Bulk handling projects rely on a web of interconnected decisions, yet stakeholders often lack engineering expertise. Jenike and Johanson general manager Corin Holmes aims to solve that.
Often in pre-feasibility studies, certain equipment is baked into the process. There are several reasons why this happens. Perhaps similar equipment worked well elsewhere, or it could come down to costs.
Jenike and Johanson general manager Corin Holmes said this can lead to a project getting stuck with equipment that will not work in the long term.
“Fundamentally, there are a lot of companies out there that do a pre-feasibility study but don’t necessarily have the subject matter expertise in bulk materials handling,” he told ABHR.
“And so, they often make decisions and select equipment based on previous experience on similar projects. This means they might not be leveraging the science that exists to make more informed decisions.
“There’s typically a disconnect between procurement and engineering. Procurement is going to want the best cost option upfront, which is known and defined. The downstream cost of operation and reduced throughput rate isn’t something that gets considered. There may even be additional maintenance costs and flow issues if the wrong equipment is used further increasing the operational costs.”
Once a decision gets baked into the process, it can be hard to remove. Other equipment and considerations are based on its inclusion, which can create more work and headaches if revisions are required.
As a specialist engineering firm, Jenike and Johanson can help companies avoid getting stuck with subpar equipment. Its specialists use a variety of tests and tools, including discrete element method modelling, physical scale modelling, and flow characterisation using the Jenike Direct Shear tester, to understand the material being handled and then determine which equipment would be optimal.
Holmes said the company is vendor agnostic, meaning it can focus on finding the right tool for the job.
“Once we’ve analysed the system, we present all of the information to the client and inform them of any potential risks and benefits. We leave it up to them to decide, using the information to make an informed decision,” he said.
“The thing we find missing in most projects when the wrong equipment has been baked into the design is a lack of expertise on the spider web of capability.”
Building the web
In order for a bulk handling project to be successful, it requires expertise from a complex network of specialists.
For example, a new mine development will need to incorporate many different fields of expertise.
Homes said most engineering, procurement, and construction (EPC) contractors are driven by reducing up-front costs to remain competitive.
“One of the first things that is taken out is the upfront cost of material characterisation test work , because it’s viewed as something that can happen in the detailed engineering phase,” he said.
“By that time, decisions have already been made and are now much harder to undo or correct.”
For Jenike and Johanson’s engineers, a conversation with the client is the first step.
They learn about the range of materials that will likely be handled, the overall moisture content, and all the factors that define each material.
Then, the company provides characterisation tests to inform a review of the equipment selection.
A key part of this process is determining the flow characteristics, as that helps to assess whether a piece of equipment is fit for purpose.
The company’s size is a major boon for this kind of work. Holmes said Jenike and Johanson is one of the largest engineering, consulting, and testing companies in the world, with extensive experience with an array of equipment and materials.
“The people we have on staff have been with us for a long period of time,” he said. “People like myself have been with the company for more than 25 years.
“I can look around our global entities and find engineers with decades of experience. We can leverage that to help find solutions.
“For example, I can send an email to our organisation detailing a certain engineering challenge. I can rely on engineers from around the globe to help find previous projects, learn what the pitfalls were, and take advantage of our in-house testing facilities.”
With an 80 per cent retention rate, the company’s customers are keen to stick around.
Holmes said this is because clients see the value of engaging with Jenike and Johanson and continue to engage with is in future projects.
“We’re taking on more complex projects and helping bulk handling businesses make informed decisions,” he said.
“Although here in Australia, we are very heavily mining focused, we service other industries around the world. Our target is to continue to expand across Australia and the pan-Pacific Australasian region, growing our reach globally.”
