14 Apr Referro Systems completes multi-million discard spreader project
Referro Systems – a distribution company for many of the world’s leading electrical, automation and global software and hardware brands – recently completed a project for a large iron ore mining operation in the Northern Cape, where the team leveraged their experience and long-standing client relationship to see the solution to success. The complex multi-million rand project involved the supply of intelligent motor control, control system and HMI, as well as full integration into the existing plant control system, among other interlocking for the mine’s new discard spreader conveyor system .
Adrian van Wyk, Managing Director, Referro Systems explains: “The client required an integrated discard spreader conveyor system, which levels out discarded low-grade iron ore to create stable piles. The spreader conveyor ensures the product is stored optimally in terms of safety, space, location and accessibility. This helps manage the product more efficiently, and mitigates the need for heavy hauling trucks, reducing the mine’s carbon footprint as well as automating the process.”
The mine produces around 600 tons per hour of low-grade product for the discard pile. Prior to automation, trucking the product could only manage a maximum of 400 tons an hour when running at full capacity with a truckload every six minutes, weather conditions permitting. “To optimise the materials handling capability, the spreader conveyor can now manage 1500 tons per hour optimising the piling, while lowering the operations CO2 footprint as this function is now fully automated,” explains van Wyk.
The project required Referro Systems to install an integrated HMI, control and motor control solution, which was also required to be integrated into the existing control system backbone. “We installed an Allen-Bradley ControlLogix system into the existing substation as well as the discard spreader conveyor for the new system, which enables future expansion. To reduce starting currents required by the conveyor, we added Allen-Bradley SMC Flex low voltage soft-starters which were crucial to ensure efficient start-up control of the conveyor,” says van Wyk.
Van Wyk explains that the project faced several hardware supply challenges due to global supply chain disruptions impacted by the availability of plastics and semiconductors. “This limits the availability of certain products key to industrial applications. However, our in-depth understanding of our client’s systems and processes as well as our detailed knowledge of our customer’s hardware standards coupled with Referro Systems’ comprehensive Allen-Bradley product range – built over years of working together – ensured we were able to overcome several challenges without impacting the project negatively or compromising the system’s functionality,” stated van Wyk.
“We are proud to have built lasting relationships with our customers and suppliers, which gives our customers a competitive edge over their global competitors in delivering projects to a high standard which are fit for purpose. We continue to grow our expert delivery in the project environment with our clients in the mining industry,” van Wyk concludes.
About Referro:
Referro Systems is a sales and distribution company for many of the world’s leading electrical, automation and global software and hardware brands across industrial and commercial sectors. The Level 2 BBBEE company supplies best-in-class industrial automation, electrical control and instrumentation fit-for-purpose and provides cost-effective solutions – info@referro.co.za