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Our Innovation. Your Advantage.
Australia
China
Europe
North America
South America
Africa
Metal Recycling
Foundry
Workshop
20 McIntosh DriveMayfield West NSW 2304 Australia T +61 2 4926 8200 F +61 2 4926 8201 E [email protected]
PACIFIC20 McIntosh DriveMayfield West NSW 2304 Australia T +61 2 4926 8200F +61 2 4926 8201E [email protected]
AMERICASSuite 647, 12200 NW Ambassador DriveKansas City MO 64163 USAT +1 816 270 0700F +1 816 270 0799E [email protected]
EUROPE2 Vantage DriveSheffield S9 1RG United KingdomT +44 1142 841 000F +44 1142 841 001E [email protected]
AFRICAUnit G1 The Palisades 39 Kelly RoadJetpark South AfricaT +27 11 025 5403F +27 86 515 1792E [email protected]
ASIANo.26, XuHai Road SouthEconomic Development ZoneXuzhou P.R. China 221131 T + 86 516 8355 3958F + 86 516 8355 3959E [email protected]
Continental Head Offices
Corporate Head Office
Visit bradken.com for your local representative.
Our Innovation. Your Advantage.Our Innovation. Your Advantage.
SIZING
ChutesFeeder BreakersHammersJawsLiftersPloughsRoller SegmentsRotary BreakersScreen PlatesSizer TeethSprocketsTrunnionsWear PlatesWedge Bars
ProductsRotary Breaker RefurbishmentCrusher Roller RefurbishmentWear Liner PackagesWear Monitoring
Services
ROM BIN
Grizzly BarsHoppersROM GratesScreensTransfer ChutesWear Plates
ProductsTransfer Chute DesignWear Liner PackagesWear Monitoring
Services
THICKENING
Elbows, Pipes & TransitionsPump Casings & ImpellersScrapers/Rakes
ProductsHigh Chrome Weld Overlay
Services
DEWATERING
Ceramic TilesChutesPumpsScraper BladesWear Resistant Ceramic
ProductsHigh Chrome Weld OverlayCarbide Weld Overlay Pipes
Services
STOCK PILING
Boom ScrapersBucketsChutesBelt ScrapersGET
ProductsTransfer Chute DesignWear Liner Packages
Services
TRAIN LOAD OUT
HoppersSpoons & HoodsTransfer Chutes
ProductsWear Liner PackagesWear Monitoring
Services
SHIP LOADING
Spoons & HoodsTransfer Chutes
ProductsWear Liner PackagesWear Monitoring
Services
PUMPING
Ceramic EpoxiesCeramic LinersElbows, Pipes & TransitionsHigh Chrome Weld OverlayPump Casings & ImpellersRubber Liners
ProductsCarbide Weld Overlay Pipes
ServicesSCREENS/GRIZZLY FEEDERS
ChutesExcitersGrizzly BarsLiner PlatesRoller ScreensScreensWear Plate & Block
ProductsGrizzly Bar DesignScreen RefurbishmentTransfer Chute DesignWear Liner Packages
Services
GRAVITY SEPARATION
Ceramic EpoxiesCeramic TilesChutesElbows, Pipes & TransitionsHigh Chrome Weld OverlayPump Casings & ImpellersTablesWhite Iron Cyclones
High Chrome Weld OverlayCustom DuaCeramic Tiles
Products Services
RR
POWER PLANT
Balls & RingsCrusher TyresElbows, Pipes & TransitionsPulveriser Hammers
High Chrome Weld OverlayWear Liner Packages
Products Services
COAL PROCESSING
Bradken has a proud and proven 50 year history in the supply of differentiated consumable wear products to the coal processing industry.
Our continuously expanding range of products covers the Coal Handling and Preparation Plant through to Train Load Out. Bradken provides off-the-shelf and custom designed solutions including wear plates, hoppers, hoods, spoons, transfer chutes, screens and rotary breakers.
Bradken strives to reduce your Total Cost of Ownership by implementing product design improvements, wear monitoring and inventory management programs. Regionally located manufacturing and service facilities give Bradken the ability to promptly respond to your needs making us a supplier of choice for coal processing products.
Bradken’s highly skilled team has technical expertise in an extensive range of process applications including:
• Worldclassmanufacture
• Productdesign
• Technicalsupportandservice
• Materialselectionanddevelopment
• FEAandfatigueanalysis
Bradken’s technically advanced wear solutions will protect your Coal Handling and Preparation Plant while ensuring maximum process throughput.
• Chromium Carbide weld overlay plate
• Ceramic-Polyurethane composite liners
• Ceramic-Rubber composite liners
• Chrome-Molybdenumwhiteironblockbrazedtomildsteel
• Nickel-Chrome white iron liner castings
• Epoxies Arangeofabrasion&impactresistantepoxycompounds
• Pipes Chromium Carbide weld overlay of straight and elbow pipe
Bradken’s regionally supported continuous improvement process, DRIVE™ ensures we deliver the best products and service in the industry.
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Bradken is a one-stop-shop for all your coal handling and preparation plant wear protection needs
Coal Processing Capability
VisionProud to belong.
WebelieveourVisionappliestoallofBradken’sstakeholders,including our employees, our customers, our community and our shareholders.
WehopeyoucometoshareourVisionwithus.
MissionTo maximise our shareholder’s worth in a manner consistent with our Vision and Values.
Business ModelThe creation of differentiated consumable products for the resources industry and sale of their value to our customers.
ValuesWevaluepeoplewho:
• arehealth,safetyandenvironmentallyresponsible;
• haveexemplarypersonalintegrity;
• enjoyabalancedlifestyle;
• striveforcontinuousimprovementinallthattheydo;
• arecustomerfocused;
• possesscourageandloyalty;
• arehighlymotivated;
• worktogetherforcommongoals;
• respecttheindividualrightsofothers;
ensuringBradkenisagoodcorporatecitizen.
Cost Savings: $1,460,000 per annum 570% Increase in Chute Life 83% Safety Improvement
PROBLEM
The customer had two slide chutes lined with bond-onceramic tiles.Extensivewear and tile failurewereobserved in high impact areas on the side of the chutes.
The two chutes were lined with 63mm and 100mm ceramic tiles. The respective throughput of each chute was2.6Mtand4.9Mtbeforefailure.
TOTAL COST OF OWNERSHIP IMPROVEMENT
DRIVE™ Success StoryCurved Slide Chute – Gold Mine
What is DRIVE™?
Before After
Liner Cost Liner Life (weeks) Liner Cost Liner Life (weeks)
$200,000 7 $65,000 40
Operational Savings Per Annum
Cost Reduction Shut Time Reduction (hrs) Increased Tonnes Safety Improvement
$1,460,000 233 2,326,000 83%
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Bradken’s DRIVE philosophy is the foundation stone which helps to reduce the Total Cost of Ownership ofyourplantequipment.Withafocusonwearmonitoringandinventorymanagement,DRIVE has been developed to deliver continuous value improvement through dedicated customer focus.
Bradken’s product development program delivers immediate benefits to our customers through continuous focus on specific needs. Implementing DRIVE ensures our products are continuously improving and reducing Total Cost of Ownership.
DISCOVER the problem, the current performance and the customer’s needs.
REVIEW all available information and propose a solution.
IMPLEMENT the proposed solution.
VERIFy the solution and identify performance improvement opportunities.
ENGINEER any required changes and roll out the improved solution.
DRIVE – continuous process improvement to help lower your costs
SOLUTION
The ceramic tiles on the chute sides were replaced with our Duablock product to create a rock box formation promoting ore-on-ore flow. Duablock was chosen for this application as it is Bradken’s best product for high impact application. The design underwent two iterations to arrive at the final solution which had a significantly improved chute life.
DISCOVER
ENGINEER VERIFy
REVIEW
IMPLEMENT
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Bradken has a vast range of technically advanced fixed plant wear solutions to protect your CHPP. Wecan supply both fabricated and cast protective solutions including pressed and rolled plate, cast Nihard billets and ceramic tiles.
Bradken’s extensive solution range includes:
Bradken is ISo 9001:2008 certified ensuring production of only the highest quality product
PipesOur patented high chrome weld overlay pipes and elbows have an extremely smooth weld overlay surface resulting in lowerflow turbulenceand longerservice life.Withouttraditional lobster backs, these fabrications are ideal for high velocity bends and transitions.
Awhite iron block brazed to amild steel backing plate.Whiteironisasuperiorwearresistantproductcontaininghard chromium carbides. The blocks are excellent for localised protection and for constructing rock boxes.
EpoxiesA two pack resin-ceramic composite offering highwearresistance. Epoxy is ideal for protecting those hard toreach places or as an emergency repair to keep your plant running.
and A combination of an exceptionally abrasion resistantceramic in a polyurethane or rubber matrix. Ceramics are extremely resistant to sliding abrasion.
CHPP Equipment Protection
Chromium Carbide clad wear plate, proven to outlast quench and tempered steel by up to 10 times in high abrasion, high impact applications.
Cast Nickel-Chrome white iron liner billets that are highly customisable to meet site specific needs.
Product Applications
Pressed, formed or rolled, Duaplate is well suited to high impact application.
• Transferchutes• Sizingscreens
• Spoons• Hopperliners
Ceramics are ideal in extremely abrasive applications.
• Transferchutes • Loadingfunnels
Duablock is great for localised protection in your plant.
Nihard is great in high impact applications.
• Transferchutes• Castpipes
• Rockboxes• Castcyclones
Epoxies Great for protecting difficult to reach places or as an emergency repair.
Pipes Cast or fabrication replacements for existing ceramic/basalt lined pipes.
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Rotary Breakers Product Development
With over 30 years experience in manufacturing, maintaining and refurbishing rotary breakers,Bradken is able to meet all your rotary breaker requirements. Our world class foundries supply spare components for your rotary breaker including screen plates, ploughs, lifters, trunnion rollers, drive sprockets and chains.
Bradken’s integrated machining and assembly facility allows full control of assembly timing and quality assurance.AllofourrotarybreakerbuildsandrefurbishmentsundergotestingbyNATAaccreditedinspectors before delivery.
Allcriticalareasareinspectedusing:
• MagneticParticleInspection(MPI)
• UltrasonicInspection(UT)
• DimensionalCorrectness
Bradken can design and engineer a custom breaker barrel to fitanyexistingbreakerstation.Wehaveacompletesuiteofdesign and analysis tools available to ensure you receive the best product for your needs.
Unsureifyouroldbreakerbarrelcan be refurbished? Your regional Bradken representative can carry out a full inspection ofyourbreakerstation.Adetailedreportwillbeprovided outlining the best recommendation suited to your application.
Bradken’s reputation for producing high quality and innovative products results from understanding our customer’s operating conditions, a willingness to customise and a longstanding track record of providing superior performance products.
Bradken’s product development team is dedicated to reducing your operating costs and improving equipment efficiency. Bradken engineers provide on-site technical collaboration and engage in a consultative design process with our customers.
Bradken embraces new technologies that help us produce world-class products. Our design, analysis and manufacturing capabilities feature:
• Computer-aidedengineering,designandmanufacture
• Dynamicmotionanalysisandcontact force analysis
• FiniteElementAnalysis
• DiscreteElementModelling
• Virtualprototyping
• Castingsolidificationsimulation
• Concurrentengineering
• Rapidprototyping
• Fatiguetesting
• 3Dscanningandreverseengineering
• Standardandcustompartsupply
When you talk to Bradken, you are talking directly to the manufacturer
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Knowing the forecast life of your wear liners allows Bradken to help manage your inventory stock, ensuring all required components are on site when needed.
Asdirectaccesstothewearlinersisnotneededforwearmonitoring,SmartLinermakescheckingthecondition of your wear liners quick, easy and most importantly, safe!
Wear Monitoring
yOUR REGIONAL REPRESENTATIVES
Bowen Basin – Queensland
T +61749520307
F +61749520390
M+61417481538
Hunter Valley – New South Wales
T +61249268465
F +61249268201
M+61418778114
A safe, easy and quick way of monitoring high wear areas
Bradken’s patented SmartLiner wear monitoring system allows users to remotely monitor plant wearconditionsinunsafeanddifficulttoaccesslocationssuchasROMbinsandtransferchutes.Sensors embedded in the wear liners provide real-time wear data which can be viewed on the SmartLiner website.
Usingthisinformationwecanforecasttheremaininglifeofyourwearliners.Thisdataallowsyoutoplan and budget for an upcoming shutdown while reducing the incidence of unplanned maintenance.
The majority of Bradken’s current wear liners can be used with the SmartLiner system. Our wear sensors are available in 20 – 80mm usable wear liner thickness and are supplied with an IP66 dust and water proof connector.
CHPP ProteCtion
Duaplate
DRIVENihard
RUBATILEDUABLOCK
Wear MonitoringToTal CosT of ownership improvemenT
RotaRy BReakeRs
Australia
China
Europe
North America
South America
Africa
Metal Recycling
Foundry
Workshop
20 McIntosh DriveMayfield West NSW 2304 Australia T +61 2 4926 8200 F +61 2 4926 8201 E [email protected]
PACIFIC20 McIntosh DriveMayfield West NSW 2304 Australia T +61 2 4926 8200F +61 2 4926 8201E [email protected]
AMERICASSuite 647, 12200 NW Ambassador DriveKansas City MO 64163 USAT +1 816 270 0700F +1 816 270 0799E [email protected]
EUROPE2 Vantage DriveSheffield S9 1RG United KingdomT +44 1142 841 000F +44 1142 841 001E [email protected]
AFRICAUnit G1 The Palisades 39 Kelly RoadJetpark South AfricaT +27 11 025 5403F +27 86 515 1792E [email protected]
ASIANo.26, XuHai Road SouthEconomic Development ZoneXuzhou P.R. China 221131 T + 86 516 8355 3958F + 86 516 8355 3959E [email protected]
Continental Head Offices
Corporate Head Office
Visit bradken.com for your local representative.
Our Innovation. Your Advantage.Our Innovation. Your Advantage.
© 2013 - Bradken3BKISPMKTCoalProcessingSolutionsBrochure
