatize Basin.

The expansion of iron orecapacity on the Sishen Rail-way and the construction of amanganese terminal atNgqura may be important intheir own right but the focusremains on king coal, even ifit is more broadly spreadacross the region and is nolonger concentrated in SouthAfrica. �

Despite RBCT having a handling capacity of 91 mtpa, TFRhas been unable to rail more than 65 mtpa to the facility forvarious reasons, including vandalism on the line

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BMI March/April 2012 11

Cargo Handling

Bulking up on mobile cranes2011 was a good year for Liebherrmobile harbour cranes (MHCs).Sales were the second best onrecord, and the LHM 420 was suc-cessfully introduced as the replace-ment for the LHM 400. The LHM420 slots in between the LHM 280and the LHM 550, which replacedthe LHM 500 in 2010 (althoughLHM 320s are still being sold).

Last year Liebherr supplied 77MHCs, along with six rail portal-mounted slewing cranes and twofixed slewing cranes. This is the bestresult since 2008, when Liebherrdelivered 101 MHCs and one railportal slewing crane.

Following that record year, salesdeclined by around one third in 2009due to the global recession. The mar-ket stabilised in 2010, providing asolid base for the upturn in 2011.Sales turnover in 2011 came to€263M, 25% up on the figure for2010.

Of the total of 85 cranes suppliedby Liebherr in 2011, no less than 49(or 58%) were 4-rope cranes for bulkhandling. In the past five years it hassupplied 216 such cranes.

Driving aheadThe LHM 420 is available in liftingcapacities of 84t and 124t and theoutreach range is 10.5m-48m. Anoptimised tubular tower design re-duces corner loads by 12% comparedto the LHM 400 and the crane isavailable with Liebherr’s increas-ingly popular Pactronic hybridpower booster drive. This is claimedto provide fuel savings of up to 30%as well as faster hoisting and lower-ing speeds. According to Liebherr,the higher speeds translate as produc-tivity increases of up to 30%.

Currently the Pactronic drive isavailable on the LHM 420 and theLHM 550 models. Liebherr supplied33 of these two crane types in 2011,of which no less than one third werespecified by the customer withPactronic. This is a ringing endorse-ment and exceeds even Liebherr’sexpectations, given the price premiumassociated with Pactronic compared tothe regular hydrostatic drive.

Looking at 2012, Liebherr notesthat its order backlog at the end of2011 was higher than it was at theend of 2010. For that reason, thecompany believes it is on the righttrack at least to match 2011’s per-formance this year.

LPS 600 awardAnother highlight in 2011 was theIBJ “Crane of the Year Award” forthe LPS 600 model, of which four

were supplied during 2011, all for thefast-growing Indian bulk handlingmarket. Two are used at a multi-pur-pose terminal in Dahej and the othertwo at the coal terminal in Morugao.The award was in respect of two LPS600s supplied in 2010 to Eren’s coalhandling facility in Zonguldak, Tur-key. The four LPS 600s supplied toIndia last year and the Eren cranesare 4-rope cranes supplied with largemechanical grabs for dedicated bulkhandling operations.

The LPS 600 is based on theLHM 600. This is currently the big-gest MHC in Liebherr’s range andhas a self-weight of almost 580t. Itcan be supplied with a heavy lift ca-pacity of 208t (under rotator andhook) between 12m and 16moutreach.

At minimum (12m) outreach, lift-ing height under spreader is 45m. Atmaximum outreach (58m for han-dling with hook or containerspreader), lift capacity is 47.8t (un-

der hook) and 34.6t (under single liftspreader).

In 4-rope grab configuration (andwith A8 classification), the LHM/LPS 600 has a capacity of 63t (grabplus load) between 12m and 32m andthe maximum outreach is 50m.Thecranes are available with Liebherr’sCycoptronic anti-sway system. Thiscomes with a “Teach-In” feature thatpilots the crane semi-automaticallyfrom the hold to the hopper.

The 600s are designed for han-

dling bulk carriers up to Capesizeand productivity is claimed to bearound 1800t/crane hour through-the-ship rate.

Firm principlesThe principle of the rail-mountedslewing crane from Gottwald (HSK)and Liebherr (LPS) is the MHC up-per carriage from the slewing ringupwards matched with a rail-mounted portal undercarriage.

As Gottwald has shown with thesuccess of its HSK cranes, the railportal can be adapted to suit narrowquays, where there may not be roomfor MHC props. The absence of(de)propping means the crane can

Liebherr LHM 550 at the Port ofGulfport, Mississippi

Experience the progress.

Liebherr-Werk Nenzing GmbHP.O. Box 10, A-6710 Nenzing/AustriaTel.: +43 50809 41-725Fax: +43 50809 41-447mobile.harbour.crane@liebherr.comwww.liebherr.com The Group

11_BMI_Mar_Apr_2012.indd 1 15/05/2012 12:14:50

BMI March/April 201212

Cargo Handling

switch holds quickly. Clear-ance under the portal may alsoallow for direct discharge torail wagons or trucks.

As previously reported inBMI, Demag Cranes, theowner of Gottwald, has startedan international dry bulk com-petence centre, based inBanbury, England, to supportits growing customer base inthe dry bulk handling field inthe port industry.

The centre is headed byMark Reardon, who has morethan 20 years of experience atDemag Cranes and Gottwald,before which he worked in theopen cast mining industry. Thecentre started up last Octoberand already has a full workload,dealing with enquiries and re-quests from bulk port operatorsin South America and India.More project engineers will berecruited to support Gottwaldregional global sales centres.

Demag Cranes consideredbasing the centre in Asia or inthe U.S.A., but plumped forEurope because the Europeanmarket, although relativelymature, is still very important.Europe generally, including

the UK, is also a good sourceof engineers, with mining and/or bulk port experience, andthe UK is an easy place to flyto and from most placesaround the world.

Why bulk?Reardon notes that althoughthe 2008-9 recession led to afall in demand for port cranes(following years of uninter-rupted growth), the bulk han-dling segment held up rela-tively well.

This is because it deals, lit-erally, with the staples of life,such as agri-bulks and energycoal. It is true that mineralbulks such as steam coal andiron ore were affected by therecession, but much less sothan consumer goods demand.

Bulk seaborne trades aretied directly to populationgrowth. According to the lat-est estimates (UNCTAD Re-view of Maritime Transport,2011), international seabornetrade of the major dry bulkcommodities (iron ore, grain,coal, bauxite/alumina andphosphate) increased from1.957 bt in 2007 to 2.059 bt

in 2008, 2.094 bt in 2009 and2.33bt in 2010. Hence traderemained upwards, while con-tainer traffic fell sharply in2009 (although it recoveredsomewhat in 2010).

Quoting other sources,Demag Cranes itself has re-ported that trade in seabornethermal coal will increasefrom 680 mt in 2010 to 1.1 btby 2025, while iron ore tradeis forecast to increase by 46%between 2010 and 2020. Theoverall seaborne dry bulktrades market is forecast togrow by 7% between 2012and 2015.

Building with BRICsA second point is that the roleof the BRICs in bulk seabornetrades has grown sharply andcontinues to grow at a fastrate. In many cases, entirelynew ports are required or ex-isting ports have to be greatlyexpanded, and the expertise tosource the right equipment isnot always available locally inthe time-frame dictated by themarket.

Sometimes the equipmentthey source does not match upin an optimum way. However,the main components of a bulkterminal, such as the cranes,grabs, hoppers and conveyors,are all within the scope ofGottwald’s experience as aleading supplier of mobile har-bour cranes and, increasingly indedicated bulk terminals andoperations, the Gottwald rail-mounted (HSK) and pontoon-mounted (HPK) variants.

It is natural for the cranesupplier to take the lead withthe grabs and the hoppers,says Reardon, since the cranerepresents easily the biggestpart of the investment andGottwald can call on knowl-edge and experience from onepart of the world to help a cus-tomer in another. Many typi-cal pieces of dry bulk handlingequipment tend to be mar-keted only locally, but the bulkcentre can provide wider ac-cess to the right products forthe right job.

Silva liningJust recently, for example, the

dry bulk centre has sourcedtwo new “dedusting” hoppersfor the Port of Tyne in Eng-land, for handling biomasswoodchip pellets. Made bySilva in Spain, the hoppersfeature an advanced dust sup-pression system, with an airblade above the windwallwhere the grabs enter the hop-per. In this case, the mobileharbour cranes feeding thehoppers are Liebherr LHM320s.

Like ABP at HIT 2,Immingham, the Port of Tyneopted for Gottwald HSKcranes for its coal terminal atRiverside Quay. Rail-travel-ling cranes offer a big advan-tage over mobile cranes whenit comes to big ships, as thereis no (un)propping time be-tween holds.

In Reardon’s view, large 4-rope mobile and HSK-typecranes are more cost-effectivethan gantry grab unloaders upto around 2000 tph (through-the-ship) rate per crane. Theyare less expensive to buy, takeup less space and weigh con-siderably less, so the quay orjetty can be narrower and doesnot have to support suchheavy loads, so civil engineer-ing costs are lower. Lead timesfrom order to delivery are alsomuch shorter.

Like the gantry grab

unloader, the slewing cranesare built to last and are usu-ally designed according to theFEM A8 classification (basedon 4M cycles.). Typically, theGottwald slewing crane con-cept can achieve 30-40 cycles/h (through-the-ship) when it isdischarging onto an openstockpile. Depending on localconditions, the figure may beeven higher.

If the crane is discharginginto a hopper, however, thenumber of cycles will be in-fluenced by the position anddesign of hopper. Dependingon whether the hopper is dis-charging continuously ontoa conveyor or discontinu-ously into a truck or rail carunder the hopper, the per-formance of the system as awhole may vary.

Sign of fourGottwald has always recom-mended 4-rope cranes withmechanical grabs (from sup-pliers such as Nemag, Peiner/SMAG and Verstegen) whenthe crane is aimed mainly atbulk handling.

A 2-rope crane requires amotor grab, which is relativelyheavy and eats into the capac-ity of the crane. The powerdraw of the grab may also beconsiderable, M&R costs as-sociated with the motor or thehydraulics can be high, thepower cable is exposed todamage in some applications(eg metal scrap handling),and shippers may be con-cerned about the risk of hy-draulic oil leaks contaminat-ing the cargo.

The 4-rope mechanicalgrab offers the biggest capac-

Gottwald G HMK 6407 B in operation in Korea

Liebherr LPS 600s at Eren’s coal handling facility in the Port of Zonguldak, Turkey

ity and the best weight to ca-pacity ratio, while the 4-ropecrane itself offers considerableflexibility if it is also fittedwith a power cable in theboom head (vertical cablereel), to work with attach-ments such as containerspreaders, motor grabs, etc.Surprisingly, perhaps, anumber of dedicated bulk ter-minals specify 4-rope craneswith the extra power cable,even though it is seldom used.

There is no reason why 4-rope cranes should be associ-ated with larger cranes. As ithappens, the bulk centre iscurrently dealing with enquir-ies regarding smaller cranes.The starting point for craneselection is always related tothe vessel size.

Biomass prospectsOne area where Reardon seesa good opportunity for thebulk centre to use its know-how and experience isbiomass handling, a growingrequirement for bulk portshandling coal. Just now in theUK, for example, generatorsare waiting for the definitiveROC (renewable obligationcertificates) banding, whichwill lead to a big increase inbiomass handling in ports.

Technically, biomass posessome interesting challenges.Some types of biomass, suchas woodchip pellets, arefree-flowing, so they need tobe handled by a clamshellgrab. However, other typesof biomass, such as forestresidues, compact underpressure.

This requires differentthinking about handling. If

Liebherr-Werk Nenzing iscelebrating its thousandthmobile harbour crane order.The type LPS 550 crane willbe delivered in the secondhalf of 2012 to the MontoirBulk Terminal in France.

The crane ordered byMBT, a subsidiary of SEA-invest, has a maximum lift-ing capacity of 144t and aboom length of 48m. It isequipped with Liebherr’sPactronic hybrid drive sys-tem which reduces emissionsby 30%.

Liebherr receives order for1000th mobile harbour crane

“This huge success isbased on a constant processof technical improvement aswell as an uncompromisingcommitment to highest qual-ity standards,” Liebherr said.

Liebherr has 38 years ofexperience in the mobile har-bour crane business. While ittook 31 years to sell the first500 Liebherr mobile harbourcranes, the second 500 weresold in less than seven years,testament to the enduring de-mand for flexible cargo han-dling solutions it says. �

wcn_MRSgreifer 9/1/04 10:35 AM Page 1

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12_BMI_Mar_Apr_2012.indd 1 15/05/2012 12:20:31

BMI March/April 2012 13

Cargo Handling

Blue Group was recently awardedthe British Isles concession by Ger-many-based hydraulic hoist cranesupplier Terex Fuchs.

Blue Group has a strong presencein the growing waste processingbusiness and is now expanding intometals recycling (scrap handlers) andport applications. It has taken overthe Terex Fuchs line from the HydrexGroup. Hydrex was Fuchs’ dealersince 1999 and helped build the UKand Ireland markets into importantoutlets for the products.

Hydrex Equipment (UK) Ltdwent into administration last autumn,although its rail division was ac-quired from the receiver by NetworkRail Infrastructure Ltd.

Blue Group has taken overHydrex’s staff and Bristol premisesand continues to operate Hydrex’sPortishead office as the base for thenew dealership.�

Terex singsthe Blues

you push, say, coal or sand from thetop, remarks Reardon, it moves side-ways, but some biomass productswill simply compact and can doubletheir density.

Depending on their viscosity, thebest solution may be an orange peelgrab, but you still have to determinethe optimum size. Similarly, the dustnuisance and combustibility valuesvary according to the composition ofthe biomass. This again affects thechoice of grab as well as handlingand storage aspects.

Legal-for-trade weighingThe bulk centre will also be able toprovide help and advice with the le-gal-for-trade bulk weighing systemintroduced by Gottwald last year.

This system in itself underscoresDemag Cranes’ commitment to thebulk market. It is presently availablefor Gottwald Model 8 cranes but willbe made available for all Gottwald4-rope grab cranes in the month tocome. As previously reported, it isbased on bi-axial measuring of theforces in the rope pulleys at the boomtip in two perpendicular directions.The load elements and sensors aremounted in the boom tip.

UK-based DBIS, acquired lastyear by Demag Cranes throughGottwald affiliate TBA Nederland,is another key element of the bulkoffer, with its leading-edge softwareproducts for bulk terminals.

DBIS works independently of thebulk centre, but they can work to-gether if it suits the client. Tradition-ally, bulk terminals carry out stockmanagement with visual site surveys,weighbridges and other weighingsystems, but this does not provide thelevel of accuracy and traceability thatshippers now require. DBIS’sCommTrac bulk terminal manage-ment system has become a productof choice for operators around theworld.

Last October, Peel Ports an-nounced that it had selected DBIS tocarry out a major upgrade of the au-tomation and management systemsat the Liverpool agri-bulk terminal.This operates a 1800 tph SiwertellCSU and five MHCs, and has >0.5Mft2 of animal feed/biomass storage.

The traceability and QA require-ments at Liverpool are “intrinsic”within CommTrac. The upgrade willalso include new features, such as au-tomatic accrual of storage and han-dling charges, vessel dischargeoptimisation and the ability to pro-

Gottwald G HSK 8216 Bs at KinderMorgan’s coal transhipment andstocking terminal in Charleston,South Carolina

vide real-time KPI reports on opera-tional and commercial processes.

Brazilian firstAt the beginning of this year, Demagcommissioned its first Generation 5portal harbour crane in LatinAmerica. The G HSK 4316 B, a vari-ant of Model 4, is being used to han-dle fertilisers and construction ma-terial for Fospar S.A. FertilizantesFosfatados do Paraná (Fospar) at itsterminal in the Brazilian port ofParanagua.

The crane is based on the manu-facturer’s mobile harbour crane tech-nology and is adapted to run on rails.The compact construction, a rela-

tively low overall weight and the in-dividual portal configuration of theG HSK 4316 B make it the idealchoice for the finger pier at Fospar’sterminal at Paranagua, says Demag.Included with the delivery of the craneare two grabs tailored to handling fer-tilisers and construction materials.

As part of Gottwald’s medium-sized Generation 5 crane family,the G HSK 4316 B is characterisedby its compact and functional con-struction. �

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13_BMI_Mar_Apr_2012.indd 1 15/05/2012 12:23:10

BMI March/April 201214

Cargo Handling

Roll out the rubber carpetEssentially, a conveyor system

comprises two basic ele-ments, the belting and the

structural system which supports it.This latter system comprises a large

number of elements such as rollers,idlers and drive motors, all of whichare liable to failure and require rou-tine inspection and maintenance. Theindividual elements which make upthe drive and support structure are notcrucial to the overall operation of theconveyor and components such asrollers are relatively easy to

Advances made in belt design and manufacture havegreatly reduced overall conveyor life-cycle costsreplace.The conveyor belt, however,is a single component and its failurewill lead to a system shutdown.

Moreover, while the support struc-ture can be reinforced in areas ofhigher stress loading, such as at trans-fer points or under a hopper, the beltmust be capable of absorbing the high-est loading along its complete length.

It is possible to limit the impact of

sudden loading on a belt through thefitting of dedicated support systems.The Continental Impact Bed, for in-stance, is designed to extend belt lifeand reduce downtime by supportingthe conveyor belt and cushioning itagainst the shock of heavy loads andimpact. Its modular design allowsmultiple units to be closely fitted toform the bed length needed while an

optional impact centre roll can also bespecified.

Hot or coldIf a tear is formed, which can quicklydevelop into a rip, not only will thesystem have to be shut down to cutout the damaged section to splice in anew section, but the commodity on thebelt will have to be removed to allowthis repair and to re-tension the belt.

There are two methods used, bothfor steel cord and textile fabric belts.Hot splicing relies on heat and pres-sure, while a cold splice relies onpressure to force air from the centreout and then it is impacted with rub-ber mallets. The repaired section is

then left on the splicing board to curefor about four hours on overlandconveyors, and about two hours onsmall conveyors.

The longer the splice, the strongerthe contact area of bond, although itmight take longer to cure before re-suming operations.

Energy savingIn addition to being crucial to the con-veyor, the belt also contributes signifi-cantly to energy losses, although it isstill the single most effective meansof moving large quantities of bulkmaterials.

In the study Energy efficiency inconveyor technology and climate pro-tection carried out by the ClausthalUniversity of Technology, it was notedthat a continuous transportation equip-ment, such as conveyor belt systemsachieves a better total mass moved topayload ratio of 1.2:1 compared to thebest alternative means.

This affects the specific energy re-quirement. According to the study, abelt system needs some 0.14 to 0.25kWh per ton-kilometre (t-km). Thiscorresponds to a fifth of the energyrequirement of heavy duty trucks andhas a considerable effect on the levelof CO2 emissions. Operating a con-veyor belt emits some 55g of CO2 t-km, giving a reduction potential of276g t-km.

Rolling alongIn the contact surface between theconveyor belt and each individualidler, a force acting in the oppositedirection to the movement of the con-veyor belt is generated, resulting inadditional energy consumption. Inaddition to a series of further factors,the rolling resistance depends on thetechnological properties of the con-veyor belt and, more specifically, thematerial it is made of.

“The rubber compound plays a cru-cial role in the search for ideal mate-rial characteristics,” explains WilhelmSchrand, head of research and devel-opment, ContiTech Conveyor BeltGroup. The many different ingredientsand combination ratios result in infi-nite possibilities here.

Using complex simulations,ContiTech scientists adjusted the de-formation of the conveyor belts overthe idlers and derived hypotheses fromthis on how to provide the ideal rub-ber compound. On this basis, differ-ent compounds were mixed, tested andoptimised, and the most promisingcompounds were turned into conveyorbelts in order to try them out and findthe ideal solution.

The latest measurements, takenwith special measuring devices on atest rig at the University of Hanover’sInstitute for Transport and AutomationTechnology, showed significant re-duction in rolling resistance with thenewest energy-optimised conveyorbelts from ContiTech. This resulted inan energy-saving potential of about20%. A 5km long conveyor belt sys-tem, for example, could save morethan 3,000 kW.

Resistance to rubberFirestone has also undertaken com-plex studies into energy savings, re-sulting in the development of its ownbelting material, which it claims canreduce energy requirements by up to40%. Its designers calculated that ap-proximately 60% of a standard con-veyor power demand was caused bythe roll-over resistance when the beltpassed over a roller, while a further10% is due to the belt deflection (sag)between the rollers. The specificationof the rubber used for the outer cas-ing is crucial in reducing the energyrequirement of its design. �

14_BMI_Mar_Apr_2012.indd 1 15/05/2012 12:27:39

BMI March/April 2012 15

Cargo Handling

Engine advances drive front loaders forwardVolvo Construction has been

steadily upgrading its frontloader product range with

the introduction of the G-series, allpowered by Tier 4 Interim/Stage IIIBdiesel engines.

At the lower end of the range, thenew compact L45G and L50G wheelloaders feature the latest emissions-compliant engines and Volvo pat-ented TP Linkage, ensuring highbreakout force and parallel move-ment throughout the entire liftingrange. This combination gives hightilt-back torque and lifting power,increasing productivity when load-ing or rehandling, while the progres-sive lift helps retain loose bucketmaterial and minimises disturbingthe load when lifting pallets.

The breakout torque is also use-ful if a log grapple is fitted, givingtotal control of the load in all posi-tions. The combination of stable loadand high-reach of the linkage designallows dumping into high-sidedtrucks.

These new machines meet the re-quirements of the Stage IIIB and Tier4i emissions legislation, being fittedwith Volvo’s 4l, four-cylinderturbocharged off-highway diesel en-gine which features cooled gasrecirculation and a particulate filterwith active regeneration. The active-type diesel particulate filter (DPF)temporarily holds the particulatematter and then incinerates it, furtherreducing emissions.

This process is conducted with-out any loss of performance duringoperation. The engine cooling fan al-lows the engine to reach optimumworking temperature faster, operat-ing only when needed. This requiresless power to operate, uses less fueland reduces the noise of the machine.The fan is also reversible, automati-cally blowing air back through thecooling pack in order to remove de-bris drawn into the radiator.

Infinite choiceBoth the L45G and L50G come withan infinitely variable hydrostatictransmission available in both Highand Low Speed variants dependingon application. Maximum rim pullon the bucket is available at allspeeds, regardless of the direction oftravel.

For working in wet and/or heavyconditions, 100% differential locksin the heavy-duty axles allow allwheels to turn simultaneously. Therear axle is allowed to oscillate, in-creasing stability of the machine bymaintaining ground contact and pro-viding optimum traction in difficultterrain.

Load-sensing hydraulics deliverpower to hydraulic functions onlywhen needed, eliminating unneces-sary oil pumping. Maintaining theoptimum balance between lifting andtractive forces allows effectivebucket penetration when digging orpushing into a pile. The smooth andprecise pilot-operated hydraulics,meanwhile, enable the operator tocomfortably control the attachment,resulting in higher productivity andcomfort.

Joy of leversDepending on preference, operatorscan choose between joystick andmulti-lever hydraulic pilot control –both providing precise and steadyload control. To encourage operatorsto work smoothly, an ‘eco’ accelera-tor pedal applies an appropriateamount of mechanical back-pres-

Increasing emission control can entail extensive enginebay modifications, allowing front loader manufacturersto further enhance their product rangessure, encouraging low fuel consump-tion operating techniques. Fuel useis also reduced, thanks to a load-sens-ing steering system that only acti-vates when the wheel is turned. Aninch brake pedal allows further ma-chine control. Applying light pres-sure on the pedal slows the machineusing the hydraulic transmission

only, while firmer pressure engagesthe axle brakes to assist operationsif working on an incline.

Monitoring performanceThe G-Series incorporates advancedelectronic monitoring diagnostics de-signed to prolong machine life, en-hance uptime and maximise produc-

tivity. Contronics monitors functionsin real time and alerts the operator ifproblems occur. MATRIS, mean-while, charts and analyses data onmachine handling and operation.VCADS Pro is a system that allowsa machine to be fine-tuned to spe-cific applications, further improvingperformance. Finally, the optionalCareTrack system is a Volvo Con-struction Equipment telematics so-lution, which allows machine lo-cation and operating data to be se-curely viewed via the Internet.

Servicing is made easy with the G-Series, with daily pre-start itemsquickly checked and scheduledservice items convenientlygrouped together.

The engine cover also providesgood ventilation of the engine com-partment. It gives good access forfast and easy cleaning or servicingduties, while consumables such asfilters are easy to reach and replace.The rear axles are supported onmaintenance-free cradles and includegreased-for-life bearings and bush-

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15_BMI_Mar_Apr_2012.indd 1 15/05/2012 12:32:55

BMI March/April 201216

Cargo Handling

ings that reduce service re-quirements.

Big brotherAt the other end of the wheelloader product line, the newVolvo L180G features a 13lTier IIIB-compliant 333hp en-gine, optishift transmissionand axles all designed andmanufactured by Volvo. It of-fers a full turn tipping load of17.2t, a 20% increase in lift-ing force and 10% increase inbreakout force over its pred-ecessor.

This, coupled to the engineoutput with high torque at lowengine rpm, has resulted infaster cycle times and in-creased productivity.

Two stronger, variable dis-placement load-bearing axialpiston pumps and hoses havebeen introduced to handle theincreased pressures. Theseprovide superior control of theload and attachments, as wellas high breakout force, fasterlifting and tilt functions. Anew hydraulic cooling systemhas been designed to reducethe working temperatures by upto 20oC over the F series model.

JCB breaks outFollowing the launch of itsflagship 457 wheel loader ear-lier this year, JCB has nowupgraded its mid-range de-signs with the introduction ofnew 427 and 437 models.Both new models are poweredby a 6.7 litre Cummins QSBengine, which is Stage IIIB(Tier 4 Interim) compliantwithout using a dieselparticulate filter or selectivecatalytic reduction.

As well as the variable ge-ometry turbocharger, theCummins engine incorporatesa high-pressure common railfuel injection system, exhaustgas recirculation and a dieseloxidation catalyst.

The JCB 437 delivers129kW, equivalent to the out-going 436 model but with sig-nificant fuel savings. The JCB427 also offers reduced fuelconsumption with power of118kW (158hp), as well as a9.4% increase in torque, tak-ing it to 801Nm.

Both machines achievehigh power outputs with lowemissions without the need ofany supplementary additivesor a DPF. The machines alsofeature a low idle speed andan engine shutdown mode,which activates after a pre-de-termined period to save fuel.

A ZF four-speed automaticpower shift transmissioncomes as standard, with a newoptional five-speed powershift box also available. Alock-up torque converter onthe five-speed transmissionactivates in second through tofifth gear, reducing lossesfrom the transmission and in-creasing productivity.

Clever clutchingAn intelligent clutch cut-offsystem is incorporated as stand-ard, for both the 4-speed and5-speed transmissions whichdynamically adjusts the clutchcut-off point depending ontransmission output torque andbrake pressure. It effectivelydisengages the clutch to limittractive effort, and also reducesbrake wear on the ZF axles.

When the operator pressesthe brake pedal, maximumpower is provided to the loadsensing hydraulic system,while reducing power to thedriveline. This providesgreater control at higher en-gine rpm and lower travelspeeds, boosting productivitywhen loading.

The new ZF automatic dif-ferential lock axle option al-lows the choice of a standard

open differential, limited slipdifferential, or an automaticdifferential lock on the frontaxle only.

The automatic option locksthe differential when required,without the operator needingto activate the system, provid-ing increased traction and lessslippage. The new axles alsobenefit from wheel speedbraking, lengthened serviceintervals to 1,500h and in-creased service life in heavyduty applications with the op-tion of sintered pads.

Moving upThe introduction of its new457 model earlier in the yearhas seen JCB move up a classin the wheeled loader market.Replacing the earlier 456, thenew 457 is the biggest and mostpowerful wheeled loader thefirm has ever built with a 235kg

increase in load capacity of theprevious range 6300kg.

The 457 is powered by thenew 8.9l Cummins diesel,equipped with variable geom-etry turbocharger, to meet Tier4 Interim/Stage IIIB emis-sions requirements. Full elec-tronic control of engine func-tions is incorporated, whilethe ZF WG210 transmissionis available in the standardfour speed or optional fivespeed version, both of whichfeature intelligent clutch cut-out functions.

Torque proportional trac-tion and an automatic differ-ential lock ensure good trac-tion in rough terrain. The in-tegrated JCB Livelink systemprovides real-time data onhow the machine is being usedsuch as cycles, performance,distance travelled and engineoil and hydraulic fluid tem-peratures and pressures.

Case studyEarlier this year, Case Con-struction Equipment intro-duced the new 621F wheelloader model which providesup to a 10% increase in fueleconomy over the previousmodel, while delivering fasteracceleration, quicker cycletimes and higher travel speeds.

The new Case 621F wheelloader, like other models in theproduct line, evolved from thecompany’s E Series machines.To meet Tier 4 Interim emis-sions standards, the Case FSeries wheel loaders use se-

lective catalytic reduction(SCR) technology, which re-sults in lower temperatures inthe exhaust system whileoptimising combustion.

The Case 621F wheelloader features a 6.7l Tier 4Interim-certified engine thatdelivers up to 121 kW. Clas-sified as a 2.1 m3 wheel loader,the Case 621F has an operat-ing weight of 12 084 kg.

“The Case 621F wheelloader delivers the best fueleconomy and performance inits class size,” claims TimO’Brien, brand marketingmanager, Case ConstructionEquipment.

“Like other F Series mod-els, the 621F offers four pro-grammable power modes tosave fuel and increase avail-able power. These easy-to-program power modes –Economy, Standard, Max andAuto – give operators flexibil-ity in matching engine powerto their jobs.”

A new dual-mode shut-down feature maximises fueleconomy and monitors vitalengine components. Using thefuel-saver mode, the operatorcan limit the time the machinewill idle. The desired shut-down time can be set in five-minute increments.

“The automatic engineshutdown feature can provideup to another 30% percent infuel savings,” O’Brien said.

Sure footedThe new Case wheel loadersinclude standard limited-slipfront and rear axles that pro-vide optimum traction in allconditions, especially in non-compacted surfaces, such asgravel. Optional heavy-dutyaxles with locking front andconventional rear differentialshelp reduce tyre wear whenworking on hard surfaces. Thestandard four-speed transmis-sion with manual kick-downcapability provides maximumtraction and increased bucketpenetration.

“The Case 621F wheelloader can perform in a widerange of applications, fromconstruction sites to aggregateoperations,” O’Brien said.

“We also offer a Commod-ity King option package thattakes advantage of our uniquemid-mounted cooling module.”

The Commodity Kingpackage provides special

Spending spree slowsThere is some concern thatas China’s economy slows,the commodity boom and thecapital investment requiredto fuel it, will be hit.

Both Rio Tinto and BHPBilliton have announcedplans to ‘re-evaluate’ newdevelopment projects and in-stead prioritise on profitableoperations and balance in-vestment with cash flows.The two conglomerates ac-count for around of a thirdof capital investment in thissector, which is anticipatedto rise only some 13% thisyear compared to 34% lastyear, while the outlook for2013 is expected to fall again.

This will have a signifi-

cant ‘trickle-down’ effect onequipment suppliers, whichhave until now enjoyed aboom in orders and highprice levels. Caterpillar’s or-der books for some of itsequipment range is full until2014, although some opera-tors may seek to delay or re-negotiate deliveries.

Sectors such as the frontloader market could be hit asoperators postpone new or-ders and extend the life oftheir existing fleet. However,this can only be for a limitedperiod as emission regula-tions will eventually requireoperators to comply with themore stringent standards andupgrade their machines.�

Volvo is progressively upgrading its wheel loader productrange from the F to the G-series to incorporate the latestStage 3B/Tier 4 engines. These offer lower fuel consumptionthan previous comparable models

cooling and air filtration com-ponents for working in cementplants, agriculture and otherapplications where the ma-chine operates in extremelydusty or particulate-laden en-vironments.

The Case joystick steeringenables operators to move be-tween the joystick and steer-ing wheel for high-productionoperations. An optional two-lever hydraulic control systemis available. The CasePowerInch feature lets theoperator quickly and preciselyapproach targets in tight areas,regardless of engine speed.PowerInch maintains highRPMs to maximis

e hydraulic power and con-trol. A new rearview, wide-angle camera with an adjust-able colour monitor is avail-able in the Case F Series. Thecamera option nearly elimi-nates blind spots and is idealfor jobs that require operatingaround other machines orworkers, the company says.

“A machine with excellentvisibility to all corners of thevehicle improves everyone’ssafety on a busy jobsite,” saidO’Brien.

“The Case F Series wheelloaders offer best-in-class rearvisibility and a panoramicview to the front and sides forenhanced operator confidenceand productivity.”

The Case 621F wheel load-ers includes an advanced in-strument cluster that monitorsfuel consumption and enablesthe operator to adjust variousfunctions without relying ona service technician. All CaseF Series models also offer er-gonomically placed controls.

Attached valueCase offers a range of attach-ments for the 621F wheelloader, including pallet forks,brooms, jib booms, bucketsand weigh-load systems. It isalso available with JRB- andACS-compatible couplers.Case F Series buckets areavailable with standard CaseSmartFit bucket teeth or bolt-on edges. The SmartFit sys-tem provides stronger, moredurable teeth and adapters,and hammerless, reusablelocking pins, says Case. TheSmartFit line-up includes gen-eral purpose, rock chisel,heavy penetrator, tiger, twintiger and flare teeth. �

JCB has had a busy year to date, with the launch of its flagship457 wheel loader and upgrade of its mid-range designs

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16_BMI_Mar_Apr_2012.indd 1 15/05/2012 12:42:04

BMI March/April 2012 17

Sampling & Inspection

M&A activity primes inspection and testingmarket for growthSGS has acquired Metlab

(Pty) Ltd., Boksburg,the metallurgical test-

ing laboratory in SouthernAfrica.

With a network of over1,350 offices and laboratoriesaround the world, SGS offersa wide range of services to theminerals sector includinggeochemical analysis, re-source calculation, mineral-ogy, metallurgy, advancedsystems, water treatment, en-ergy and fertiliser mineralstesting and trade services.

Metlab provides a range ofdestructive and non-destruc-tive metallurgical testing andis renowned for its replication,hardness and chemical testtechnicians, as well as its abil-ity to conduct specialised test-ing on client sites. It serves theheavy engineering, power en-gineering, testing & inspec-tion, heat transfer, piping andtubing, steel mill and steel fab-rication industries.

“Metlab is an exception-ally well-run business and thisacquisition will solidify SGS’metallurgical laboratory test-ing footprint globally and pro-vide access to key South Af-rican industrial accounts,”said Chris Kirk, CEO of SGS.

“This acquisition supportsSGS’ growth in the destructiveand non-destructive testingSouthern African markets.”

MSPU launchesSGS has also announced theopening of its new MobileSample Preparation Unit(MSPU) in Ouagadougou,Burkina Faso.

“The MSPU expands ourrock and drillcore samplepreparation capacity inBurkina Faso, ahead of ourmajor new laboratory com-plex being built inOuagadougou,” SGS said.

The MSPU will immedi-ately add an additional 600samples/day capacity. Cou-pled with this increase in sam-ple preparation capacity hasbeen a 60% increase in fireassay capacity at the SGSOuagadougou laboratorywith a retooling of the fireassay lab.

The new unit is the latestaddition to its strategically lo-cated fleet of MSPU unitsin four continents, whichmake use of industry standardequipment and employ stafftrained using SGS globalmethod protocols. SGS bringsover 30 years of on-site andcommercial laboratory expe-rience to the design of its mo-bile laboratories.

SGS says that its mobilelaboratory services offers cli-ents competitive advantagesincluding fast turnaround, ac-curate geochemical and/or as-say data, customised samplepreparation protocol and re-duced shipping delays andcosts.

Oyu Tolgoi contractAt the end of 2011 SGS was

total of 29 testing and samplepreparation laboratories in 12countries, mainly in North andSouth America.

AcmeLabs uses cutting-edge technologies such as In-ductively Coupled Plasma(ICP), ICP-Mass Spect-rometry (ICP-MS) and X-RayFluorescence (XRF).

Bureau Veritas andAcmeLabs have highly com-plementary activities and lo-cations in services related tometals and minerals. BureauVeritas says that this acquisi-tion enables it to create a min-erals centre of expertise in

awarded the operational con-tract for the on-site laboratoryat the Oyu Tolgoi mine in theSouthern Gobi Region ofMongolia.

Oyu Tolgoi is the world’slargest undeveloped copper-gold project and is located inthe South Gobi region ofMongolia, approximately 550km south of the capital,Ulaanbaatar, and 80 km northof the Mongolia-China border.

Operation at the on-sitelaboratory is expected to be-gin on 1 June 2012 and the fa-cility is scheduled to operate24 hours a day, 7 days a week.Its scope of operations will in-clude rapid grade control,process plant, final concen-trate and environmentaldeterminations.

SGS currently runs an on-site sample preparation labo-ratory for the Oyu Tolgoi ex-ploration team at the OyuTolgoi site. Samples are pre-pared at the exploration siteand shipped to SGS’ nearbycommercial laboratory inUlaanbaatar for all requiredanalyses.

New facilityThe new on-site facility willemploy more than 50 staff andmany are currently beingtrained at SGS’ local labora-tory in Ulaanbaatar. TheUlaanbaatar facility is a fullyequipped commercial facilitywith fire assay, ICP, XRF,fluorine, chlorine, sulfur, car-bon and classical wet chemis-try capability as well as a fullscope of testing for coal andconforms to the requirementsof ISO/IEC 17025 for specificregistered tests.

A metallurgical laboratoryis also being commissioned bySGS in Mongolia to servicethe Oyu Tolgoi mine. The OyuTolgoi on-site laboratory com-plements SGS Minerals Serv-ices’ existing facility inUlaanbaatar and further ex-pands our broad network ofcommercial labs around theworld.

Stronger positionBureau Veritas has acquiredAcmeLabs, the third largestplayer in upstream mineralstesting in Canada.

With this acquisition, Bu-reau Veritas says that it nowhas a stronger business posi-tion in Canada, a market of-fering high growth potential,and has expanded its globalposition in Metals & Miner-als (M&M) with a full pres-ence in key global mininghubs in Australia, Canada andSouth Africa.

Founded in 1971 andheadquartered in Vancouver,Canada, AcmeLabs providessampling preparation, assay-ing and geo-analytical serv-ices. The company operates a

Canada, one of the largest pro-ducing countries, and to en-hance Bureau Veritas’ miner-als footprint in SouthAmerica.

In addition, synergies areexpected from improved op-erating efficiency, notablythrough network opti-misation and the leverage ofthe ‘hub & spoke’ operationsmodel of AcmeLabs, andthrough the development ofboth Bureau Veritas andAcmeLabs’s key accountswith its combined networksand capabilities.

UK investmentAt the end of 2011, interna-tional inspection and analysisspecialist Stewart Group an-nounced that it had made a‘significant investment’ at itsUK laboratory.

The company, which wasacquired by global minerals

experts, ALS Group lastyear, extended its facility inLiverpool, England and in-vested in new state of the arttechnology.

It invested almost£200,000 in the PANalyticalAxios max-wavelength dis-persive Spectrometer, whichwill supplement its laboratoryinstrumentation to provide re-liable, accurate and fast analy-sis of metals and minerals,ensuring its quality of report-ing is as advanced as the mar-ket demands.

The investment includesan upgrade in Omniniumplus software improving ac-curate semi-quantitativeanalysis.

This technology boost ena-bles Stewart Groupto continue to offer clients ac-curate analysis and rapidturnaround times, it said. Theentire procedure is dedicated

towards delivering to clientswith pressing deadlines andexceeding expectations.

“We are one of the fore-most umpire and partyanalysis laboratories in theworld,” said Chris Walker,group general manager ofStewart Group Inspection &Analysis.

“This investment in tech-nology reaffirms our dedica-tion to expansion and devel-opment. Our network of pro-gressive laboratories will con-tinue to develop and invest inadvanced technology.

“We will also be offeringadvanced training to our staff,to ensure they remain expertsin the field of inspection andanalysis.”

Stewart Group operatesfrom 26 laboratories and of-fices throughout NorthAmerica, Africa, Asia andEurope. �

A spate of recent merger and acquisitionactivity in the inspection and testing markethas increased optimism in the sector

If you need MORE growth or want to generate LEAN efficiencies, contact SGS. Daily, the SGS global team delivers technical expertise, effective services and sustainable solutions that can enhance your project.

SGS IS THE WORLD’S LEADING INSPECTION, VERIFICATION, TESTING AND CERTIFICATION COMPANY

MINERALS@SGS.COM WWW.SGS.COM/MINING

17_BMI_Mar_Apr_2012.indd 1 15/05/2012 12:44:57

BMI March/April 201218

Commodity Focus

India is poised to surpassChina as the world’s big-gest thermal coal importer

as i t seeks supplies forpower producers that havehalted plans for US$36B ofnew plants because of fuelshortages.

India’s imports may ex-ceed 118 mt this year, com-pared with China’s 102 mt,said Daniel Hynes, director ofcommodity research atCitigroup in Sydney.

India imported 81.1 mt ofthermal coal in 2011. Its im-ports may rise after the gov-ernment ordered state-runCoal India to plug a localshortfall with foreign supplies,according to analysts atSanford C Bernstein & Co.

India’s US$1.7T economygrew at the slowest pace intwo years from July to Sep-tember as power and factoryoutput slowed.

“Coal shipments to Chinawill be diverted to India,” saidMichael Parker, a HongKong-based analyst atBernstein.

In China, power consump-tion growth rates will continueto decline and coal productionand transport capacity growthare rapidly improving, he said.

The deficit between demandand supply of domestic coal inIndia may rise as high as 150mt by 2014 if the country failsto increase local supplies by 6%this year, said Hynes.

The nation is seeking toimprove infrastructure toachieve average economicgrowth rate of 9% over thenext five years.

Thermal coal imports byChina will drop this year byabout 40 mt, an amount thatmay be bought by India in-stead, Parker said.

Chinese demandChina’s purchases rose 17% toabout 138 mt last year, exclud-ing coking coal used to makesteel.

China will add 200mt ofcoal-production capacity thisyear, twice as much as in2011, according to the Na-tional Energy Administration.

Power consumption in-creased 12% last year and mayincrease 8.5% this year, theofficial Xinhua News Agencyreported.

China’s coal output in-creased 11% in 2011 and maygrow 6.6% this year,Bernstein said.

Komi coalElsewhere, the Komi Repub-lic, Russia’s autonomous re-gion at the western edge of thePolar Ural mountain range, islooking to almost double itsannual coal output from 13mtpa to 23 mtpa by 2020.

Russian steelmakersNovolipetsk Steel (NLMK)and Severstal have beengranted licences to exploit al-lotments of the Usa coalfieldin transpolar Komi. BothNLMK and Severstal, throughits Vorkutaugol coal miningarm, are planning to build newintegrated works to annuallymine and process 4.5 mt and4 mt of coal respectively.

Moscow-based System-group, whose mining assets

are concentrated mainly ineastern Siberia (Yakutia), willupgrade Intaugol, the Komi-based miner it acquired latelast year, to increase its annualcoal output by 1.5 mt.

According to YevgeniyShumeiko, a member of theState Council of Komi, therepublic is the site of Russia’slargest coalfields. Total re-serves of the Usa and Seidadeposits are estimated at 4 btof coking coal and 7 bt ofsteam coal respectively.

But Shumeiko has voicedconcerns that the full poten-tial of the coalfields may notbe realised unless the poortransport infrastructure in theregion is developed. There isjust one rail line that connectsInta and Vorkuta with the restof the Russian territory and sowill be incapable of dealingwith a growth in freight.

It is expected that the en-dorsement of the mining pro-gramme will encourage theconstruction of a rail link inRussia’s north-western re-gions and specifically the re-vival of the long shelvedBelkomur project aimed tolink the northern Ural region(including Komi) with theWhite Sea harbours.

Belkomur InterregionalCompany director generalElman Khudazarov said thatthe US$5.2B rail line could bein operation by 2017.

In January this year, Rus-sian premier Vladimir Putinendorsed the US$125B pro-gramme for developing thenation’s coal sector by 2030.In view of the growing globaland domestic demand for coal,Putin placed special emphasison the necessity to tap newRussian sources.

Ukraine’s reformReformation of the coal sec-tor is a priority in Ukraine,where the energy and coalministry is mulling over theprivatisation of some 120

state-run coal mines this year.According to deputy en-

ergy and coal minister IgorPopovych, the country’s cabi-net will soon release a list ofthe collieries subject to dena-tionalisation.

Earlier, the Ukrainian gov-ernment determined that pri-vatisation of its coal mineswas an important part in thereformation of the coal sectorand said that it planned to at-tract around US$457M of di-rect investment into the indus-try this year.

The full-scale privatisa-tion of Ukrainian mines isscheduled to finish by 2015under the nation’s energystrategy.

“We will follow the exam-ple of the 1990s Russia, whichprivatised its entire coal indus-try,” says Yuriy Korolchuk, anexpert with the Ukrainian In-stitute of Energy Research.

Half of the Ukrainian coalsector is already in privatehands, he said.

According to Korolchuk,last year - for the first time intheir history - state-run collier-ies fell behind the productionvolumes of privately-heldmines, contributing just 47%to the country’s overall annualoutput.

Currently some 30 mines,or just 18% of their totalnumber, account for 50% ofthe total domestic coal pro-duction and so form the coreof Ukraine’s coal sector, saidOleksiy Stogniy, the head ofthe forecasting department atthe Energy Industry Instituteof Ukraine’s National Acad-emy of Sciences. One third ofUkrainian mines are unprof-itable, he said.

Ukraine has the world’sseven largest commercial coalreserves estimated at around6 bt as of 2011. The coal sec-tor’s aggregate mining capac-ity is 90 mtpa, including 55 mtof steaming coal and 35 mt ofcoking coal. �

India’s coal imports set to surpass China’sInfrastructure improvements and mineprivatisations have been announced as countriesseek to capitalise from steady demand for coal

Hua Yang Electric Company,a subsidiary of ChinaShenhua Energy, has ordereda circular storage facilityfrom Schade Lagertechnik.This latest circular storagecontract is the seventh whichSchade will deliver to HuaYang.

The facility will beerected in Xiamen provinceby the end of 2012, and trialoperation is scheduled forMay 2013.

The storage unit has a di-ameter of 120m and can store4400t of coal per hour andreclaiming capacity is set at2000t/ hour.

Schade is also to supplya circular storage facility of100m in diameter. The unitwill be supplied to JiahuaChemicals, near Shanghai.The circular storage is de-signed for a storage capacityof 900t of coal per hour; thereclaim capacity is 600t/hr.

Schade Lagertechnik suppliesnew coal storage unit to China

Circular storage facilitiesoffer a combination of lowspace requirement and highstorage volume and are avail-able in various configura-tions employing a combina-tion of stacker, slewing, cir-cular or portal scraper.

Storage of the material isperformed based on the coneforming process, the scrapersare equipped with a doublestrand chain and wear-pro-tected buckets. The simulta-neously enabled stacking andreclaiming processes areSPS-controlled.

Stricter environmentalprotection regulations havesignificantly increased thedemand for enclosed storagefacilities. The first circularstorage facility with com-bined stacker/scraper was de-signed and built in 1988 inorder to store 95,000m3 ofcoal on a stockyard measur-ing 97m in diameter. �

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J Infrastructure needed to develop South Africa’s natural gas potential

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J Water management & drilling experiences in CBM operations – What can be learnt from Australia?

J Workforce challenges and planning

J Why UCG? – Its potential in Southern Africa

J End users perspective of CBM

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Paul Tromp, Exploration Director, Badimo Gas

Andy Lambert, Managing Director, Kinetiko Energy Ltd

Ian Tchacos, Chairman, Instinct Energy Limited

Andrew Elf, General Manager – Drilling Services, Mitchell Drilling Services

Michel Thuysbaert, Managing Director, Cobramar Ltd

Dr. Lin Tu, Executive Director, Clean Coal Technology South Africa

Prof Philip Lloyd, Energy Institute, Cape Peninsula University of Technology

Alan Golding, Director, Analytika Holdings

Prof Danie Vermeulen, Director of the Institute for Groundwater Studies, University of the Free State (UFS)

Conrad Kahts, Managing Director, Aqua Alpha

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