Commodity:  Fertiliser;  Contract Type  EPCM

DemcoTECH supplied a mobile ship offloading and warehouse distribution system for Grindrod Terminal’s  fertiliser storage facility at Maydon Wharf 13 in Durban, South Africa. The system comprises four mobile tyre-mounted conveyors positioned on the jetty at locations to suit ship docking requirements.  Once the ships have been offloaded, the conveyors convey the fertiliser to a central pivoting and retractable boom conveyor, straddling the quayside. Read more …

Commodity: Coal, Phosphate Rock and other; Contract Type: EPCM

Appointed by Grindrod as an EPCM contractor, DemcoTECH was responsible for the materials handling portion (excluding the civils and earthworks) of the expansion to Grindrod’s multi product terminal at Richards Bay in South Africa. The scope of the contract covered providing the materials handling to convey various materials, but mainly rock phosphate and coal, from the three Richards Bay terminal sites: Navitrade, Kusasa and Valley. Read more …

Commodity: Iron Ore; Contract Type: Turnkey

DemcoTECH completed an upgrade to Kumba Resources iron ore sampling plant at the Saldanha iron ore terminal, converting it from a mass to a time based system, which reduces bias in the selection of material sizes for sampling purposes. The upgrade covered the installation of new conveyors to feed the sampling plant, the addition of load cells into the weigh hopper for more accurate readings and the introduction of a two way splitter. Read more …

Commodity: Manganese Ore; Contract Type: Turnkey

DemcoTECH was contracted, with Kantey & Templer Consulting Engineers, for the expansion to the manganese export facility at Assmang Limited’s Cato Ridge Alloys plant in KwaZulu Natal. The expansion consisted of upgrading two existing rail tipplers, installing a series of troughed conveyors with transfer houses, from the tipplers to a new 80,000 ton stockpile, an elevated travelling tripper, tunnel reclaim equipment and a road load-out facility.  Read more …

Commodity: Limestone; Contract Type: Design, Engineering and Supply, Erection and Commissioning

DemcoTECH delivered a feed and discharge materials handling system for the Loesche Mill Plant at Idwala Carbonates in KwaZulu-Natal, South Africa. As a brownfields project, it presented a number of difficulties associated with designing and erecting the systems around the existing plant without interrupting plant operations. In particular, integrating the new plant with the existing plant resulted in challenging design and plant interface issues. Read more …

Commodity: Clinker; Contract Type: Lumpsum Turnkey

DemcoTECH, working in joint venture, established a 50,000 t clinker silo feed and discharge system at NPC Cimpor’s Simuma Plant in KwaZulu-Natal, South Africa. Designed to handle hot clinker up to 100 ºC, the silo features a clinker system that can be diverted to service the existing or new silo. The project covered a silo feed Aumund pan conveyor and two DemcoTECH-designed reclaim belt conveyors, to feed either the existing plant or rail loading system. Read more …

Commodity: Iron Ore; Contract Type:  Turnkey, including installing tripper during plant shutdown

The DRS Optimisation Project had the objective of assisting in achieving an annual production of 12 Mtpa from Kumba Resources’ Sishen Iron Ore Mine by optimising the performance of the DR/DRS downstream handling facilities. The project covered project initiation through to handover of the 4,250 tph redesigned tripper car, which operates at a speed of 0.25 m/s, feeding a 2.25 m/s conveyor. DemcoTECH also provided a new belt for the system. Read more …

Commodity: Ilmenite (FeTiO₃); Contract Type: Detailed Design followed by LSTK Project Execution

A project to provide a belt filter and cooling system for the processing facility at the Tronox Namakwa Sands heavy minerals mine near Brand-se-Baai in South Africa, was carried out in two phases: the detailed design comprised a six month contract, followed by the award of a fast track lump sum turnkey (LSTK) execution contract. The cooling system was installed to increase the separation efficiency of the WHIMS, as magnetic separation is highly temperature sensitive. Read more …

Commodity: Fly Ash; Contract Type: Design, Supply, Erect & Commission

DemcoTECH supplied a fly ash silo incorporating an ash feed and discharge system for NPC in KwaZulu-Natal, South Africa. The new 1,000 t silo has a variable extraction rate of  – 20 tph. The silo reclaim conveyor is automatically operated and feeds onto the existing conveyor system. The automatic pre-selected feed system consists of a surge bin with a variable speed rotary proportioning valve. A dust extraction filter system is also included. Read more …

Commodity: Iron Ore; Contract Type: Design, Engineering, Procurement, Erection & Commissioning

DemcoTECH was contracted by Assmang Limited for the design through to commissioning of the multi-stream sampling plant for Khumani Iron Ore Mine. The plant features 3 sample processing streams,  multiple load-cell mounted weigh hoppers, 2 driers and multiple sample splitters. Other features include deck screens and vibrating feeders, an automated process crane, conveyors and storage bin. The process building is a 80 m  x 25 m  x 30 m high structure. Read more …

Commodity: Iron Ore; Contract Type: Supply & Install

DemcoTECH was awarded the fabrication, supply and fast track installation of an elevated shuttle conveyor for Kumba Iron Ore’s Sishen Mine in Kathu, South Africa. The contract required disassembling the existing shuttle conveyor and the supply and installation of the new conveyor. The site installation at a height of approximately 24 m within the plant shut was particularly challenging. The new shuttle conveyor travel rails were required to be replaced and Thermit welded, introducing further challenges. The project was successfully completed within the demanding time constraints and restrictive environment imposed by Kumba without incurring any penalties and to the clients satisfaction. Read more …

Commodity: Fertiliser; Contract Type: Design Review & Recommendations

DemcoTECH’s upgrade to Steinweg Bridge’s storage and distribution facility in Durban, South Africa, comprised a full design review and plant assessment study. Based upon these recommendations, DemcoTECH completed the supervision and implementation of these upgrades. The upgrade included new ceramic-lined pulleys, reclaim gates and chutes, spillage improvements and crusher refurbishment. A complete corrosion protection refurbishment was also included. Read more …

Commodity: Manganese; Contract Type: Design, Engineering, Erection Supervision & Optimisation

DemcoTECH performed the full design, engineering, procurement of mechanical components, erection and commissioning supervision and optimisation for a sinter plant for Cato Ridge Alloys in KwaZulu-Natal, South Africa. The plant is self-standing and installed to enhance the overall existing process and profitability of the operation, which processes manganese. Read more …

Commodity: Limestone; Contract Type: Turnkey

DemcoTECH, in joint venture with Kantey & Templar, carried out the design and engineering of the plant for Idwala Carbonates in KwaZulu-Natal, South Africa as a turnkey project. The project is now in the execution stage with the joint venture responsible for contractor managing appointments, supervision of erection and commissioning and optimisation of the plant. The washing technology was imported from Germany, while, for sorting, a RED Wave sorter, has been used. The new plant is required to be integrated into the existing plant. Read more …

Commodity: Ash; Contract Type: Design Studies

DemcoTECH undertook detailed concept studies and audits for the Matla and Tutuka power station fly ash, coarse ash and ash water return systems for South Africa’s national power utility, Eskom. The studies included the expansion to Eskom’s ash dump at the Tutuka Power Station in Mpumalanga, to cater for a planned additional 25 year life extension of the power station. A dry ashing system was included. Read more …

Commodity: Coal; Contract Type: Concept Feasibility Study

DemcoTECH investigated the coal delivery facility at the Majuba power station with a view to upgrading the throughput and system reliability. DemcoTECH developed various conceptual designs and prepared a simulation model for the rail delivery, tippler and power station feed system in order to predict the required equipment capacity and the rail infrastructure modifications necessary to deliver 14 Mtpa of  coal reliably by rail. Read more …

Commodity: Cement; Contract Type: Concept Study

DemcoTECH Engineering completed a concept study for NPC-CIMPOR’s new limestone handling and processing project at its Durban works in South Africa.  The concept study provided a completely integrated plant, capable of achieving the plant’s operational requirements to store 10,000 tons of additional clinker, as well as storing and reclaiming limestone and pressed clinker in the existing silos. Read more …

Commodity: Manganese; Contract Type: Study

DemcoTECH undertook a materials handling study for Newlyn whereby manganese ore arrives in 100 ton rail carriages and 50 ton haul trucks, with the ore tipped through a rotary tippler, stockpiled and thereafter conveyed overland to two rail-mounted ship loaders addressing Capesize vessels moored at two Coega manganese quays.  The scope of work included all materials handling conceptualisation and development, block plan and detailed drawings, locating and sizing of hoppers and silos, preliminary conveyor designs, budget costing and operational costing for the terminal. Read more …

Commodity: Sulphur Prills; Contract Type: Feasibility Study

DemcoTECH undertook a desktop study covering a new materials handling system that was to be developed to import sulphur prills from handysize vessels and barges moored along the jetty and convey the product to a private stockyard complex and to enable the product to be distributed to mining customers via road haul trucks from within the harbour complex. Being a multi-product, multi-client harbour, emphasis was placed on mobile / removable hardware wherever possible along the jetty to make way for other client import / export operations. Read more …

Commodity: Phosphate rock and other; Contract Type: Feasibility Study

DemcoTECH was appointed by PMC to investigate and propose a means of upgrading the existing infrastructure and operations to achieve up to 15 Mtpa exports by rail. This was a brownfield projects, which interfaced existing rail and road infrastructure on a congested section of the plant. The scope included analysing the entire materials handling logistics chain and investigating the current operations that transport product from each of the material sources to the central discharge facility. Read more …