Longest overland conveyor in Africa

Effective 30 November 2010, FLSmidth has acquired majority ownership of Roymec (Pty) Limited. The company has 32 years’ experience in a wide range of equipment for the conveying and handling of various mineral products, mainly coal, but also iron ore, kimberlite and platinum ore. Among the products it designs and supplies are conveyors and a number of other bulk material handling systems.

The 15.9 km long Zibulo overland conveyor was successfully commissioned by Roymec on 2 December 2009 and will continue to add significant value to the Zibulo Colliery operation for many years into the future
— Rudi Pieterse FLSmidth

Roymec is an accredited company under South Africa’s Broad-Based Black Economic Empowerment (BBBEE) legislation. Among the aims of this legislative framework is to increase broad-based and effective participation of black people in the economy and promote a higher growth rate, increased employment and more equitable income distribution. Commenting on the acquisition, FLSmidth Group CEO Jørgen Huno Rasmussen stated: “The local platform of Roymec will give FLSmidth a strong base for supplying equipment under the BBBEE act and permit us to further strengthen our position as a leading regional bulk materials handling solutions provider.”

Roymec is involved in a number of exciting projects. They are currently executing projects in South Africa, Botswana, Mozambique and Zambia. An important differentiator is that they are executing these projects with their own construction division which includes a regional fleet of cranes. Below is the description of a project that included the longest single flight conveyor in Africa.

Zibulo overland conveyor
Coal from Zibulo Colliery is processed at the Phola processing plant – an Anglo Coal, BHP Billiton joint venture operation. Zibulo Colliery is connected to the Phola processing plant by means of the Zibulo overland conveyor. At Zibulo Colliery coal is brought to surface with incline conveyor CV001 and discharged into a 6,000 tonne buffer silo. From the buffer silo coal is fed into a crushing and screening circuit with a second conveyor CV002. The material is then accelerated to a predetermined speed with an acceleration conveyor CV003 and transferred to the Zibulo overland conveyor CV004. This configuration allows the Zibulo overland conveyor to operate at optimal efficiency in conveying coal to the Phola processing plant almost 16km away.

The Zibulo overland conveyor is the longest single flight overland on the African continent and one of the longest single flight overland conveyors in the world. It features three horizontal curves and several convex and concave vertical curves. The high vertical lift (176m) of CV001 combined with the very long length of 15.9 km for CV004 necessitated comprehensive static and dynamic analysis of the entire system.

The 15.9 km long Zibulo overland conveyor was successfully commissioned by Roymec on 2 December 2009 and will continue to add significant value to the Zibulo Colliery operation for many years into the future. This followed the completion of the materials handling system at Phola processing plant, also executed by Roymec, which included FLSmidth® stackers and bucket wheel reclaimers.

CONTACT: Rudi Pieterse