PLANT DESIGN
Tailings Reintroduction Pocket Belt Conveyor

The goal was to provide a fully costed, mobile, modular system, covering everything required to reintroduce the coarse tailings material into the feed opening of an existing Sandvik tertiary crusher. The design focused on a complete materials handling solution consisting of a hopper landing frame, a vibrating feeder and a 500mm width pocket belt conveyor, as well as all associated chutes. The feed material (coarse tailings) would be deposited into the existing crusher feed chute with minimum or no modification to the existing equipment and layout, as far as possible.
The customer specification called for a cost-effective, non-permanent mobile structure. Furthermore, the layout of the installation needed to be such that it would leave ample space for maintenance vehicles to have access to the main plant. The structure could also not interfere with maintenance on the existing tertiary crusher.
The equipment was designed to be mobile without any permanent fixing to the existing structure. The head end of the pocket belt cantilevers over the crusher feed opening. All equipment is free-standing, and can be dragged/lifted out of the way for maintenance purposes.
Detailed design of the pocket belt conveyor was completed including mechanical sizing of all equipment and structural analysis for the pocket belt conveyor frame. The general arrangement design for this project was successfully completed and project costing was supplied to the client for a turn key solution.
Modular Waste Wood Gasifier

Meganika has approached this challenge using a formal product development strategy to target a larger market than just one client, thereby addressing the greater need for sustainable, cost effective waste processing in the industry.
A review of existing technologies revealed modular gasification as the most viable solution. The Meganika gasifier meets the following requirements:
- A small scale industrial unit, capable of processing between 5 and 50 tons of waste wood per month (25 to 250kW capacity).
- Able to produce electrical power as a standard output delivered directly to the client’s distribution board.
- Optional further heat recovery system.
- Easy to operate and robust enough to accept various fuel types.
- Capable of continuous operation.
- Complies to all relevant environmental emissions standards.
- Cost effective and maintenance-friendly design.
All systems and parts have been fully designed and developed by Meganika.
The gasification unit and the gas conditioning system is provisionally patented, and full patents will be sought once final build is complete.
COMPONENT DESIGN
Single Flap Valve


The single flap valve provides a cost-effective means to discharge batches of free-flowing bulk material ranging in particle size while maintaining a low- pressure air seal when the valve is in the closed position. If used in a dual flap setup the air seal is maintained in operation as only one flap opens at a time. Typical applications include metered batch feeding processes.
The unit can operate as a single flap valve, or as a dual (double) unit.
The motor is fully controllable and provides full control over the opening frequency and speed.
Specifications | |
---|---|
Size range: | 200×200 – 500x500mm |
Materials of construction | Mild steel/Stainless steel/VRN as required |
Valve seat: | Silicone rubber/steel/brass |
No of flaps: | Single/Dual |
Pressure: | 0.1kPa(g) |
Temperature: | Ambient to 250°C |
Max cycle rate: | 0-15cycles/min |
Actuator: | Electric/pneumatic, gravity opening |
Voltage: | 12/240/400V |
Flange bolting: | As required |
Dual Butterfly Valve System


The unit can operate as a single butterfly, or as a dual (double) unit. In both modes, only a single common actuator motor is required, resulting in significant cost savings.
The motor is fully controllable and provides full control over the opening frequency and speed.
Specifications | |
---|---|
Size range: | 50-300mm |
Materials of construction | Mild steel/Stainless steel (316) |
Valve seat: | Silicone rubber |
No of butterfly flaps: | Single/Dual |
Pressure: | 0.1kPa(g) |
Temperature: | Ambient to 250°C |
Max cycle rate: | 0-60cycles/min |
Actuator: | Direct drive electric motor, spring return, normally closed |
Voltage: | 12V |
Flange bolting: | SABS 1123/BS4504 |
Explosion Relief Valve


The valve can be fitted with a number of instruments for monitoring purposes if required.
Specifications | |
---|---|
Size range: | Square or round- 50 – 500mm |
Materials of construction | Mild steel/Stainless steel. Can be refractory lined if required. |
Valve seat: | Steel/Gasket material as per requirement |
Pressure: | 0.1kPa(g) -10kPa |
Temperature: | Ambient to 800°C |
Actuator: | None, Spring loaded, normally closed |
Shaft-less Screw Feeder


The unit can operate in forward or reverse rotational directions without modifications. Customised screws can be manufactured to suit a wide range of materials and applications. Rotation sequences can be programmed for the feeder providing full control over the speed and direction of feed.
Specifications | |
---|---|
Inlet and outlet configuration customisable to fit requirements. | |
Orientation of feeder customisable to fit requirements. | |
Diameter size range of feeder chamber: | 50-300mm |
Length size range: | 500mm – 4000mm |
Body materials of construction: | Application specific: Mild steel/VRN/Stainless steel |
Shaft-less screw material of construction: | Application specific: Mild steel/VRN/Stainless steel |
Particle size range: | 0,1mm – 50mm |
Temperature: | Ambient to 250°C |
Angle of Incline: | 0-90° |
Operating speed: | 0-120rpm |
Drive: | 12V Direct/240/400V geared motor |
Voltage: | 12/240/400V |
Circular flange bolting: | SABS 1123/BS4504 |
Square flange bolting: | As per requirement |
PROTOTYPING AND TESTING
BUILD
CLIENTS



CORE TEAM

Dr. Gerard Van Harmelen
Managing Director

Vincent Ellerbeck
Technical Director