Local foundry develops new sheave wheel

This is, currently, the largest sheave wheel design manufactured by KEW Foundries, which is the only supplier of cast headgear sheave wheels in Africa. Modifications to existing plant and equipment are currently under way to increase this size to a 6,8-m sheave wheel with an outside diameter of 7,1 m.

The 6,5-m sheave wheel has a 6,7 m outside diameter and will be one of four mounted on a single shaft, reports the company.

"The present contract that Kew Foundries has secured is for two sets of 6,5-m deflection clusters for a well-known mining project house to be used on one of the new platinum projects in the Phokeng area, outside Rustenburg. These sets are due for delivery in early-2009," reports Goncalves.

He explains the applications and customised specifications of its new 6,5-m sheave wheel used as part of the cluster arrangement.

"The new trend in mining is to use Koepe winders situated on top of the headgear, or on the bank-level, using multiple ropes going down the shaft connected to either a conveyance or a counterweight. As the winder drum is mounted over the shaft, the rope drops off-centre relative to the position of the conveyance or counterweight. The sheaves, mounted below the winder, deflect the rope back to the centre line. If the winder has four ropes, then four deflecting sheaves are required, having all four wheels on a single shaft." says Goncalves.

KEW Foundries' sheave wheels are currently being manufactured at the company's manufacturing facility in Kimberley.

KEW Foundries supplies sheave wheels to all the big mining houses as well as to consulting and project engineers working on big shaft-sinking and expansion projects for the array of mines in Southern Africa and abroad.

Some of the projects that the company has been involved in over the last two years include the supply of a 5,5-m four-wheel cluster to the Karee No 4 shaft, 3,6-m sheave wheels for the Konkola No 4 shaft, a 4,8-m sheave wheel for the Crocodile River No 1 shaft and a 3,6-m sheave wheel for Impala No 17 shaft, among a number of other projects.

Kew Foundries has developed the best of specifications after working with different mining houses over many years, reports Goncalves.

"We have taken the best requirements of mining house specifications to produce sheave wheels and associated equipment that meets, and in most cases, surpasses the requirements requested by our customers. This KEW Foundries specification has been adopted by a number of mining operations who were without a detailed specification," states Goncalves

The company was established in 1891 and specialises in numerous grades of Grey and SG Iron in a range of sophisticated small and large castings up to 6 500 kg that include, sheave wheels, gearbox castings, bearing housings, pump casings, valve bodies and discs, girth gear castings, flywheels and crusher parts, as well as counterweight and mass weight castings of up to 7 500 kg, among many other products.

"Kew Foundries' key focus is on developing new products, as well as improving existing products by forming solid customer partnerships. The company offers in-house casting, non-destructive testing, machining, material testing, and design and draughting facilities, through its comprehensive foundry and engineering capabilities," says Goncalves.

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