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The electric 320t port material handler SENNEBOGEN 885 G
Hybrid handling scrap in Croatia. SENNEBOGEN Maschinenfabrik GmbH Sennebogenstraße 10 D-94315 Straubing, Germany T: +49 9421 540-0 E: info@sennebogen.com W: www.sennebogen.com PUBLISHERS Jason Chinnock jason@dc-int.com
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SEPTEMBER 2023 issue
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Dry bulk trade looking brighter Brazilian North terminals grain exports growing RISING ACREAGE FOR CORN, SOYBEANS: IMPROVED FEEDSTUFFS OUTLOOK IN 2023/24
SHIPPING & TRANSPORT
Zinus: pioneering a brighter, greener maritime future Regulation, innovation and cleaner hulls DRYDOCKING PRE-INSPECTIONS AVOID FUTURE PAIN NOW SERVING IN BULK: BULKER SERVICES
PORTS, TERMINALS & LOGISTICS
Port of Hamburg handles 58.2 million tonnes Barranquilla now operating with stable 10-metre draught Romania offers Ukraine more access to Danube ports Port of Southampton rail project: double award for driving rail freight growth Cargo by barge between North Sea Port & hinterland increases to 60%
2 4 6
16 18 19 21
34 35 35 36 37
ENGINEERING & EQUIPMENT
Energy-efficient and smart solutions from SEW-EURODRIVE 38 Are your rubber conveyor belts safe for human health and the environment? 40 Koch Solutions acquires FLSmidth’s Bulk Material Handling business 40 More Rotainers commissioned in outback New South Wales in September 2023 42 CIRCULAR ECONOMY IN THE CONSTRUCTION INDUSTRY WITH SENNEBOGEN MATERIAL HANDLERS 43 MOVING INTO HIGH GEAR WITH BULK CONVEYOR SYSTEMS 45 A MOVABLE FEAST? MOBILE EQUIPMENT PLAYS A VALUABLE ROLE IN THE BULK INDUSTRY 93 DUST EMISSIONS MANAGEMENT: DON’T MESS WITH THE BEST 110 SEEKING SHELTER: ENCLOSED STORAGE AND HANDLING 129 TRANSPORT AND STORAGE OF GRAIN: IMPROVING EFFICIENCY WITH HIGH-TECH SYSTEMS 139
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SEPTEMBER 2023
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BULK CARRIER TRADE & FLEET OUTLOOK
Dry bulk trade looking brighter ommodity import demand trends around the world are looking more positive than envisaged earlier. This perception is reflected in expectations of significant growth in global seaborne dry bulk trade during 2023, reversing last year’s reduction. The pace of economic activity in a number of dry bulk importing countries has not proved especially beneficial for trade movements, however. In China import demand has strengthened, despite the economy’s faltering recovery after pandemic control restrictions were lifted at the end of last year. Meanwhile, restraining inflationary pressures is still a challenge for central banks elsewhere, and rising interest rates in Europe and the USA are set to achieve this aim by restricting economic activity.
C
GRAIN & SOYA Tentative predictions for grain trade in the new 2023/24 marketing year ending third quarter 2024 reveal a mixed pattern. Following an estimated downturn during the current year, US Department of Agriculture calculations published a few weeks ago suggest that global trade in wheat plus corn and other coarse grains could increase by 2–3%, amid varying performances in individual importing areas. Forecasts for the principal importing regions are shown in table 1, combining a July/June wheat year with an October/September coarse grains year. European Union imports are expected to be about 16% lower, accompanying
improved domestic grain supplies. Middle East volumes could be about 7% lower. In other regions increases are foreseen, including an 8mt (million tonnes) or 9% rise in East Asia to 97mt, partly due to an envisaged upturn in China’s corn purchases.
COAL Evaluations of world seaborne coal trade have become more positive in recent months, although this re-appraisal has largely reflected the much stronger buying trend in China. Forecasts of world trade in 2023 have been lifted to show a sizeable expansion. But there are doubts about potential for this trend to persist through next year given underlying negative influences on coal consumption in many countries. During the first seven months of 2023, China’s coal imports (including some overland movements) rose by 121mt (86%), compared with last year’s same period, reaching 262mt. This remarkable growth was exaggerated by the comparison including an especially low volume in the first quarter of last year, but emphasized again the continuing dependence of China on foreign supplies. Nevertheless there are reasons for doubting whether a continued strengthening through next year is likely.
IRON ORE Signs of rising iron ore imports among most of the main buyers are limited. This pattern reflects weaker steel production
volumes amid restraints on demand in many steel consuming industries. China is an exception, with iron ore imports increasing by 7% to reach 669mt in the January–July 2023 period. According to World Steel Association figures for crude steel production, China’s steel output was 3% higher at 626.5mt in the first seven months of this year. That result contrasted with decreases in other countries. South Korea saw a 2% decrease to 39.4mt, while in Japan a 4% decline to 51.2mt was recorded. In the European Union there was far larger 10% reduction to 76.7mt.
MINOR BULKS Prospects for growth among the many and varied elements of the minor dry bulk commodities segment currently seem modest. The largest part of trade (including steel products, forest products and ores/minerals) relates to manufacturing activity and construction work, restrained by quite subdued economic activity.
BULK CARRIER FLEET A fairly brisk pace of newbuilding deliveries, accompanied by continued low scrapping, is likely to result in the world bulk carrier fleet growing in 2023 at a similar rate to the 2.9% seen last year. As shown in table 2, deliveries could be higher, while sales for recycling remain minimal albeit slightly larger, resulting in an end-year fleet totalling around 1,000 million deadweight tonnes.
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TABLE 1: MAJOR GRAIN IMPORTING AREAS (MILLION TONNES)
East Asia Southeast Asia European Union Middle East North Africa Sub-Saharan Africa
Wheat and coarse grains, crop years ending June (wheat), September (coarse grains) 2018/19 2019/20 2020/21 2021/22 2022/23* 58.9 69.1 106.0 96.5 89.5 45.6 47.5 46.3 45.3 42.9 32.1 24.2 21.2 26.2 39.0 58.8 65.2 59.7 68.2 70.4 47.7 51.5 49.5 46.7 43.2 26.2 30.9 30.3 30.8 28.1
source: US Department of Agriculture
*forecast, as at 11 August 2023
2023/24* 97.2 45.9 32.8 65.7 50.5 30.3
SEPTEMBER 2023
TABLE 2: WORLD BULK CARRIER FLEET (MILLION DEADWEIGHT TONNES)
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Newbuilding deliveries Scrapping Losses Other adjustments/conversions Net change in fleet Fleet at end of year % growth from previous year
2018 28.6 4.4 0.2 0.0 24.0 846.0 2.9
2019 41.7 7.9 0.1 0.0 33.7 879.7 4.0
source: Clarksons Research (historical data) & BSA 2023 estimate
2020 49.1 15.2 0.5 0.0 33.4 913.1 3.8
2021 38.2 5.2 0.1 0.0 32.9 946.0 3.6
2022 31.5 4.3 0.1 -0.1 27.0 973.0 2.9
2023* 34.0 6.0 0.0 0.0 28.0 1001.0 2.9
*forecast
by Richard Scott, Bulk Shipping Analysis, Tel: +44 (0)12 7722 5784; Fax: +44 (0)12 7722 5784; e-mail: bulkshipan@aol.com
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Brazilian North terminals grain exports growing
Cargill CBU at Santarem Terminal, operating at maximum capacity.
On 1 September 2023, USDA (US Department of Agriculture) confirmed that Brazil was for a second year the main corn exporter. This development is the result of a growth in continuous production, and is being supported by logistic expansions at ports in the north of the country, writes Paulo Lemgruber, INTEROCEAN Engenharia. Mainly using inland navigation that started 30 years ago, Madeira river inland navigation for grains feed the new private harbours enterprises that are currently operating at Itacoatiara, Santarem, Vila do Conde and Santana harbour complexes. The Itaqui harbour is serviced by railway from the eastern farming region as well as by roads. These new logistical options support the farmers’ best priorities to enlarge productions, originally of soya and lately corn. It’s also of key importance that the USA is using more corn for ethanol, in the same way that Brazil uses sugar cane production for clean fuel — a far better environmental solution than Europe’s electrical generation mainly by coal power plants. Amazonian inland navigation has been driven by modern azimuthal pusher boats that operate more reliable at higher speed than conventional pushers. They provided better convoy controls at the bends and narrows of wild waterways subject to expressive flood currents and depths exceeding 18m at Madeira, 23m at Amazon and 7m at Tapajos rivers, the main waterways from Central North to the world, providing the extra production
TGPM Floating Terminal (ADM & GLENCORE ) at Para river with two roofed barges for SIWERTELL barge unloader 1,800tph.
A 5x5 UNITAPAJOS (BUNGE & AMAGGI ) convoy 50,000dwt designed by Brazilian INTEROCEAN. At Tapajos-Amazon-Para the river is subject to waves because of Amazonian storms. The hatch covers with aluminium light weight fast handling, supplied by Belgian manufactures Blommaert, provides full hold access during fast loading and unloading operation and provides safe watertightness.
natural gas). The seasonal forest fires as result of warm equatorial weather are far from the catastrophic situations presently seen in more developed countries areas Hawaii, Greece, California, Canada, France and Spain. More inland navigation transportation volumes in the north decreases pressures on trucking and railways (which have far bigger diesel oil consumptions and gas emissions, not to mention the social impact and road damage, resulting in more accidents and casualties at crowded south Brazilian roads and cities). The southern farmers will also enjoy less crowded harbours when more cargo moves to the north from inland western areas, that will continue to grow as Brazil is only using 13% of the country’s land for plantation. Besides about 25% for cattle, it’s a wise assumption that a move towards more farmland will continue, increasing Brazil’s production and feeding a still hungry world. This will inevitably be followed by inland fleet expansions and more exports of soya, corn, cotton, sugar, orange juice, coffee, rice, fruit, as well as beef, poultry, pork meat and soon fish from farms.
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has replaced two pneumatic unloaders with a single CSU with triple capacity and the same energy consumption — this is a big improvement that is already in use for unloading 80% of inland grain barges. Cargill’s CBU (continuous barge unloader) is installed at the floating terminal, designed by INTEROCEAN, at Santarem. It is used in all weathers and river levels, and has a roof to protect it at all times from the weather during rain. CSUs and CBUs with capacities from 1,200tph (tonnes per hour) to 1,800tph are in operation at five Amazonian terminals, but installations offering 3,500tph will be in operation soon. The USA’s internal corn market consumption boosting international prices, combined with new inland logistics in the north, makes more corn plantations feasible using fertilizer. Considering Brazil’s outstanding clean energy sources (hydropowers exceed 52%, followed by wind and solar clean sources providing about 30%, plus the biomass 15% and only 1% nuclear) thermo diesel is only used by 2% isolated sites within the Amazonian region. However, some of them are being replaced by LNG (liquefied
NEWS
required by world market. Nowadays 80% of grains and also minerals at South American waterways use azimuthal propulsion pushers, both within Amazonian and Mercosul (Paraguay-Parana rivers down to Argentina and Uruguay terminals). The long-recognized competitiveness of Brazilian farm inner fields is being supported by the best technologies for the modern pusher hulls that are being used for inland navigation and in harbours. These provide hydrodynamic protection against floating wood debris, as well as new barge standards that are bigger than those that are feasible in the USA — due to lock restrictions which do not affect both Amazonian and Mercosul waterways, with only one dam with locks at both North and South rivers. Several barges are 3,000dwt and some are even bigger at 3,500dwt, improving logistical handling during loading, navigation and unloading operations. This combines with extensive use of the modern continuous ship-unloading (CSU) technology from Siwertell. This technology ensures no leaking, no dust and superior performance compared with other solutions. At the Santarem terminal, Cargill
INTEROCEAN Engenharia & Shipmanagement Ltda 34 YEARS INNOVATION AND PERFORMANCE n Development of Amazonian floating
UNITAPAJOS (AMAGGI & BUNGE) at Tapajos river.
terminals and convoys n Navigation for agribulk and minerals n Outstanding performance from Pushers with Hidroprotector hulls against floating debris, with azimuthal propulsions both mechanical and electrical n Operating with HFO and also ATBs for safe reliable navigation and fast turnaround n Development of Mercosul waterways n New inland convoys standards with optimized ore barges and azimuthal pushers, for best performance and more economical than conventional pushers
CARGILL floating terminal at Santarem, Amazon river.
Av. Marechal Câmara 160, suíte 1014, Centro, Rio de Janeiro, BRAZIL interocean@interocean-rj.com.br | T: +55 21 2262 6023 | Mobile: +55 21 99235 9692
TRADE & COMMODITIES
Rising acreage for corn and soyabeans improves feedstuffs outlook in 2023/24
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Maria Cappuccio The International Monetary Fund (IMF) predict global growth at 3% in both 2023 and 2024, the slowdown being concentrated in advanced economies, where growth will fall this year and 1.4% next year. The euro area, still reeling from last year’s sharp spike in gas prices caused by the war, is set to decelerate sharply. By contrast, growth in emerging markets and developing economies is still expected to pick-up with year-on-year growth to 4.1% this year and next. The average, masks
significant differences between countries, emerging and developing, Asia growing strongly at 5.3% this year, while many commodity producers will suffer from a decline in export revenues. The IMF confirms that while stronger growth, lower inflation and some adverse risks have moderated, the balance remains tilted to the downside. Global crop prices are expected to fall in 2023/24 as global supply improves on rising acreage for coarse grains and
oilseeds with record output for corn and soybeans. Global wheat supply is forecast slightly lower in 2023/24. Increasing uncertainty around Black Sea exports following Russia's withdrawal from the Black Sea Grain Initiative, means global grain and oilseed prices are expected to experience further volatility in 2023/24.
DROUGHT CURBS WHEAT YIELDS IN NORTH AMERICA The global wheat and coarse grain harvests
SEPTEMBER 2023
GLOBAL FEEDSTUFFS-PRODUCTION, USE, FEED & STOCKS 2022/23-2023/24 (MT)
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Wheat Coarse grains Total grains Oilseeds
Prod 22/23 791 1,446 2,237 630
Prod 23/24 787 1,497 2,284 661
Use 22/23 796 1,456 2,252 *521
Use 23/24 796 1,485 2,281 *541
Feed 22/23 156 892 1,048 **348
Source: IGC/USDA — Prod major feedstuffs-mainly harvested Jul-Dec/Local Marketing years *Oilseed crush; **Oil meals feed use-excludes fishmeal
Feed 23/24 158 913 1,071 **357
Trade 22/23 215 221 436 201
Trade 23/24 210 234 444 196
Stocks 22/23 267 328 595 122
Stocks 23/24 259 340 599 136
Experienced Soya Bean Inspections Your global network of inspection and analytical services 21 Sefton Business Park, Aintree Liverpool, Merseyside L30 1RD United Kingdom T: +44 (0) 151 525 1488 E: glenn.forbes@alexstewartagriculture.com www.alexstewartagriculture.com
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are anticipated to rise by 47mt (million tonnes) to 2.28bn/t in 2023/24. Drought across the Canadian wheat belt is expected to cut spring wheat yields, reducing output to 31mt. Heat, dryness also featured across most of the US Southern Plains and in the EU 134mt, while heavy rains in key regions in China, dented yield prospects. The small reduction in the global wheat harvest is eclipsed by a substantial rise in coarse grains to over 1.49bn/t. Due mainly to an exceptional increase in the US corn crop, where increased acreage compensated for weather induced yield loss-large corn crops expected in Brazil and in Argentina; rising global output for sorghum and less barley. The global crop for oilseeds, is forecast to rise by 31mt to 661mt, including a large US soy crop with bumper crops anticipated for Brazil and Argentina.
FEED USE OF GRAINS AND OIL MEALS TO GROW IN 2023/24 Consumption of wheat and coarse grains to rise by 29mt to 2.28bn/t. Global wheat use at 796mt outstrips supply by 9mt — a small reduction for food/industry use 638mt and a 2mt increase for feed wheat to 158mt. Global coarse grains feed use is expected to grow by 21mt to 913mt with more corn, sorghum especially in China and less barley fed this year. Oilseed crushings
are forecast to increase by 20mt to 541mt, underpinned by demand for food, renewable biofuels with feed use of oilmeals forecast to rise by 9mt to 357mt.
RISING COARSE GRAIN IMPORTS TO CHINA China’s rising feed demand for livestock is expected to increase coarse grain imports by 7mt to 39mt in 2023/24; wheat imports are forecast 2mt lower at 11mt.
TRADE IN COARSE GRAINS RISES IN 2023/24 Due to a substantial fall in corn, barley and sorghum prices due to increased output, global trade in coarse grains is expected to rise by 13mt to 234mt in 2023/24. Lower trade is forecast for wheat 210mt and oilseeds 196mt.
GLOBAL WHEAT STOCKS AT LOWEST LEVEL IN EIGHT YEARS
SEPTEMBER 2023
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GLOBAL WHEAT PRODUCTION 2019/20–2023/24 (MT)
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EU UK Other Europe CIS Baltic’s N & C America S America N East Asia F East Asia Africa Oceanic Total
2019/20 138 16 4 129 89 29 41 271 27 15 759
2020/21 127 10 4 140 88 28 42 277 26 32 774
2021/22 138 14 5 134 71 33 34 284 31 37 781
2022/23 134 16 4 144 83 27 37 277 28 40 790
2023/24 135 15 5 136 81 31 41 289 28 26 787
Source: FAO, USDA, IGC trade — totals may not add due to rounding
GLOBAL WHEAT SUPPLY & DEMAND 2019-2023/24 (MT)
Global wheat stocks are lower at 259mt, while coarse grain stocks rise by 12mt to 340mt and oilseeds stocks by 14mt to136mt.
EXTREME WEATHER DENTS WHEAT OUTPUT IN MAJOR EXPORTERS
Despite extreme weather conditions occurring this season a mix of searing heat, drought, typhoons and floods, the global wheat harvest in 2023/24 is provisionally pegged by USDA at 787mt, 4mt below last year with larger wheat crops forecast for India, Argentina, Ukraine, the US and Turkey. Given, the extreme weather conditions experienced suggests global wheat output likely to be revised lower especially in major exporting countries.
DROUGHT IN KEY WHEAT PRODUCERS Production Consumption Trade Stocks of which China World Key exporters *
2019/20 759 746 195 298 150 148 62
2020/21 774 787 199 284 139 145 57
2021/22 781 792 205 273 137 136 63
2022/23 791 796 215 267 139 128 57
Sources: IGC, USDA-Production — mainly harvested Jul-Dec/Local marketing years *Argentina, Australia, Canada, US, EU, Kazakhstan, Russia, Ukraine
2023/24 787 796 210 259 133 126 54
In the northern hemisphere winter and spring wheat harvesting is wrapping up under mixed conditions with drought in several areas. El Niño has exacerbated drought in key wheat producing regions in the EU, US and Canada. StatCan confirmed, that despite a big increase in the planted acreage, Canada’s Spring wheat crop, would fall by 4mt to 22.1mt (all wheat 29.5mt) after a hot, dry summer diminished yields.
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In the southern hemisphere, there are expanding dry concerns in Argentina and Australia. Prices are likely to rise towards the end of the year as focus shifts to harvests in countries such as Argentina and Australia where dry weather has hit yields, and reduced supply; this should support a rise in wheat prices towards the end of the year according to Dennis Voznesenski Rabbobank. The most-active wheat contract on the Chicago Board of Trade (CBOT) closed up at $5.89/bu (19/09/23).
ARGENTINA’S WHEAT HARVEST REVISED LOWER
A shift from dry to wet conditions (due to the influence of El Niño) in Argentina is expected to cause a rebound in wheat production in 2023/24. Sowing progressed under mixed conditions as soil moisture starts to recover. The wheat harvest for 2023/24 is forecast at 15.6mt but according to the Rosario Grains Exchange this is likely to be 15mt — while abundant rainfall has fallen in the centre and east of the country, the same is not the case for western and northern areas, that are under drought conditions.
SEARING HEAT REDUCES AUSTRALIA’S WHEAT CROP
Australia’s ABARES forecast a muchreduced wheat crop of 25.4mt due to searing heat in some key producing Australian states. Poor harvests in major exporting countries further tightening global supplies
for wheat. Australia is a key supplier to buyers such as China, Indonesia and Japan, but a strengthening of the El Niño weather event suggests more dry weather is likely after the warmest winter on record. Ole Houe, of agricultural brokerage IKON Commodities said, “Compared to last year, the crop’s going to be over 10 mt smaller.”
ABUNDANT BLACK SEA EXPORTS PRESSURES PRICES
Prices remain pressured by abundant, competitively priced Black Sea exports. US wheat prices closed lower in September, as markets weighed efforts to renew the Black Sea Initiative, the prospect of tight global stocks due to drought versus hefty Russian wheat supplies. Since Moscow’s decision to quit the Black Sea grain export deal in mid-July, attacks on Ukraine’s export facilities have intensified. Ukraine has used routes to access the Danube ports. Romania is expected to approve a plan to upgrade road infrastructure in the Black Sea port of Constanta, increasing transit capacity to 4mt to assist Ukraine’s exports in the coming months.
FEED DEMAND SMALL INCREASE FOR
VIETNAM IMPROVES ACCESS FOR RUSSIAN
WHEAT
WHEAT
Global feed demand for wheat is expected to rise by 2mt in 2023/24, due to higher feed wheat use in China, where record rainfall during the wheat harvest adversely affected grain quality. In South East Asia, feed wheat demand is lower in 2023/24
The Vietnamese agriculture ministry recently removed creeping thistle (Cirsium arvense) from its quarantine list. This decision removes the main obstacle preventing Russian grain from entering this growing market. Wheat imports projected
Brakes, Couplings and Components info@sibre.de | www.sibre.de SIBRE Siegerland Bremsen GmbH | Auf der Stücke 1 - 5 | 35708 Haiger - (Germany)
to increase in Egypt 12mt, Iran 4.5mt, Morocco 6.5mt Indonesia 10mt and Philippines 6.5mt due to increased demand for feed and food/industry. The fall in shipments from Australia 22.5mt and Ukraine 11mt, outweighs exports from Argentina 10.5mt, EU 37.5mt and Russia 49mt with global trade in wheat 5mt lower at 210mt in 2023/24.
SOME BUYERS OPT FOR DIRECT PURCHASES Despite increasing attacks by Russia on Ukrainian port infrastructure, the wheat market focused on plentiful supplies from Russia, reportedly trading wheat at cheaper levels privately, to what they offer in public tenders, in order to incentivize government-to-government deals. Egypt’s state buyer, the General Authority for Supply Commodities (GASC) bought c.480k mt of Russian wheat in a private sale from Solarisc $270mt C&F; followed by purchases of 120k French, 120k Romanian wheat at $249mt and $261mt FOB respectively; offers from Russia $270mt FOB. South Korea’s Nonghyup Feed Inc. (NOFI) purchased c.55,000/t feed wheat in a private deal, optional origin c.$273.90mt c&f plus a $1.50/t surcharge for additional
TRADE & COMMODITIES
reflecting increased use of corn.
WHEAT STOCKS DECLINE IN 2023/24 With demand for wheat outpacing supply, global stocks are drawn-down to 259mt (World 126mt, China 133mt), the lowest level in eight years; stocks in key major exporting countries falling to 54mt.
HUGE US CORN CROP ANTICIPATED IN 2023/24 Coarse grain output in 2023/24, weather permitting is expected to chalk up a near record harvest 1,497mt some 51mt up on last year. In the US, any increase/decrease in corn yields, expected to have less impact. Additional acres planted on new data from the Farm Service Agency increased total US corn plantings to 94.9m/acres, expected to compensate for yield loss.
RECORD OUTPUT FORECAST FOR COARSE GRAINS IN 2023/24 Global coarse grain output is forecast to rise by 51mt to 1.497bn/t in 2023/24. Mostly due to a huge increase in the US corn crop 384mt and expected recovery in Argentina. Larger crops are indicated for sorghum 62mt with smaller crops for barley142mt and oats 21mt. Higher corn production in Argentina and the US is expected to offset lower barley production in key exporting countries such
GLOBAL COARSE GRAIN SUPPLY & DEMAND 2019/20–2023/24 (MT)
Production Consumption Trade Stocks of which China: Key exporters*
2019/20 1,420 1,436 215 337 201 84
2020/21 1,442 1,456 235 323 207 68
2021/22 1,504 1,489 237 338 210 86
2022/23 1,446 1,456 221 328 206 85
2023/24 1,497 1,485 234 340 202 102
Source: IGC/USDA * US, Argentina, Brazil, Russia, Ukraine, EU, Australia, Canada/red means check
GLOBAL CORN SUPPLY & DEMAND 2019/20–2022/23 (MT)
Production Consumption Trade Stocks of which China: Key Exporters*
2019/20 1,123 1,138 176 307 201 59
2020/21 1,129 1,144 184 293 206 38
2021/22 1,219 1,201 194 311 209 51
2022/23 1,155 1,167 181 299 205 50
TRADE & COMMODITIES
port unloading, to arrive in South Korea 20th November.
2023/24 1,214 1,200 194 314 202 70
Source: IGC/USDA * Argentina, Brazil, Ukraine, US
as Russia, the EU and Australia.
COARSE GRAIN DEMAND TO RISE IN 2023/24 Global demand for feed, food/industry use of coarse grains, is set to rise by 29mt to 1.485bn/t in 2023/24. This includes feed use increased by 23mt to 915mt and a 9mt increase in food/industry use to 572mt. Increased use in North and South America,
Middle East, North Africa, East Asia and South East Asia.
COARSE GRAIN TRADE 234MT Coarse grain exports are forecast at 234mt in 2023/24 an increase of 13mt on last year.
LARGE SUPPLIES DRIVE DOWN FEED PRICES IN 2023/24 Global corn output is forecast to rise by
www.drycargomag.com SEPTEMBER 2023
DCi 13
TRADE & COMMODITIES
59mt to 1.21bn/t in 2023/24 buoyed by a huge US crop of c.384mt, EU 59mt, Ukraine 28mt, China 277mt. With demand increasing to 1.2bn/t, higher feed use is set to rise by 26mt to 756mt due to falling prices, with non-feed use expected to rise by 8mt to 444mt. Growth in corn supply, to outpace the growth in demand, driving down world prices for feed, food/industry and ethanol production while incentivizing major corn producing countries such as US and Brazil towards greater industrial consumption.
WET WEATHER DENTS CORN IN CHINA The prospect of a record US crop, will support higher feed use by the livestock sector and compensate for reduced pasture in the Midwest due to drought. Increased output in Canada and Ukraine more than offset lower crops in EU, Russia and China, where extreme wetness (excess rainfall and tropical storms) likely impacted some corn-producing regions. Official estimates point to a cut in production of
WORLD-MAJOR OILSEED SUPPLY & DEMAND 2020–2023/24 (MT)
Production of which (soybeans) Crush Consumption* Trade meals* Trade seeds Stocks of which (soybeans) key exporters**
2019/20 582 341 509 337 96 192 112 68
2020/21 609 369 509 341 97 192 116 64
2021/22 612 360 511 341 96 179 119 56
2022/23 630 370 521 347 97 201 122 73
2023/24 661 401 539 356 100 196 136 65
Source: USDA/*Meals cons/trade-excl. fishmeal **Argentina, Brazil, US
3mt; but an uptick in imports of corn and other coarse grains, suggests China is taking advantage of low grain prices to replenish stocks, increasing feed demand or, output is more affected?
CORN IMPORTS SUPPORT FEED USE China's corn imports are forecast to remain high in 2023/24 due to the large pig
herd and strong consumer demand for meat, with imports needed to supplement insufficient domestic feed production. Historically, China has relied on the US and Ukraine for imports. However, given the ongoing war in Ukraine and until recently higher US corn prices, China has diversified into new markets, like Brazil.
SOUTH AMERICAN PRODUCTION PROSPECTS MIXED?
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Evolving El Niño conditions are expected to increase prospects in Argentina-with corn production forecast at 54mt, exports 34mt in 2023/24, while possibly reducing production prospects in Brazil. Conab forecast Brazilian farmers will produce 129mt corn crop due to a larger planted area and higher yields. Brazilian farmers had harvested 93% of the area planted for their second corn crop in the centre-south region by early September. Producer margins for corn are positive, underpinned by agreements signed with China. Brazil’s exports are forecast at 59mt in 2023/24, given large supplies, favourable exchange rates, robust demand and improving logistics.
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MAJOR EXPORTER BIDS FOR CORN DRIVEN HIGHER
Global corn stocks are increased to 314mt in 2023/24 (World 112mt, China 202mt), including an increase in major exporters stocks. With plenty of Brazilian corn in the market, a record crop in the US, improved crop in the EU, pressured prices at major export ports which have fallen since last year by c.$60/t-$90mt. Brazil Feed (Paranagua) $227/t (Sept 19 ’23); Argentina Feed (Up River) $241/t (Sept 19 ’23); US 3YC (Gulf) $233/t (Sept 13 ’23).
MODEST EXPANSION FOR MEAT TRADE IN 2023/24 The outlook for global meat trade remains relatively unchanged. Beef, chicken meat
GLOBAL BARLEY CROP REDUCED TO 142MT IN 2023/24
TRADE & COMMODITIES
exports are similar, while pork is 2% higher since April. Brazil continues to make export gains and set new records for beef, pork, and chicken meat. Higher beef prices, global production is revised up to 59.6mt. Drought induced herd liquidation in Argentina increased production; larger feedlot placements and higher cow slaughter are expected to boost US output; New Zealand production is raised as male dairy calves are marketed for beef. Global pork production for 2023 is forecast at 114.8mt with increases for China, Canada and Brazil offset by reduced output in the EU, Japan, the Philippines, and Mexico. Despite mostly negative margins industry-wide, China’s output is raised as producers reduce herds to maintain cash flow. EU production is pressured by environmental regulation, weak consumption and higher feed costs; production in the Philippines is stymied due to the expansion of African Swine Fever (ASF). Strong demand in China, supports increased global pork exports of 10.8mt in 2023 — while reduced pork supplies from Canada, UK, EU, gift opportunities to the US and Brazil, to supply several Asian markets like South Korea and the Philippines. Chicken meat output has increased to 103.5mt, on a continued outlook for improved feed prices and no major outbreaks of highly pathogenic avian influenza (HPAI) in Brazil, EU and China. Chicken meat exports are slightly higher at 13.8mt, Brazil 4.8mt, Thailand 1.1mt.
importers like Saudi Arabia and Thailand compete for supplies. By contrast French and Argentine barley prices are c.$238mt and $235mt respectively.
SORGHUM OUTPUT TO RISE IN 2023/24 Global sorghum output is expected to rise to near record 62mt in 2023/24, the increase mostly due to a large US crop of almost 10mt, with better crops in Argentina and Brazil. Global sorghum exports are forecast at 10.2mt. China is the largest market importing 8.5mt. With domestic feed costs increasing in China, imports of sorghum from the US are driven by demand for the pig, poultry feed sectors and for baijiu (a national spirit beverage) made by fermenting cooked sorghum. Major sorghum exporters include the US 6.5mt, Argentina 1.8mt and Australia 1.7mt. Sorghum values, like other coarse grains have fallen-FOB Texas $245.36 (11 Sept ‘23).
CHINA TO IMPORT 104MT SOYBEANS IN 2023/24
With an increase in the planted area, global oilseed production underpinned by demand for food, feed and renewable biofuels is expected to rise by 31mt to 661mt in 2023/24. The huge global oilseed crop if realized will cap price gains. USDA forecast the global soybean crop to rise to 401mt; this includes a huge soybean crop in Brazil 163mt, Argentina 48mt, Paraguay 10mt, with a smaller US crop 112mt. Some analysts suggest the downgrade for the US crop
Global trade in oilseeds to fall by 5mt to 196mt. US soybean exports are lower as Brazil’s large crops overshadow the market. Similarly, rapeseed exports from Canada are also lower. China is projected to remain the world’s largest soybean buyer with increased imports forecast at 104mt, to support the livestock industry, buying more from Brazil and less from the US, as new US soy crop prices have risen on lower supply expectations. DCi
CHINA REMOVES DUTIES ON AUSTRALIAN
SEPTEMBER 2023
GLOBAL SOYBEAN OUTPUT TO RISE TO 401MT IN 2023/24
BEANS
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USDA data showed the weekly condition ratings for US soybean crops declined this past week (Sept 11), hovering at their lowest levels in a decade as dry conditions expanded, with crop estimates likely subject to further downgrades.
EXTREME HEAT DENTS OUTLOOK FOR US
Global trade is 3mt lower at 27mt with exports increased to Algeria, Jordan, Morocco and Tunisia. This year, with a smaller global barley harvest China is expected to import 7.5mt of barley along with other coarse grains, removing the duties imposed on Australian barley in place for some years. Australian export prices jumped 8% to $255mt as other
RISING CONSUMPTION MEAL, OIL AND SEEDS IN 2023/24 Consumption of meals expected to rise by 9mt to 356mt. With crush profitable and soybean oil in demand for food and biofuels, the US soybean market is anticipated to move sharply higher on a lower yield, despite reduced crush output in August. The crush industry’s recent capacity expansion, the adverse Midwest heat wave and hurricane disrupted transportation in the southeast, made estimating the August crush more difficult. “When you’ve had margins over $2/bu and you’re cranking out profits, going into the next harvest you have to throttle back to get ready,” said Don Roose, president of US. Commodities. “I expect it to bounce back pretty soon.”
This is driven by reduced area planted and weaker yield potential across major producing areas including the EU, Russia, Ukraine and Australia more than offsetting higher production in Argentina, where good yields are expected to improve outturn. The global barley crop is forecast at 142mt, 10mt lower in 2023/24. Feed use is forecast lower at 98mt, with a small increase in food/industry 46mt.
BARLEY
may be premature and the final US soy output likely to be higher c.121mt/122mt. Despite lower rainfall in Brazil’s northern and central regions, production in the south, being responsible for around half of Brazil’s soybean output is expected to offset any production shortfall from these regions. Elsewhere, better crops are also anticipated for palm kernel 20.5mt, groundnut 50.7mt, sunflower seed 55.8mt and copra, partially offset by smaller rapeseed and cottonseed crops.
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NEWS SEPTEMBER 2023
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SHIPPING & TRANSPORT
Zinus: pioneering a brighter, greener
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In a time where the world is pushing towards sustainability, Zinus stands as a leader of innovation and green technology in the maritime sector. Established within Los Electro and later branching out as a standalone entity in 2018, Zinus quickly expanded, growing from a team of three individuals to employing over 40 expert professionals, all within a span of five years. This swift progression is a tangible testament to its mission statement: ‘Supplying the most innovative, efficient, aesthetic, and user-friendly solutions for an electrified world’. At the core of Zinus’s operations is the production of innovative shore power charging and cable management systems — which are suitable for use with all vessels, including bulk vessels. These include products such as their Compact ZPP215 &
ZPP115 shore power units, autonomous charging solutions, and more. Crafted with an eye for aesthetics and a dedication to efficacy, these products encapsulate innovation, scalability, stringent safety protocols, and a small footprint, setting a high bar within the market. Zinus’s diverse portfolio caters to a wide range of vessels including bulk vessels, container ships, tugboats and ferries, a clear indication of the versatility and effectiveness encapsulated in their design philosophy. The utilization of Zinus products is a significant stride towards environmental conservation, allowing for a significant reduction in the maritime carbon footprint, and fostering a cleaner, greener future. In recent years, Zinus has made a significant footprint in the global market,
with an expanding influence stretching far beyond its Norwegian roots. Its recent ventures in North America have initiated collaborations with industry behemoths like Seaspan in Vancouver and Shell in Texas, a clear indication of their growing global stance. These collaborations are just the beginning, paving the path for an even broader global presence and a commitment to spearheading a maritime revolution. The journey does not end here. As Zinus forges forward, it continues to invest heavily in research and development. This commitment to continuous improvement and evolution ensures that they remain at the forefront of technological advancements in the sector, driving change, and fostering sustainable practices that resonate well with the global push towards green energy. The company’s dedicated
maritime future
team tirelessly works towards perfecting their existing products while also developing new solutions that embody efficiency and innovation. Furthermore, Zinus has been building robust relationships with key players in the industry. Having worked with all the major ferry companies in Norway and establishing ties with global giants such as Shell, Seaspan, Wärtsilä, ABB, and Powercon, Zinus is steadily establishing itself as a trusted name in the sector. Its focus remains on fostering partnerships that facilitate growth and promote green energy solutions in the maritime industry. As the company evolves, it retains a close-knit community spirit, sponsoring local events and intertwining itself with the societal fabric. This approach not only fosters a sense of community but also aligns with their mission to contribute positively to the world, reflecting a corporate philosophy that goes beyond business. Looking at Zinus’s journey so far, it’s clear that their story is not just a business growth narrative. It is a glowing illustration of what is possible when innovation meets passion and commitment to a greener world. As they continue to grow, they remain dedicated to their mission, embodying the spirit of innovation, and fostering a brighter, cleaner future for the maritime sector and the world at large.
SOME THINK THAT RAW MATERIALS TRANSPORT REQUIRES TRUCKING. WE THINK DIFFERENT. beumer.com
NEWS SHIPPING & TRANSPORT
Regulation, innovation and cleaner hulls More collaboration and disruptive innovation is urgently needed if the shipping industry is to succeed in reducing emissions, preserving fuel and protecting the environment, argue Jotun and Bellona executives. Speaking at the Tradewinds ocean stage panel discussion at NorShipping, Morten Fon, President and CEO of Jotun when asked where shipping is at when it comes to decarbonization and reducing emissions said, “We have a long way to go. Everybody is focusing on it. One thing that we have to acknowledge is that everybody can contribute because this is not a one company game. We must do this together if we are going to achieve the decarbonization goals.” Agreeing with that sentiment, Petter Korslund, Regulatory Affairs Manager Jotun Performance Coatings added, “From a regulatory perspective, it’s encouraging to see the impact new requirements such as CII and the EU’s ETS are already having on the industry ... we’ll face more regulatory challenges in the future. Decarbonization is vital and adopting new regulations to deliver the long-term goals of the Paris Agreement requires significant collaboration from industry and policymakers.” Hallstein Havåg, CEO Bellona Foundation highlighted that the world is behind schedule in cutting emissions and it is too easy to fall into the trap of looking far ahead for solutions when some such as Jotun’s are already available. Both he and Korslund made the point that although the focus of action is mainly around alternative fuels it could be some time before they are available but energy efficiency measures are already here.
SEPTEMBER 2023
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BIOFOULING NOT ON EVERYONE’S AGENDA
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Referring to the recently published results of Jotun’s Clean Shipping Survey, Fon said biofouling and its impacts are not on everyone’s agenda. “We have to work hard to increase the focus on it across the industry and find solutions together today. We cannot wait for tomorrow.” He continued, “The hull performance systems that we are providing have been proven to deliver reduced emissions, better financial performance and also reduce the transfer of invasive species around the world. So, we can do it today but I’m afraid much more needs to be done if the industry is to combat the global biofouling issue. It’s also important to point out that regardless of what fuels will be used in the future, a clean hull will always be beneficial because operators will use less fuel and
thereby save costs.” Discussing some of the findings of the Jotun survey report Korslund said, “It’s worrying to see that two thirds of maritime professionals underestimate the impact of biofouling. There’s a definite need to increase awareness of this major issue”. According to the survey, 62% of respondents said they do not invest in reducing biofouling outside of drydocking but focus on it every five years. “That’s concerning as there’s a need to address biofouling regularly if shipping is to become more sustainable,” said Korslund. “On a positive note, the survey highlighted the positive impact of new CII regulations, with the majority of respondents saying they expect tackling biofouling to form part of their strategy to improve fuel efficiency, reduce GHG emissions and support environmental policies,” he added. The survey found return on investment (ROI) is a dominant consideration for new technologies. “It seems clear from the survey that many operators, when considering new emissions technologies, they look through the lens of finance and there needs to be an incentive for them, to make sure the finance is well spent. Our message is investing in proven technologies will bring benefits today. And even if there’s not the highest ROI right now to do something to reduce your emissions, it will be in the future as regulatory and commercial demands increase,” said Korslund.
MORE COLLABORATION AND DISRUPTIVE INNOVATION NEEDED
Fon also emphasized the survey highlights the lack of focus on tackling biofouling comes back to the need for innovative, disruptive thinking to create solutions to keep clean hulls today – and in the future. “Jotun’s Hull Skating Solutions is a good example of what can be done to help solve the problem. And I think it’s also a very good example of collaboration. When we developed our Hull Skater we did it together with industry partners like Kongsberg, DNV, Telenor, Semcon and Foss Tech. Our collaborative approach enables us to join forces, share our knowledge and expertise to help solve the global biofouling issue.” All agreed that international regulation was essential for progress to be made and that it was good the IMO was reviewing its biofouling guidelines. “Today we have different practices from port to port, country to country and this is a major challenge. We hope the IMO will address
this because the best solution would definitely be one regulatory framework that we can rely on — it would make life much easier,” said Fon. Looking ahead, Havåg said, “There isn’t a silver bullet to decarbonize shipping, there’s no single solution. You have to do everything and focus on both short and long-term efforts so we’re involved in many projects, including hull cleaning practices, that are vital to address the challenges today and tomorrow.” Fon agreed, adding, “Partnerships are very important, and the development of the Jotun Hull Skater is a good example of what can be achieved through good collaboration. We all share the benefits, there is no one winner. Going forward, we have to partner more with our ship operator customers because we have to get the solutions onboard their ships and clean hulls regularly.”
GO GREEN BY BLACK NUMBERS “Our experience shows that when businesses step up and use solutions to improve their environmental footprint, then things really start to fast track,” said Havåg and added, “We really hope to see that here because there’s definitely a business case. As a foundation we often say we have to go green by black numbers. We can’t be in the red and solutions like Jotun’s definitely will help improve operational costs as well as reduce emissions so why wait?” Korslund pointed to a practical example of collaboration and opportunity, “Bellona has started the Clean Hull Initiative, where international stakeholders, including Jotun, are working together to develop an ISO standard for in-water proactive cleaning. This work is ongoing and industry wide participation, including ports and regulators, is important to make sure the standard is accepted and adopted to the widest extent possible.” Speaking on the sidelines of the panel talks, Morten Sten Johansen said, “Participating in industry initiatives and partnerships are important. Shipping is a global industry and it’s imperative that we take a united international approach if we are to succeed in reducing emissions, preserving fuel and protect the oceans’ biodiversity” and concluded, “Industry collaboration is also an important part of Jotun’s Clean Shipping Commitment, and a means to accelerate sustainable innovation at a time when the entire industry is grappling with new regulatory measures.”
in position for timely installation. “It’s no secret, with supply chains routinely disrupted, that ordering steel parts that must be fabricated or sophisticated electronic parts should be done on a ‘sooner the better’ basis,” comments Andreozzi. “Late redelivery after a drydocking is counted in off-hire time and resulting costs.” With Andreozzi covering ships drydocking around the Mediterranean, and Büsing mainly focusing on Germany, the superintendents offer different accounts of customer attitudes and expectations where repair services are concerned. However, both emphasize pre-docking inspection (PDI) as an increasingly powerful tool for ensuring that dry dock work is planned for relevance, thoroughness and time efficiency.
SEPTEMBER 2023
relationship with clients and offers a chance to increase mitigation against the risk of late ship redelivery. Among those filling the newly formalized ‘Drydock Superintendent’ role are Luca Andreozzi and Kai Büsing, two individuals with long industry experience who have been appointed from within the MacGregor ranks. Both superintendents co-ordinate drydocking to support MacGregor’s broad portfolio of cargo access and load handling equipment, liaising with the supplier’s teams of locally based experts who support shipyards and owners in maintaining OEM-based equipment performance standards. Büsing says that MacGregor is now offering to start planning as much as a year ahead of a scheduled drydock, to ensure that all parts are fully tested, approved and
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re-docking inspections provide an increasingly powerful means of ensuring a successful dry-docking, according to MacGregor. Sometimes costly, periodically mandatory and ultimately inevitable, the drydock is part of the normal life of a ship. However, with days in dock also experienced as lost earnings, the stakes are high for what is a rare opportunity to deal with the safety, environmental and efficiency issues that cannot be handled in service. MacGregor recently created a new drydocking superintendent function within its organization to provide internal and customer-facing focal points for project delivery. The load handling specialist says that adding new oversight changes the nature of its drydocking service
SHIPPING & TRANSPORT
Drydocking pre-inspections avoid future pain
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SHIPPING & TRANSPORT
FORMAL APPROACH “Crew report maintenance issues to the ship’s owner or manager on continuous basis, while marine engineers are renowned for their resourcefulness in getting machinery working,” says Andreozzi. “However, checking equipment prior to drydocking against the operating manual to establish condition, based on safety parameters, potential operating risks and repair requirements need a formalized approach.” “After the engine, the readiness of the handling and access equipment to do its job will determine whether the ship itself can work,” says Büsing. “In simple terms, if the quarter deck is stuck in the open position, then the ship can’t leave port, but suboptimal equipment performance is also of relevance to the charter party agreement, or the vessel’s attractiveness for future hire. Our focus is to maximize our operational availability and to minimize unplanned downtime.” Where the conventional approach will see planning based on experience, owners will wait for the drydock to take full stock of requirements. The PDI allows MacGregor to identify current issues long before the drydocking and make its recommendations ahead of time. “We are not in direct contact with individual ships as such, but as ex-service engineers we are fully aware of the nuances involved in the dialogue,” adds Büsing. Once the PDI is underway on board, capturing digital images is a key part of establishing the real condition of equipment in service, he says, so that effective maintenance can be planned for — “not just general requirements based on its age”.
SEPTEMBER 2023
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PLANNING RESOURCE
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In a complementary part of the process, MacGregor’s newly framed pre-inspection service is reflected by new dry-dock functionality in its CRM that is helping it make better use of records, according to Andreozzi. “We are anticipating forthcoming surveys and liaising directly with customers to share our insights with them on what their needs will be and the advantages of planning for potential solutions. We already have the service reports for our equipment in the system to access before we go on board.” Sometimes, customers use competitor services so MacGregor may not have access to all documentation, Büsing acknowledges, while Andreozzi says that customer records may not always
be exhaustive. Nevertheless, the PDI is a ‘value add’ just because it works from the most comprehensive records available to the OEM and provides a platform for better drydocking management for the client. “Over the years, MacGregor has supplied equipment for installation on board something like 30,000 commercial ships, so you can see that pre-inspection service capability is significant for drydocking efficiency — for us but also for a reasonable slice of commercial shipping,” Andreozzi observes. Andreozzi says around half of the drydocking projects he has been involved in over the last 12 months have taken advantage of the PDI approach. Büsing says that customers quickly appreciate the PDI service when planning for complex jobs. However, Büsing adds that customers can overlook benefits where straightforward maintenance is concerned. “Customers will feel comfortable taking care of hatch cover renewal or deck machinery maintenance and see the PDI as only relevant when they know that cranes or steering gear need to be repaired or upgraded.”
SIMPLICITY ITSELF “The pre-docking inspection gives MacGregor the opportunity not only to assess and co-ordinate parts dispatch, but also to co-ordinate where and when those parts are most usefully delivered, and at what point MacGregor personnel should attend the docking project,” adds Andreozzi. The PDI also offers an opportunity for MacGregor to give clients
fair warning of obsolescence or any approaching non-compliance issue where their shipboard systems are concerned. “In a recent case involving a post Panamax container ship, we identified that steering gear pumps were obsolete four months ahead of drydocking. While the system was still functional, our health check led on to pump exchange and refurbishment being included seamlessly in the drydocking. That project led on to another with the same owner.” Andreozzi points out that an owner ordering well in advance of a drydocking is also less vulnerable to price inflation than one seeking parts for immediate delivery, adding that the moderate costs associated with a PDI can be quickly dwarfed by a hard to find spare. But so convinced is MacGregor that the PDI approach works that the company is offering daily inspection prices that are not only fixed but deductible from the cost of spares over a pre-agreed minimum. “I think it’s fair to say that once we get the PDI service in front of customers they immediately see benefits,” adds Büsing, “but perhaps they still don’t recognize the full potential. They see that doing this now and saving two weeks off-hire later is a clear win, but still struggle with the cost of travel for a service engineer. That’s why we came up with the fixed day rate offer that is also deductible.” “If you bought a certain number of spares, I suppose you could look at it as a free pre-inspection,” comments Andreozzi. “But I think it’s really more of an acknowledgement that the PDI has mutual benefits for both sides.” DCi
Bulker Services
SHIPPING & TRANSPORT
Now serving in bulk
Rendered image of a Bocimar bulk carrier in development. Jay Venter
Future fuels for bulk carriers WINGD SUPPORTS BULK CARRIER TRANSITION TO ALTERNATIVE FUELS
THE VALUE OF COLLABORATION
THE DEVELOPMENT TIMELINE While ammonia is expected to be particularly viable for bulk carriers
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The combustion engine is the ideal vehicle to maintain flexibility in fuel choice and is likely to remain a critical factor in achieving operational viability for all emerging alternative fuels. As the development work continues, collaboration with customers and technology providers is essential to accelerate the process. Following successful small scale engine tests in May 2021 and full scale combustion tests in December 2022, WinGD is confident that it will have the first X-DF-A dual-fuelled ammonia engines ready for commercial introduction by 2025. This is being made possible by both the company’s in-house research investments and strong collaboration with engine and shipbuilders in China, Korea and Japan. WinGD has also signed a Memorandum of Understanding (MOU) with Mitsubishi Shipbuilding to prepare the X-DF-A engine for applications in a range of vessel sizes. At the same time, work is under way to ensure
smooth integration with the engine’s ammonia fuel supply system. A similar agreement was signed with Hyundai Heavy Industries (HHI), ensuring that multiple shipbuilders and engine builders will be ready to deploy WinGD technologies as shipowners consider their options. As WinGD’s CEO Dominik Schneiter explains: “The value of collaboration cannot be overemphasized. The various parties each bring their own expertise and experience, and this will accelerate technological innovation to enable a seamless transition to safe and reliable operation with net-zero carbon fuels.” For both owners and operators, preparing for alternative fuel operations is as important as investing in technology. Ensuring that ship crews can familiarize themselves with operating the new engines is an essential part of the transition. WinGD is playing an active role in this area too. Earlier this year the company signed an agreement with AET tankers and its sister company Akademi Laut Malaysia to develop crew training for ammonia engines.
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When Swiss marine power company WinGD agreed to develop ammoniafuelled engines for a series of 210,000dwt bulk carriers being built for Belgian owner Bocimar, the term ‘future fuels’ began to appear misplaced. The aim is to have the engines — all ten of them — installed and operational as soon as 2025 and 2026. The ‘future’ is, therefore, undoubtedly close at hand. The ships will be powered by WinGD X72DF-A two-stroke dual-fuel engines. The development work for the large bore engines is being carried out jointly by WinGD and CMB.TECH, a company that builds, designs, owns and operates large marine and industrial applications running on hydrogen and ammonia. The vessels will be the first of their kind to run on ammonia and will clearly demonstrate that large bulk carriers can successfully operate with zero-carbon fuels. The vessels’ entry into service will come ahead of regulatory requirements to reduce greenhouse gas emissions, giving operators time to gain experience with new fuel and engines. At its latest Marine Environment Protection Committee meeting in July, IMO agreed to new
greenhouse gas reduction ‘indicative checkpoints’ in 2030 and 2040, including an alternative fuel use requirement of 5–10% by 2030, with specific economic and technical measures coming into force by 2027.
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SHIPPING & TRANSPORT
deployed to specific trades, especially those where a complementary trade in ammonia is emerging, other alternatives will also be needed in the sector. In addition to X-DF-A, WinGD is also developing its X-DF-M dual fuel engine, which can run on both methanol and conventional fuel. The use of green methanol, made with hydrogen from renewable-sourced electricity and recaptured carbon, would make ship power from these engines near zero emissions. While introduction of the X-DF-A ammonia-fuelled engine is targeted for 2025, the timeline for the methanol-fuelled
X-DF-M engine is such that engine validation will be carried out in early 2024. The engine is expected to be commercially available by the end of that year. Since they will be capable of operating with both conventional and alternative fuels, there is a well-established emissions abatement concept with both these engines. They will have nitrogen oxide (NOx) compliance, and the use of selected catalytic reduction (SCR) will be required only for IMO Tier III compliance.
SERVING THE BULK CARRIER SEGMENT As the Bocimar development highlights, WinGD continues to expand its customer
base within the bulk sector and sees further opportunities for innovative projects as the transition to alternative fuels gathers pace. Providing the technology and support necessary to implement these changes is a key element of WinGD’s strategy. “There is a clear incentive for owners, fuel suppliers, and technology providers to prepare for zero and near zero fuels. The IMO’s emission targets require that decarbonization is well under way by 2030. At WinGD, we are working hard to be sure that operators have the means for easy compliance,” commented Dominik Schneiter.
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Navigating the digital wave in maritime operations: strength of partnership
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In the dynamic world of maritime operations, the winds of change are blowing towards digitalization. As ports across the globe confront challenges like burgeoning vessel traffic, environmental sustainability, and the imperative for realtime, data-driven decisions, the role of Software as a Service (SaaS) solutions has become paramount. These solutions, like Unikie POLO, are not just tools; they represent a partnership, a commitment to walking alongside ports in their digital transformation journey. Unikie POLO, a standout SaaS solution, offers a comprehensive suite of tools designed to integrate port area functions seamlessly, providing a virtual operation room adaptable to all port types. But beyond its features, what truly sets POLO apart is the strength and commitment of partnership it brings to the table. Here’s how this partnership, embedded in the very fabric of the SaaS solution, is shaping the future of maritime digitalization: 1. ENHANCED SITUATIONAL AWARENESS Beyond just offering a tool, our partnership ensures that ports maximize the benefits of POLO’s Activity View feature. Unikie works closely with stakeholders to customize port call timelines, ensuring real-time data is always at their fingertips, leading to informed decisions.
2. GLOBAL TRACKING WITH A PERSONAL TOUCH While the Global AIS feature offers unparalleled map visibility, Unikie’s partnership ensures that this tool is tailored to the unique needs of each port, facilitating efficient planning and reducing potential conflicts.
5. EXCEPTION HANDLING WITH A HUMAN TOUCH While POLO’s EvIA tool efficiently handles exceptions, the partnership ensures that ports have the support they need during unforeseen events. Unikie is available to offer solutions, guidance, and the assurance that they’re not alone.
3. CO-CREATION AND COLLABORATION The essence of POLO’s Open Ecosystem model is partnership. By allowing stakeholders to join, share, and innovate, Unikie is not just providing a platform but fostering a community. Its commitment is to evolve with the industry, ensuring that its software remains relevant and cuttingedge.
6. A JOURNEY TOGETHER Digital transformation is not a destination but a journey. As ports embark on this path, the partnership ensures they have a trusted ally every step of the way. From initial integration to ongoing support, Unikie is committed to making their digital journey smooth, efficient, and future-ready.
CONCLUSION 4. SUSTAINABILITY AS A SHARED GOAL The partnership goes beyond software. With features like emission calculations, Unikie is committed to helping ports achieve their sustainability goals. Together, it is possible to identify areas of improvement, adopt eco-friendly practices, and make a tangible difference.
In conclusion, while technology and tools like Unikie POLO are reshaping the maritime sector, it’s the strength of partnership that truly makes a difference. As ports navigate the digital wave, Unikie is here to assure them that with the company by their side, they’re poised for success, sustainability, and a brighter digital future.
jotun.com
Clean Shipping Commitment The need to improve sustainability in the shipping industry is accelerating. The global industry must cut carbon emissions, protect marine biodiversity and leverage the use of data for smarter decision-making. With nearly 100 years of experience of charting through unknown waters, Jotun is committed to continuously innovate and develop advanced products and solutions designed to protect biodiversity and cut carbon emissions to support global sustainability ambitions and achieve cleaner operations for all industry players. A clean hull ensures cleaner operations.
HULL PERFORMANCE
SHIPPING & TRANSPORT www.drycargomag.com SEPTEMBER 2023
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Rotor Sails on course for improved bulker efficiency In June, the 82,000dwt Kamsarmax bulk carrier TR Lady was retrofitted with three 24m-tall Rotor Sails from Anemoi Marine Technologies at Chengxi Shipyard in China. These mechanical cylinders were installed with the sole purpose of improving the energy efficiency of the vessel by providing alternative wind propulsion to reduce its fuel consumption and carbon emissions. The results of the vessel’s maiden voyage following the installation showcased the true effectiveness of Rotor Sails for modern bulker vessels. Initial data from the vessel’s voyage from China to Australia indicated that the vessel can expect to save around 10% of fuel and emissions annually as a direct result of the newly installed technology. Owners and managers of bulk carriers are in the midst of improving or bolstering the energy efficiency of the vessels. This issue continues to be a major talking point amongst major players, most recently following the 80th meeting of the International Maritime Organization’s (IMO’s) Marine Environmental Protection Committee (MEPC) in July, which reinforced the need for vessel owners to strengthen the energy efficiency of their vessel in line with global requirements. This includes the Carbon Intensity Indicator (CII), Energy Efficiency Existing ship Index (EEXI) and the Energy Efficiency Design Index (EEDI). Fortunately, technologies, fuels and energy sources that reduce vessel emissions are becoming more readily available. With the recent success of the TR Lady voyage, it stands to reason that Rotor Sails are a leading option for bulker owners that are seeking viable, costeffective and commercially available decarbonization technologies that can be installed swiftly and provide a long-term return on investment.
BENEFIT FOR BULKERS According to Morten Løvstad, DNV Maritime’s vice-president and global business director for bulk carriers, more than 60% of the global bulk carrier fleet will require measures to improve their CII rating if they are to remain compliant and competitive through to 2030. Bulkers are ideally suited to rotor sail technology. Their large, open deck space allows for multiple Rotor Sails to be fitted in a configuration that can take advantage of plentiful wind supplies and maximize savings. Crucially, modern rotor sail technology can be installed with different
deployment systems that can take advantage of a bulkers deckspace and alleviate concerns over loading and unloading operations. While Rotor Sails are, as standard, fixed to the deck of a vessel, Anemoi supplies two other bespoke deployment options that are ideal for bulk carriers: folding and rail mounted. The folding deployment system lowers the Rotor Sails from vertical using hydraulics, making them ideal for vessels operating on routes with air draught restrictions and enabling them to the repositioned to ensure cargo operations are not impacted. Anemoi’s patented rail-mounted system allows the Rotor Sails to be moved along or across the deck of the ship when in port to again avoid impacting cargo loading and unloading operations. This latter option was installed on the 64,000dwt Ultramax bulk carrier Afros in 2018. The vessel’s limited deckspace required an innovative approach to rotor sail placement and Anemoi’s rail-mounted system offered the flexibility to ensure the vessel could still operate effectively while taking advantage of the vast amount of renewable wind energy available during the vessel’s voyages. Installation simplicity also remains one of rotor sail’s key advantages. They do not require any wholesale changes to the vessel’s structure or drydocking, making them ideal for retrofitting. Each rotor sail can be installed in a single crane lift and connected to the foundation on the ship’s deck. In the case of Afros, the installation of all the equipment took less than two hours per unit.
GROWING INTEREST “With shipowners and managers looking to minimize their carbon emissions while maintaining full operations, Rotor Sails have picked up steam in recent years as a way to provide auxiliary propulsion and reduce fuel consumption,” said Kim Diederichsen, CEO at Anemoi.
“The recent installation of Rotor Sails on TR Lady and the results we have seen so far show how effective Rotor Sails are when it comes to reducing the fuel consumption and emissions of a vessel. Rotor Sails are a visible, viable and costeffective decarbonization technology, not just for bulkers but for all types of vessels.” The market for rotor sail technology continues to grow as ship owners and managers increase their efforts to meet the IMO’s GHG targets. According to the International Windship Association, more than 100 wind-assisted ships will be in operation by 2025, although wind propulsion stands to play a major role for vessels far beyond that, owing to the abundance of renewable wind power, the industry’s continued push for decarbonization, and the ability to combine wind propulsion with other energy saving devices and fuels. Anemoi currently has 13 Rotor Sails in production and, due to growing interest, the company is ramping up its capacity to be able to install 50 Rotor Sails annually by the end of 2023. In November 2022, Anemoi reached an agreement with COSCO Shipping Heavy Industry (CHI), one of China’s leading shipbuilding organizations, to offer turnkey installations of Anemoi Rotor Sails. CHI has numerous yards capable of up to 7.5 million dwt annual production across all major vessel segments, making it an ideal yard partner for the uptake of this technology. With more eco-friendly innovations in development, Rotor Sails have found their place in the industry as a credible decarbonization technology and offering ship owners a viable option to make an immediate impact on their fuel consumption and emissions. Anemoi has made its mark on the sector with a catalogue of successful installation projects on a number of bulk carriers and are putting the motions in place to ensure ship owners have access to a viable, cost-effective and long-term decarbonization technology.
TR Lady with Anemoi Rotor Sails leaving Chengxi Shipyard, China, in June. Credit: Anemoi Marine Technologies.
TR Lady on its first voyage with Rotor Sails from China to Australia. Credit: Anemoi Marine Technologies.
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Installation of Anemoi Rotor Sails on Tufton’s TR Lady Kamsarmax in Chengxi Shipyard in China. Credit: Anemoi Marine Technologies. delighted to see the project brought to life and for the initial performance results to be so positive. The installation is a testament to our large supply chain in China and our dedicated team. We look forward to assessing the performance and
seeing continued positive results for our environment.” TR Lady retrofit project has been nominated for the ‘Retrofit Project of the Year’ award at the Annual Marine Propulsion Decarbonization Awards 2023.
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Installation of Rotor Sails on TR Lady, an 82,000dwt Kamsarmax bulk carrier, was completed in Chengxi Shipyard, China, in June 2023. TR Lady is owned by TR Lady Shipping Ltd, a portfolio company of Tufton Investment Management Ltd (Tufton) and is on a time charter with Cargill. The vessel was retrofitted with three 5×24m Rotor Sails by leading windpropulsion provider Anemoi Marine Technologies Ltd (Anemoi). The technology was installed on Anemoi’s unique and patented transverse rail deployment system. This system enables the sails, which are fixed to the centre line during voyages, to be moved port or starboard when berthed for cargo operations, meaning loading and unloading can continue without being obstructed. Class approvals have been awarded by Lloyd’s Register. Rotor Sails, also known as ‘Flettner Rotors’, are vertical cylinders which, when driven to rotate, harness the renewable power of the wind to provide additional forward thrust. These highly efficient mechanical sails capitalize on the aerodynamic phenomenon known as the Magnus Effect and will deliver significant fuel and emission savings to TR Lady. The vessel has now completed its first voyage with the Rotor Sails from China to Australia. During this voyage, Anemoi engineers sailed with the vessel for sea acceptance testing and trials, with positive initial performance results which suggest that TR Lady can see average annual fuel and emissions savings exceeding the original expectations. The performance of the Rotor Sails will continue to be monitored over the coming months. Of the installation, Andrew Hampson, CEO of Tufton, said, “We and our investors are committed to shipping’s decarbonization journey and believe wind propulsion is a key enabler in helping Tufton reach its 2050 net-zero goals. We are very proud to have been able to support this innovative application of decarbonization technology on TR Lady.” Jan Dieleman, President of Cargill’s Ocean Transportation business, said, “We are pleased to be partnering with Tufton who share our decarbonization ambition and belief in wind propulsion as a key part of the future of shipping.” Kim Diederichsen, CEO of Anemoi Marine Technologies, commented, “I am
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Tufton’s Kamsarmax bulker installed with Anemoi Rotor Sails expected to save 10% of fuel & emissions annually
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Supporting bulk carriers – Wärtsilä Marine Power “Wärtsilä’s technical expertise and experience can support owners and operators of bulk carriers in many ways, such as with reducing fuel costs and optimizing maintenance processes, thus increasing the profitability and the lifetime of their vessel.” says Lilli Chi, General Manager, Technical Sales, Small Merchant — Wärtsilä Marine Power. She continues, “However, it’s important to understand that there is no one-size-fits-all solution to this sector as the challenges faced by, and the priorities of, owners and operators of bulkers can vary significantly depending on factors related to the region, local market, vessel size and fleet. “For retrofit projects, the focus is usually on extending the lifetime of a vessel and increasing cashflow, whilst remaining compliant with current and incoming regulation; whereas for newbuild, this is usually around futureproofing. “Decarbonizing the industry is complex and a lot rides on getting it right. It’s a multi-decade puzzle that is constantly evolving. It’s why owners and operators of bulkers need a partner with the technical know-how and focus on their customers commercial needs to deliver the decarbonization solutions that are right for them.”
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Customer case studies
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v battery pack and energy management system.
2. CARISBROOKE SHIPPING Last year Wärtsilä announced that its customer Carisbrooke Shipping has reported a saving of over 600 tonnes of CO2 emissions since the beginning of the year, with the help of Wärtsilä’s Fleet Optimisation Solution (FOS). Since implementing FOS across 31 vessels in 2019, Carisbrooke Shipping has been using the platform to gather insights that have supported the UK-based dry bulk and general cargo ship operator in its objectives around reducing carbon emissions and ensuring fleet performance, which is core to the company’s current strategy. Carisbrooke’s Fleet Operations Centre is responsible for monitoring vessel position, passage plans and routes, advising on maximizing cargo intake, and monitoring vessel safety and performance. Around 25 vessels are reviewed daily and an average of 20 voyages are optimized per month. Having insight into the efficiency of a vessel at any given time enables the company to take action to optimize fuel consumption across its vessels. Already, Carisbrooke Shipping has reported fuel savings of 5–7% since the roll-out of FOS.
1. AASEN SHIPPING
3. MISJE REDERI
When Norwegian shipper Aasen decided to build two new self-discharging bulk carriers, it naturally wanted them to be as fuel efficient as possible. The solution was a fully integrated Wärtsilä HY hybrid system, proven to offer outstanding reliability and performance while cutting fuel consumption and emissions. By combining a Wärtsilä engine with batteries and an intelligent energy management system, the new vessel design would deliver even bigger savings for two newbuild self-discharging bulk carriers — the Aasfjell and Aasfoss. Together, the hybrid system, electrically powered machinery, optimized hull design and additional cargo capacity were projected to cut fuel consumption and emissions by 50% compared to standard self-discharging vessels of a similar size. The full scope of the hybrid system for both ships included: v Wärtsilä 26 main engine; v power take-off/power take-in (PTO/PTI) gearbox and controllable pitch propeller; v DC switchboard; and
The bulk carrier Misje Vita is the latest step on Misje Rederi’s journey to build one of the world’s cleanest and most sustainable fleets. Misje Vita has the Wärtsilä HY hybrid system onboard, which combines engines and batteries and is designed to optimize the propulsion system’s response to changing conditions. This greatly enhances the vessel’s fuel efficiency and overall performance. Because the Wärtsilä HY hybrid system has a high level of flexibility, it allows the engine to operate in the most efficient way possible, saving fuel and emissions. It also allows the Misje Vita to sail in and out of port and carry out cargo operations purely on battery power. This helps the vessel to comply with ever-stricter port emissions regulations. In addition, it means there is less need to use the auxiliary engines during operation, which has a direct impact on the vessel’s CII rating. The Misje Vita was designed by Wartsila Ship Design, and Wärtsilä supplied the complete hybrid system including: v Wärtsilä 20 main engine v Wärtsilä NOx Reducer;
v power transmission system and electrical and automation systems; v controllable pitch propeller; v Wärtsilä ProTouch bridge control system; and v hybrid battery solution and energy management system (EMS).
3. TRANSWORLD SHIP MANAGEMENT Wärtsilä announced in June that it will partner with Transworld Group to apply the most advanced decarbonization modelling capabilities to the bulk carriers sector of Orient Express lines of Dubai, owned by Transworld Group and Managed by Transworld Ship Management (TWSM), one of India’s premium private sector ship management firms. The aim of the project is to provide decision-making support by simulating the impact of efficiency upgrade technologies on the vessel’s environmental performance. By creating and validating a digital model of the ‘TBC Prestige’ based on measured real-life data, various technology solutions can be simulated and assessed. The technology simulations will indicate their effect on emissions profiling, the impact on the ship’s Carbon Intensity Indicator (CII) rating, and Return on Investment (ROI) calculations. This is the first such modelling project for the Indian maritime market. The modelling is part of the Wärtsilä’s Decarbonisation Services offering.
4. MARFIN MANAGEMENT AND SOLBIAN At the end of 2021, Wärtsilä’s announced that it had completed the installation and commissioning of a unique hybrid power system combined with a PV solar energy system in collaboration with Marfin Management and Solbian, onboard a bulk carrier vessel, making it one of the most technologically advanced vessel of its type in the global fleet. The innovative, fully integrated Wärtsilä HY Module solution includes, an energy management system and batteries that delivers auxiliary power to the grid. When coupled with other sources of energy such as PV panels the benefits are enhanced. It will address the marine sector’s major challenges to lower operating costs while simultaneously reducing environmental impact. The solution achieves this through significant reductions in fuel consumption and maintenance needs, while offering cleaner, safer, and more efficient operations.
Mitsui Transportation & Machinery Business Div. I General Manager Akihito Hamada and WE Tech CEO Mårten Storbacka. towards sustainable shipping and a zeroemission future. “Transaction is subject to Finnish Foreign Direct Investment filing and parties expect closing of the transaction to happen during [Q3/Q4 2023]. Parties have agreed not to disclose the details of the Transaction. WE Tech was advised by Access Partners & Avance Attorneys.”
WE TECH SOLUTIONS IN BRIEF: WE Tech Solutions, with headquarters in Vaasa, Finland, is a leading energy efficiency solution provider with a global presence in the shipping industry. The company specializes in supplying solutions based on DC-link power distribution, variable speed power generation, energy storage and energy management systems. The solutions, suitable for new buildings and for retrofits, bring numerous benefits to the shipping industry worldwide.
MITSUI & CO., LTD IN BRIEF: Mitsui & Co., Ltd. (8031: JP) is a global trading and investment company with a diversified business portfolio that spans approximately 63 countries in Asia, Europe, North, Central & South America, The Middle East, Africa and Oceania. Mitsui has about 5,500 employees and deploys talent around the globe to identify, develop, and grow businesses in collaboration with a global network of trusted partners. Mitsui has built a strong and diverse core business portfolio covering the Mineral and Metal Resources, Energy, Machinery and Infrastructure, and Chemicals industries.
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emission shipping. “We believe that by combining our presence in the global shipping market and WE Tech’s innovations, we are confident to enhance the growth of WE Tech and even to catalyse the transformation of Japanese shipping industry into a model of environmental responsibility,” stated Akihito Hamada, General Manager, Transportation & Machinery Business Div. I, “This partnership exemplifies our unwavering commitment to sustainable practices and our determination to contribute not only to the decarbonization of the global shipping industry but also the increase of the competitiveness of Japanese shipping industry.” The agreement signing ceremony, held in the city of Vaasa in Finland, serves as a symbolic inauguration of a new era where international collaboration emerges as the driving force behind transformative progress. Representatives from both entities gathered to mark this historic moment. “Our mission has always been to create savings and emissions reduction for the shipping industry through technology. We are excited to bring our innovations to the Japanese shipping market and to work together with Mitsui towards a zeroemission future” WE Tech’s CEO Storbacka shared. The collaboration between Mitsui and WE Tech comes at a crucial juncture when the world is seeking solutions to address climate change. This partnership serves as a testament to the power of international cooperation in driving meaningful progress
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A significant step towards the realization of sustainable shipping and a zero-emission future has been taken, as the Finnish leading energy efficiency solution provider WE Tech Solutions (WE Tech) join forces with one of the largest Japanese general trading companies Mitsui & Co., Ltd (Mitsui). In landmark agreements, WE Tech further strengthens its position as global energy efficiency solution leader by calling in Mitsui’s strategic investment leading it to be a significant minority shareholder in WE Tech and simultaneously appointing Mitsui as an exclusive agent in Japanese market. The co-operation will also solidify Mitsui’s commitment to Global Energy Transition, which is one of its growth strategies in its medium-term management plan for 2026, and contribution to the promotion of decarbonization in the shipping industry. WE Tech is a leading energy efficiency solution provider with a global presence in the shipping industry. The company specializes in supplying solutions based on DC-link power distribution, variable speed power generation, energy storage and energy management systems. The solutions, suitable for new buildings and for retrofits, bring numerous benefits to the shipping industry worldwide. WE Tech has been at the forefront of zero-emission solutions for the shipping industry. Its cutting-edge innovations and pioneering spirit have led to breakthroughs that promise to reshape global shipping’s future. “By seamlessly integrating WE Tech’s innovative solutions with Mitsui’s operational excellence, the partnership aims to accelerate the adoption of sustainable practices and technologies across the maritime domain,” WE Tech’s CEO Mårten Storbacka said, “Moreover, the partnership will strengthen WE Tech’s position in the Japanese market. By aligning with Mitsui, we gain a formidable ally that enhances our visibility and influence within Japan.” The partnership is rooted in a mutual vision for a sustainable shipping industry, with both companies firmly dedicated to enacting tangible change in global emissions. Mitsui, a renowned player in the shipping and logistic business, brings decades of experience and expertise to the table. With a longstanding commitment to sustainability, the company has set its sights on pushing the boundaries of what is achievable in the realm of zero
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WE Tech Solutions, together with Mitsui & Co. Ltd will drive zero emission shipping future
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OSM Thome and Pherousa Green Shipping collaborate on major Ultramax project Norwegian companies OSM Thome and Pherousa Green Shipping AS (referred to as “PGS”) have entered into a Letter of Intent outlining their collaboration on a series of 63,000dwt Ultramax vessels to be ordered by PGS. The collaboration involves Phases I, II, and III, encompassing drawing approval, project development, and site supervision for six 63,000dwt Ultramax bulk carriers. Furthermore, OSM Thome will manage the crew and technical management of the constructed vessels. Pherousa Green Shipping AS, headquartered in Oslo and established in 2023, is in the process of initiating an order for up to six modern, zero-emission Ultramax dry bulk carriers. These vessels are designed by Deltamarin in Finland. The initial ship design is derived from an existing Deltamarin Ultramax model, but it has been modified to include the ammonia cracking technology developed by Pherousa Green Technologies AS (PGT). This technology employs ammonia as a hydrogen carrier, facilitating true zeroemission propulsion. OSM Thome boasts expertize in supervising the design and construction of various vessel types, including anchor handling tug and supply (AHTS) vessels, shuttle tankers, dry bulk vessels, MR tankers, PSVs, jack-up rigs, storage platforms, car carriers, RORO and RO-Pax carriers, accommodation barges and
OSM Thome and PGS have entered into a Letter of Intent outlining their collaboration on a series of 63,000dwt Ultramax vessels to be ordered by PGS. vessels, offshore decommissioning projects, battery operated vessels (BOBs) and battery-operated ferries (Norwegian Sector), fully autonomous vessels (ammonia propulsion), expedition vessels, and cruise liners. “We are delighted to partner with the renowned Shipmanagement group, OSM Thome, to assist us on finalizing our forthcoming fleet of true zero-emission Ultramax bulk carriers. Our early agreement with OSM Thome ensures that crew members will be prepared and trained well in advance of vessel delivery. This proactive approach guarantees the establishment of safety measures and protocols in accordance with the guidelines for safe handling at sea,” said Hans Bredrup, Chairman of the Pherousa Group. The initial fleet of six Ultramax dry bulk carriers has a specific focus on serving the global copper industry. Given copper’s pivotal role in worldwide decarbonization efforts, the copper industry has set ambitious emission reduction targets,
encompassing Scope 3 emissions which involve transportation to end users. “The concept has garnered significant support, and we are actively engaging with key stakeholders in both ammonia supply and vessel end-users. This momentum is propelling us towards realizing zeroemission copper transportation, fostering a fully zero carbon supply chain from mines to destinations,” added Bredrup. “We really appreciate the trust that PGS has in our abilities by signing this agreement. Since the merger of OSM Maritime Group and Thome Group was finalized in May this year creating the combined entity OSM Thome, we have worked hard to amalgamate and build on the best attributes and skills of all our employees to provide real benefits for our customers. We are looking forward to working closely with the team at PGS to ensure that this project is successfully supervised and managed to create sustainable transportation solutions,” said Tommy Olofsen, OSM Thome’s Chief Commercial Officer.
SEPTEMBER 2023
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RAK Ports signs contract with KDU Marine
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RAK Ports Group, which includes the leading dry bulk port group in the MENA region, has signed a contract with KDU Marine for installation of a Kongsberg VTS System. Kongsberg, which is one of the foremost VTS suppliers worldwide, will provide the first VTS system for the port group. Installation will be by KDU which is based in Dubai. Roy Cummins CEO RAK Ports, stated, “We are committed to state of the art technologies and advancing digitization across all areas within the port group. The quality of a Kongsberg system supports our modernization programme.” Group Harbour Master Captain Michael Magee commented a Kongsberg system supported locally by the expertise of KDU will enhance navigational safety and surveillance across all the ports and approaches in the RAK Ports group.
Shailendra Shukla, Managing Director KDU Group and Roy Cummins, CEO, RAK Ports.
In the world of maritime design and innovation, Conoship International has once again raised the bar with its latest creation: the CIP6300 General Cargo Vessel. This forward-thinking vessel is not just a testament to cutting-edge engineering but also a symbol of environmental responsibility and adaptability.
FUEL EFFICIENCY REDEFINED At the heart of this vessel’s design philosophy lies an unwavering commitment to fuel efficiency and sustainability. Equipped with a diesel-electric propulsion system, the CIP6300 boasts a large propeller diameter, a key element in ensuring optimal propulsion efficiency. The vessel’s optimized hull lines further contribute to its exceptional fuel economy, a crucial factor in today’s eco-conscious shipping industry. One notable feature that sets this vessel apart is its compatibility with windassisted propulsion — a recommendation that aligns seamlessly with the vessel’s green agenda. Embracing wind-assisted propulsion underscores the commitment to reducing carbon emissions and minimizing the vessel’s ecological footprint.
ENVIRONMENTAL PROWESS
VERSATILITY IN CARGO HANDLING
tailoring every aspect of the shipbuilding process to their specific requirements.
FUTURE-PROOF The fuel consumption of the vessels in the CIP-series will be best in class, with its well-thought-out diesel-electric propulsion system, enlarged propeller in combination with a ConoDuctTail® and optimized hull lines. To further improve its performance, the design is ready for wind-assisted propulsion, as it is prepared for the placement of Econowind VentoFoils®, which would reduce fuel consumption and CO2 emissions by about 10%, depending on the sailing route.
ADVANTAGES OF A STANDARD VESSEL The emphasis of the CIP series is on providing value for money to the customer with optimum time and cost without compromising quality, and specifications. The beauty of Conoship’s approach lies in its flexibility, as it offers customers the opportunity to build their vessels in a shipyard of their choice. A switch of fuel type to future fuels such as liquid hydrogen or ammonia is facilitated by smart arrangement design, where the requirements of the future fuels have been taken into account from the beginning of the conceptual design process.
VALUE FOR MONEY By designing and building for a specific market and standardizing certain ship types, product innovations can be introduced more easily and with less risk.
PROPULSION AND TANK CAPACITY The vessel is powered by four gensets and two electric motors, ensuring smooth and efficient propulsion. A 350bkW (brake kilowatt) bow thruster enhances manoeuvrability. In terms of tank capacity, the vessel can carry 2,500 cubic metres of ballast water, 190 cubic metres of fuel oil (MGO), and 50 cubic metres of potable water.
CARGO HOLD DETAILS The spacious cargo hold measures 66.40 metres in length, 13.15 metres in breadth, and 10.60 metres in height. With a tanktop load of 15t/m², it can accommodate a remarkable 317 cubic feet of cargo.
TECHNICAL SPECIFICATIONS
FLEXIBLE SUPPLY CHAIN
To put it all into perspective, here are the key technical specifications of the CIP6300 General Cargo Vessel: Length overall: 99.99m Breadth moulded: 15.85m Depth to main deck: 8.80m Deadweight: Ranging from 5,800 to 6,375 tonnes Gross Tonnage: 4,657 Cargo hold capacity: 8,978m³ or 317,055ft³ Service speed: 10.00 knots
As a customer, one always has the option of having Conoship’s standard design ship built at a shipyard of your choice. This level of customization allows customers to realize their maritime visions while
In conclusion, the CIP6300 is a testament to Conoship International’s commitment to sustainable, adaptable, and efficient maritime solutions.
REDUCED DELIVERY TIME Standardization of the design speeds up the delivery time. Opting for a standard design of the CIP series reduces the delivery time for you, the customer because the design and processes have already been prepared.
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The CIP6300 design doesn’t just prioritize sustainability — it also emphasizes versatility. With a single, spacious cargo hold boasting high cubic capacity, this vessel is well-equipped to handle a diverse range of cargo, whether heavy or light. This flexibility is a testament to Conoship International’s dedication to meeting the evolving needs of the maritime industry.
Perhaps one of the most groundbreaking aspects of this vessel is its adaptability in fuel selection. The well-thought-out design allows for the possibility of changing the type of fuel in the future without the need for a radical and costly conversion. This feature is especially important as the industry transitions towards cleaner, alternative fuels. The CIP6300 ensures that vessel owners can stay ahead of environmental regulations without major disruptions to their operations. “For example take off the generators and replace them with a methanol power generator set and then put in methanol tanks as well, or take them off completely and put on liquid hydrogen tanks and fuel cells,” explains Jan Jaap Nieuwenhuis, Managing Director at Conoship International. “All these redesign possibilities were taken into account from the beginning of the conceptual design process.”
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Following in the footsteps of Conoship International’s successful CIP3600 and CIP3800 models, the CIP6300 is an example of an environmentally friendly cargo vessel designed with the future in mind. The diesel-electric propulsion system, combined with the vessel’s thoughtful engineering, ensures the lowest possible fuel consumption, reducing not only operational costs but also greenhouse gas emissions. For those who wish to take sustainability to the next level, the CIP6300 offers the option to install three VentoFoil units, further enhancing fuel efficiency and demonstrating a commitment to innovative eco-solutions.
ADAPTIVE FUEL OPTIONS
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Navigating the future: Introducing the CIP6300 General Cargo Vessel
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SHIPPING & TRANSPORT www.drycargomag.com SEPTEMBER 2023
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Transporting grains and soya beans – common causes of cargo damage
G
rains and soya beans are essential staple food sources and important raw materials for industries such as animal feed production, biofuels, chemicals, and food processing. This trade operates on an extensive scale, and the smooth maritime transportation of these commodities plays an indispensable role in maintaining global trade dynamics. A new guide from The Swedish Club, Bulker focus: Carriage of grains and soya beans, explores the most common causes of cargo damage when these staples are transported in bulk and provides advice on how to prevent them. It also focuses on fumigation and ventilation in detail and contains case studies illustrating many of the common issues faced when transporting these goods. Senior Loss Prevention Officer, and author of the guide, Joakim Enström explains: “Soya beans and grains each show a very different claims picture, until we reach the pandemic period, when claims for both categories increased sharply.” Grains’ statistics show that whilst an average of 5.6% of all bulk carriers insured have made a grain claim in the last five years, there has been a steady increase in the frequency of claims over the period. Only 3.7% of vessels made a claim in 2018 compared with 8.9% in 2022 (see graph 1). Most claims occur in Argentina and North Africa, says Enström. “Interestingly, despite the many types of cargo damage faced by shipowners transporting grain cargoes, when it comes to claims, it’s actually cargo shortage that operators need to be prepared for.” In the last five years, the Club’s statistics show that shortage was the most common type of claim for bulkers carrying grains, contributing to 63% of all claims. About
70% of these shortage claims occurred due to discrepancies between the vessel’s figures and shore figures with most claims arising in North Africa over the five-year period as a whole (see graph 2). So why is this and what can ship operators do? Enström explains: “In Argentina and many North African countries it is not unusual for there to be issues.” In Argentina, mate’s receipts are presented to the Master by the shippers. The exporter (or importer) has the right to choose the weighing method for fiscal/customs purposes, which will invariably be the use of shore scales. It is not unusual to have discrepancies between the shipper’s figures based on shore scales and draught surveys. In Tunisia and Algeria shortage claims often arise because receivers will not accept the established trade allowance of 0.5% of the bill of lading quantity. In the event of a shortage, only the shore scale figures will be recognized by the local receivers and calculation of the claims will be on that basis. “Each country has its own rationale, but the bottom line is that the operator can Graph 1.
find themselves seriously out of pocket through no fault of their own,” he says. Before Covid-19 the Club saw few grain claims in China but since 2021 it has seen a steady increase in claims as a result of the pandemic. Says Enström, “The severe lockdowns that were seen in many cases delayed vessels and also made it difficult for surveyors to attend vessels for inspection. Crew and stevedores were also more hesitant to interact with each other because of the risk of becoming infected. This led to the crew not being able to verify the cargo operation and taking draught figures.” Graph 2.
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Graph 3.
Graph 4.
address water ingress to prevent mould and future claims; and issuing a letter of protest for wet or mouldy cargo in case of heavy weather. In addition the member should appoint a surveyor prior to loading to ensure clean, dry bilges and to record the temperature, colour and odour of soya beans in particular, prior to loading. Soya beans are high-risk due to respiration and oil content and a quick discharge is crucial, especially if the cargo is stored in piles with poor ventilation. “Many of the claims that the Club has seen over the past five years could not have been physically prevented by our members,” concludes Enström. “However the most effective defence against cargo claims is the maintenance of clear and accurate records and documentation of each stage of the voyage, from loading through to discharge, and constant record keeping including photographs and collecting samples during discharge.” Bulker focus: Carriage of grains and soya beans is available to download free of charge in the Publications area of The Swedish Club’s website.
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There are a number of actions you can take to minimize shortage claims, explains Enström. “Carry out a draught survey before opening cargo hatches while unloading and don’t sign an incorrect draught survey report but add remarks. If hatches were sealed at Graph 5. the loading port, perform an unsealing survey before opening and ensure the unsealing certificate is signed by receivers and the document discharge progress. A surveyor can monitor operations and weigh discharged cargo. “Prior to authorizing the vessel’s agent to sign shortage statements, consult the owner or Club’s correspondent. Obtain a completion statement affirming full discharge and empty holds and maintain dialogue with charterers/receivers who usually handle discharge — remember stevedores are effectively their employees. Note bill of lading discrepancies at discharge to prevent shortage claims.” When it comes to cargo damage there are many way in which a cargo can be damaged, says Enström. “Wet damage and contamination are common to both grains and soya beans, with self heating being a major issue with the latter.” There are a number of root causes for cargo damage, says Enström, but there are steps that can be taken to mitigate them.” These include maintaining hold cleanliness to avoid loading refusal or claims upon discharge; pre-load hatch cover tests (ultrasound or hose) to prevent wet damage; taking swift action to
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Although each shortage claim averages to about only US$35,000 there are so many of them that they make up nearly half (44%) of the Club’s claims costs for bulkers carrying grain. Soya bean claims show a different picture. In the past five-years only 1.1% of the Club’s bulk carriers have had a soya bean claim, but the average claim cost was US$54,000 — higher than that for grains (see graph 3). During the pandemic vessels were forced to stay at anchor for extensive periods. “These delays can lead to heat damage which is a significant concern with soya bean cargoes,” says Enström. The most common soya bean claim is for shortage at 29%, followed by spontaneous heating at 19% and contamination at 16% (see graph 4). “When compared with grains, shortage makes up a considerably smaller percentage of claims — 29% vs 63% — says Enström. “This is due to different trading patterns and also due to statistics having been influenced by heat damage caused by COVID delays.” Looking at costs, however, the picture is very different. Spontaneous heating accounts for 41% of the Club’s total claims cost in this category, with an average claim cost of US$115,000. Shortage makes up only 16% of the total cost, with an average claim cost of US$29,000 and physical damage contributes to 13% of the total cost, with an average claim cost of US$103,000 (see graph 5). Cargo self-heating depends on its moisture content, the temperature at loading, and voyage duration, says Enström. “High moisture content can lead to mould growth with an increased self-heating risk, particularly for cargo that already has an inherently high moisture content. So what loss prevention measures can shipowners take?
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SHIPPING & TRANSPORT www.drycargomag.com SEPTEMBER 2023
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‘Guidelines for Onboard Lifting Appliances’ and ‘Guidelines for Anchor Handling Winches (OLAW)’ approved by MSC 107 to support SOLAS regulation II-1/3-13 TABLE 1. LIFTING APPLIANCES AND ANCHOR HANDLING WINCHES Appliance Lifting appliance
Date of installation Before 1 January 2026
Applicable requirements ✓ Provisions covering tests and thorough examination, based on the Guidelines for lifting appliances as per MSC.1/Circ.1663 (No later than the first renewal survey on or after 1 January 2026), ✓ To be permanently marked and Safe Working Load (SWL) documented.
On or after 1 January 2026
✓ Provisions covering design, construction and installation in accordance with class rules or standards acceptable to the Administration, ✓ Provisions covering tests and thorough examination after installation and after repair or alteration, ✓ To be permanently marked and Safe Working Load (SWL) documented.
Anchor handling winches
Before 1 January 2026
On or after
1 January 2026
✓ Provisions covering tests and thorough examination, based on the Guidelines for anchor handling winches as per MSC.1/Circ.1662 (No later than the first renewal survey on or after 1 January 2026) ✓ Provisions covering design, construction, installation and testing, based on the Guidelines for anchor handling winches as per MSC.1/Circ.1663.
MSC 107, held from 31 May to 9 June 2023, adopted resolution MSC.532(107) (see MSC 107/20, Annex 2) that contains a new SOLAS regulation II-1/3-13 that covers requirements for the application, design and construction, operation, inspection, testing and maintenance of onboard lifting appliances and anchor handling winches. It should be noticed that a new regulation applies to both new and existing ships, writes Bartosz Dombrzalski, PRS Machinery and Equipment Department Deputy Manager. The amendments will enter into force on 1 January 2026; some provisions therein will retroactively apply to the appliances installed before 1 January 2026. Two related sets of guidelines were approved to support the implementation of the new SOLAS regulation II-1/3-13: v MSC.1/Circ.1662 Guidelines for Anchor Handling Winches v MSC.1/Circ.1663 Guidelines for Lifting Appliances It should be noted that the anchor handling winch in this context means any winch used for deploying, revering and repositioning anchors and mooring lines of other ships or MODUs in subsea operations and it doesn’t refer to the traditional onboard anchor windlass used for the operations with the ship’s own anchor. As from 1 January 2026 newly installed lifting appliances will be required to meet the requirements of a classification society whereas newly installed anchor handling winches will have to satisfy the
Administration as per the Guidelines contained in MSC.1/Circ.1662. Principal changes are involved with: v Final adoption of the amendments to SOLAS chapter II-1 to regulate, under the SOLAS Convention, lifting appliances and anchor handling winches; v Adding new definitions to regulation II-1/2, such as ‘lifting appliance’, ‘anchor
handling winch’, ‘loose gear’, and so forth.; and v Establishing safety provisions on lifting appliances and anchor handling winches as a new SOLAS regulation II-1/3-13.2.1.1, except for: o lifting appliances used on MODUs and offshore construction ships, o lifesaving launching appliances complying with the LSA Code.
IMPACT ON CERTIFICATES It should also be noted that MSC 106 agreed on solutions relating to the certification of existing lifting appliances to avoid duplicative testing and thorough examination resulting from the ILO regime/regulations. Additional details can be found in paragraph 11.52 of MSC 106/19.
ACTIONS TO BE TAKEN All lifting appliances and anchor handling winches, irrespective of their installation date are required to be operationally tested, thoroughly examined and inspected based on demonstration of compliance given in Table 2. The regulations and guidelines given above, which main goal is to reduce the number of accidents and ensure the safety of the crew, cargo and ship in general by mitigating the risk associated with the use of the mentioned appliances, should be respected and followed. Only regular detailed maintenance at
TABLE 2. DEMONSTRATION OF COMPLIANCE Appliance installation date Lifting appliances on or after 1 January 2026 should be certified as compliant with SOLAS reg. II-1/3-13.2.1 and II-1/3-13.2.3 before being put into use for the first time before 1 January 2026 should be certified as compliant with SOLAS reg. II-1/3-13.2.4, no later than the first renewal survey on or after 1 January 2026 existing one should be considered as compliant with SOLAS reg. II-1/3-13.2.4 when valid certificates under another international instruments acceptable to the Administration were issued prior to the entry into force SOLAS reg. II-1/3-13 Appliance installation date Anchor handling winches on or after 1 January 2026 should be certified by the Administration or PRS as RO in accordance with provisions of reg. XI1/1 as compliant with SOLAS reg. II-1/3-13.2.2 before 1 January 2026 should be certified by the Administration or PRS as RO in accordance with provisions of reg. XI1/1 as compliant with SOLAS reg. II-1/3-13.2.5 no later than the first renewal survey on or after 1 January 2026 existing one should be considered as compliant with SOLAS reg. II-1/3-13.2.5 when valid certificates under another international instruments acceptable to the Administration were issued prior to the entry into force SOLAS reg. II-1/3-13 the level of design, construction and installation plus staff familiarization will
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Table 1 above shows the scope of application of the regulation. Guidelines for anchor handling winches (MSC.1/Circ.1662) and Guidelines for lifting appliances (MSC.1/Circ.1663) cover the associated details.
give positive results and long lasting onboard utility. DCi
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NEWS PORTS & TERMINALS
Port of Hamburg handles 58.2 million tonnes Both the tense economic situation in Europe, especially in Germany, and background geopolitical factors continue to have repercussions on throughput in the Port of Hamburg. Despite these, Germany’s largest seaport can record a gain of 7.7% in bulk cargo throughput at 19mt (million tonnes). First-half general cargo throughput was 11.1% lower at 39.2mt. Terminal operators in the Port of Hamburg handled 58.2mt of seaborne cargoes were handled by terminal operators in the Port of Hamburg on the seaward side. This is a reduction of 5.8% less in comparisoned to the same period of the previous year. As one of the world’s largest rail ports, landward hinterland throughput is a significant aspect. With tonnage totalling 23.1mt, 2.1% lower, rail almost maintained transport volume there. “On a comparison with other North Sea ports in the North Range, it is absolutely clear that all players in this market are subject to the same tough prevailing circumstances,” stresses Axel Mattern, CEO of HHM – Port of Hamburg Marketing.
BULK CARGO TOTALS HIGHER
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The positive trend in bulk cargoes was attributable to all sectors. With 3.5mt handled, agribulk achieved a first-half increase of 18.6%. Up 18.1% and 5.3mt, the trend in throughput of liquid cargoes was similarly positive, while grab cargoes at 10.2mt were at almost the previous level.
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SECOND-QUARTER RECOVERY IN CONTAINER HANDLING
Container handling in the Port of Hamburg improved in every month of the first half. In June, it was 10.2% higher than in January. Comparison of the first two quarters indicates a 4.6% rise in container throughput. As a rule, growth rates in this period are of around 0.6%. In total, 3.8 million TEU crossed the quay walls then, a fall of 11.7% in comparison with the same period of the previous year. Container throughput on a tonnage basis totalled 38.7mt, being 10.8% lower.
POSITIVE DEVELOPMENTS IN NORTH AMERICA AND ASIA Traditionally, China heads the Top Ten list of
trading partners and with 1.1 million TEU, the country retained first place in the first half year of 2023. Positive developments are evident in trade with further markets, for example in America. The USA continues to take second place among the Port of Hamburg’ trading partners, and was able to further consolidate this its position with a 7.4% increase, and throughput of 313,000 TEU. Canada advanced by 6.7% to 95,000 TEU. With 108,000 TEU, Central America achieved a 6.3% advance. It is on these routes that further growth is expected in the coming years as the Port of Hamburg develops as an energy hub. Over the next few years, it is especially on these routes that further growth can be expected in the wake of the Port of Hamburg’s expansion as an energy hub. “Especially against a background of mounting uncertainty and global upheavals, we aim to establish close trading relations with a broad spectrum of partner countries. Increased dialogue with North and South America, along with India as a significant growth market, is a highly promising indicator in that context,” says Dr. Melanie Leonhard, Hamburg’s Senator of Economics. Positive developments are also apparent in many parts of Asia. With a 9.3% rise in throughput on the same period of the previous year to 99,000 TEU, India achieved its best result for four years. Trade with Japan and Thailand has also increased. One
of the Hamburg companies actively implementing this trend is packaging and digitalization specialist Deufol Group, also owner of the Wallmann Terminal. “The opportunities in foreign trade with North America and S.E. Asia are obvious to us. We are working with great commitment on expanding our intermeshed HUB solutions and infrastructures internationally, especially in North America and S.E. Asia. Our goal is to back up customers in running their project logistics more efficiently and sustainably,” says Dennis Hübner, CEO of Deufol, adding that “This positive trend is also reflected in the gratifying results on foreign trade with these regions. DEUFOL, including the Wallmann Terminal in Hamburg, is actively working on further promoting these developments, and on offering innovative and sustainable end-to-end solutions for global heavy-lift logistics.”
PROSPECTS “Persistent challenging economic and geopolitical circumstances do not allow firm predictions to be made on the development of throughput in the Port of Hamburg. We are assuming that at least the slightly positive trend of the second quarter will continue. How the year will develop further depends directly on the economic mood in Germany and geopolitical developments,” emphasizes Axel Mattern, CEO of Port of Hamburg Marketing.
PORTS & TERMINALS
The Port of Barranquilla, in Colombia, reports six months of successful operation with a draught of ten metres. There has been a significant increase in the number of vessels now able to enter the port, in larger consignments and better turnaround times, all of which has reduced the cost of doing business there. In 2023, the number of 190-metre vessels has increased by 37%, rising from 54 in the first seven months of 2022 to 74 this year. The increase in cargo moved by this type of vessel has also grown, from 753,188 tonnes in 2021 to 750,995 tonnes in 2022, then leaping to 1.129 million tonnes between January and July this year, which is an increase of 50.4% on the year. Álvaro Redondo, Executive Director of port operator Cormagdalena, noted that the ten-metre draught is the result of “continuous” and “structured work”. The availability of deeper water has also made the river increasingly competitive, he added. Measurements and forecasts made on the impact that inter-annual phenomena (El Niño and La Niña) can have on the
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Barranquilla now operating with stable 10-metre draught
behaviour of the river have allowed the authorities to dredge parts of the river where work has never been carried out before. In particular, the turning areas for vessels have been improved and there have been no negative incidents of any kind reported in the past 12 months, the latter the result of a better understanding of the river and how it works. Under consideration is a redesign of the
navigable channel, with modelling exercises already conducted with pilots in Denmark with this in mind.The channel needs to have its 30-degree curves reduced to ones of just 12 degrees. There are also aspirations to eventually deepen the draught from ten metre to 12 metres, although even larger dry bulk carriers could operate in shallower waters if the radial curves were improved. Barry Cross
Romania offers Ukraine more access to Danube ports Ukraine's grain exports. Grain, which is handled by barges, is being shipped along the Danube to the Romanian port of Constanta on the Black Sea. However, in order to handle more grain in Romania, more dock workers will be required and several infrastructure projects completed, the majority of which will be EU-funded. Romania also aims to have 60 pilots to guide ships in and out of the Sulina canal by the end of August. Furthermore, the EU has funded a project to enable night
navigation in Sulina; this is due for completion in October. Once these measures are in place, the Romanian ports of Galati and Braila will handle grain, along with Reni and Izmail. Ukraine is also looking into the possibility of organizing additional places for transshipment in Romanian waters, particularly near the port of Constanta and near the Sulina channel. It is hoped that at least 14 vessels per day will be processed to and from the Ukrainian ports on the Danube via the Sulina channel. Barry Cross
La Coruña increases dry bulk storage for solid fuel out of a three hectare area on quay A-1, which will be used for the storage of dry bulk consignments. However, the port is continuing to add to this area, issuing a new tender for the fitting out of yet another esplanade. Located to the east of the dock’s access road, this will cover an area of 33,896m², and be totally paved. Work will also require a 138-metre extension to the access road. This work will take three months to
complete and has a budget of €1.799 million. Eight bids have been received, from Misturas Obras e Proxectos, Francisco Gómez y Cía, Construcciones López Cao, Canarga, Explotaciones Gallegas, Hordescon, Construcciones Taboada y Ramos, as well as from a consortium consisting of Contratas Vilor and Martín Holgado, Obra Civil. Bids have varied from €1.229 million to €1.475 million. Barry Cross
SEPTEMBER 2023
The North-Western Spanish Port of La Coruña has decided that the Russian invasion of Ukraine has identified that some European countries are looking to source fuel supplies in Europe from other areas, with international supply chains therefore undergoing change. Some of this new traffic could be attracted to the port. In order to do this, it needs to add additional storage space. Provisional work has therefore been completed on the fitting
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Romania is seeking to double its monthly capacity to handle Ukrainian grain at its Black Sea Port of Constanta to four million tonnes. Much of the increase will come at ports on the Danube River. The move comes following the decision by Russia to end the agreement it struck with Ukraine and Turkey to allow the safe passage of bulk grain carriers to and from Ukrainian ports. Since then, it has begun attacks on port infrastructure, especially as the Danube river ports of Reni and Izmail. Previously, Danube ports handled about a quarter of
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NEWS PORTS & TERMINALS www.drycargomag.com SEPTEMBER 2023
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Port of Southampton rail project wins double award for driving rail freight growth The UK’s Solent Stevedores £17.5 million rail freight growth at the Port of Southampton is now double-award-winning following a successful night at the RFG (Rail Freight Group) Awards. The cargo handler’s latest investment project, in partnership with Associated British Ports, has been officially recognized for driving rail freight growth across the country with Solent Stevedores also winning Business of the Year Award. Judges at the awards hosted by the Rail Freight Group, the representative body for all rail freight in the UK, were impressed by the company’s long-term commitment to investments and their drive to lead a significant shift from road to rail cargo transport at the Port of Southampton. The award-winning project will complete at the end of the year creating an 18-acre site linking existing intermodal rail transport site with laden and empty container handling, storage, maintenance, and repair within a single site boundary. This is a first for the UK’s number one gateway for global deep-sea trade and will support the shift in multimodal transport and transferring cargo movement from road to rail improving local air quality, reducing congestion, the cost of imported goods and transportation time. Clive Thomas, Commercial Director at Solent Stevedores said: “We are incredibly proud to be recognized for our ambitions to drive rail freight growth at these very prestigious rail industry award. The double award reflects the hard work and dedication of our team and I’m delighted their contribution has been recognized. “The project at the Port of Southampton is part of a long-term plan of
improvements to our infrastructure and services that, in partnership with our port partners, will generate improvements in local air quality.” Maggie Simpson OBE, Director General, Rail Freight Group, said: “The rail freight sector needs companies like Solent Stevedores, active and innovative players that are prepared to continually invest in making modal shift a reality. We all know that the UK needs to move more goods away from our congested road network and onto the railway and Solent Stevedores is one company acting to make the future of sustainable transport happen.” Paul Reeves, Head of Commercial at ABP Southampton said: “It is great to be recognized for this award. We have worked closely with the Solent Stevedores throughout the project, and we are very proud to support them in expanding their business to offer additional rail capability and a container storage and repair facility on site at the port. The project supports
our sustainability ambition by enabling more freight to travel by rail and not moving containers off site to be repaired, therefore reducing emissions, and improving local air quality.
ABOUT SOLENT STEVEDORES Solent Stevedores has been proudly operating as an award-winning family-run company for more than 20 years. The company puts its employees, exceptional customer service and environmental initiatives at the heart of its operations. It is a major port services operator in the UK based in the Port of Southampton, the Thames, DP World London Gateway, the Port of Immingham and at the Port of Jersey. It also has operations in the Channel Islands and northern France. The company’s three principal areas of expertise are: v Cargo operations: Solent Stevedores provides stevedoring, storage and rehandling of fresh produce, dry bulk, general cargo, and project cargoes in the Ports of Southampton, Immingham and Jersey, and on the River Thames. v Cruise services: in the Port of Southampton, Solent Stevedores specializes in the provision of a wide range of port services to a number of established cruise operators. v Container services: in the Port of Southampton, Solent Stevedores operates an Intermodal Rail Terminal located at 109 berth. As a forward thinking and innovative organization, Solent Stevedores challenges itself to be different from its competitors by being totally customer-focused and instilling this culture in all of its staff.
FURTHER DEVELOPING INLAND NAVIGATION AND RAIL
North Sea Port is actively pursuing a ‘modal shift’ toward sustainable transport via inland waterways and rail. The crossborder port area has an extensive network of hinterland connections, lying as it does at the intersection of European transport modes including inland shipping, rail and road transport and a number of European transport corridors. Inland waterway transport will increase further with the completion of the SeineScheldt project, which will allow barges with a carrying capacity of 4,500 tonnes to travel as far as Paris. As far as rail developments are concerned, the port is working with rail operators ProRail and Infrabel on projects including a new connection on the east bank between Axel in the Netherlands and Zelzate in Belgium, a new south-east curve in the track east of the Sluiskil bridge and new access to the north, towards the Netherlands, from the marshalling yard at Kluizendok.
PORTS & TERMINALS
In North Sea Port, the transportation of goods to the hinterland by inland waterway continues to increase. Over five years, it has risen from 54% to an impressive 60%. This is revealed by the port’s fifth survey of companies throughout the cross-border port area. As a multimodal port, North Sea Port is strongly committed to sustainable transportation. For the fifth time, the port has conducted research on the transportation options used by companies (in 2022) to transport goods (inbound and outbound) to the hinterland. The survey revealed that 60% of goods are transported using the inland waterways, an increase of no less than 6% over five years. That figure includes both loading and discharging of barges. Road transport accounts for 28%, with the share of rail remaining at a 10% despite cost increases. Transferring cargo from a vessel to another vessel or mode of transport — otherwise known as transshipment — accounts for 2%. “The real progress for sustainable transport is in the share of inland navigation. Sixty per cent is pretty unique. These figures from the modal split survey show that the companies and shipping companies in North Sea Port are continuing to back inland navigation,” says Daan Schalck, CEO of North Sea Port.
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Cargo transport by barge between North Sea Port and hinterland increases to 60%
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Energy-efficient and smart solutions from SEW-EURODRIVE FUTURE SECURITY
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ENGINEERING & EQUIPMENT
WITH A STRONG PARTNER
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SEW-EURODRIVE is a major player in the cargo handling industry, and can be relied upon for the high operational reliability, system utilization, predictive maintenance and optimal service life of its drives. While the company’s drives are noted for their use in container cranes, they are also suitable for use in dry bulk handling scenarios. With increasing handling volumes with limited storage capacity, optimizing all functions along the process chain and the desire for greater sustainability are important current challenges for ship and terminal technology. SEW-EURODRIVE supports its customers in port logistics processes with smart drive and automation solutions. Its systems are renowned for their energy efficiency and automation as well as digitalization. In order to meet the complex requirements of customers, it is important to have a competent, reliable and globally active partner with a comprehensive portfolio of innovative products and services. Modern and intelligent drive technology and the closely interlinked services, functions and tools along the entire system cycle are the heart of the crane and handling technology of the future. They are the key to sustainable success and are an important factor on the way to future-proof port, ship and terminal technology. Drive and automation solutions from SEW-EURODRIVE can be flexibly adapted to the requirements in a wide range of port logistics applications. With over 90 years of experience and industry expertise, the Bruchsal, Germanybased drive and automation specialist supports its customers in optimizing their processes. The comprehensive portfolio ranges from gearmotors, frequency inverters and software modules to holistic automation solutions, from industrial gear units to comprehensive life cycle services.
INDUSTRIAL GEAR UNIT SOLUTIONS FROM A SINGLE SOURCE
With SEW-EURODRIVE, customers get more than just products. Companies are trending toward tailored drive packages and system solutions. SEW-EURODRIVE has the application knowledge needed, and offers significant process and logistics. When systems manufacturers in heavy industries such as construction, mining or cement production talk about industrial gear units, they rarely talk about individual components. In most instances, customers are looking for custom solutions with which they can quickly and reliably equip their systems and dependably get them up and running. This is why SEW-EURODRIVE considers itself to be a problem solver for all things drive technology — and has done so for more than 90 years. SEW-EURODRIVE’s customers benefit greatly from the fact that it can provide a fully comprehensive drive technology portfolio from a single source. It relies not only on its own universal expertise in mechanical, electrical and electronic drive technology for its solutions. It also offers the necessary expertise in control technology, engineering tools and system software on the one hand, and machine safety and energy efficiency on the other. As a skilled and reliable partner, it is always by the side of its customers — from initial planning and configuring to starting up and maintaining the industrial gear unit solution in the customer’s system. It offers:
v compact drive packages and tailored, complete industrial gear unit systems; v technically adept consulting from application specialists with years of experience; v order-specific drive system engineering including integration into the customer’s system; v quick availability of in-stock components near you thanks to its global production network; and v experienced service worldwide for quick availability and skilled assistance on site.
WORLDWIDE NETWORK When customers in heavy industry need industrial gear units, projects can be assembled to order (ATO). Orders without a design stage is one of the unique selling points from SEW-EURODRIVE, since the drives can have delivery times starting from one working day. Depending on the complexity of the application, projects are engineer to order (ETO) and the design will be adapted according to the requirement of the customer. The delivery times starts then with 15 working days. This is why, for SEW-EURODRIVE, problem solving begins with the sale. Since these kinds of projects are often of an international nature, the company’s technically adept consultants, with years of industry experience, provide local application support on site — even in other countries.
RopeCon® Efficient Solutions for Bulk Material Handling Wherever bulk material needs to go – across impassable terrain, rivers, highways and buildings – RopeCon® delivers without a hitch! Long distances, capacities of up to 25,000 tonnes/hour, minimal environmental footprint, quiet operation plus low operating and maintenance costs: These are the features that convinced leading mining businesses.
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Are your rubber conveyor belts safe for human health and the environment? Because of its adaptability, the vast majority of the rubber used to make modern-day conveyor belts is synthetic or, at most, contains only a relatively small element of natural rubber. Especially in dry bulk handling, conveyor belts need to be able to cope with a variety of different demands including resistance to oil, fire, abrasive wear, ripping, cutting and ozone & ultraviolet. In basic scientific terms, the creation of these rubber compounds (rubber compounding) is the process where a range of ‘specific task’ chemicals, reinforcements and anti-degradants are mixed together with rubber polymers. The most common polymers used in conveyor belts are Styrene-Butadiene rubber (SBR) and Nitrile rubber (NBR). There are literally dozens of different chemical components used such as antidegradants, antiozonants as well as ‘accelerators’, which are essential for the vulcanization process. The chemical agents form chains of polymers to form rubber compounds that will ultimately be vulcanized to create the finished product. It is an inescapable fact that it
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Non-EU and UK based manufacturers are not subject to European regulation.
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is necessary to use chemicals that are potentially extremely dangerous. However, it is the type of chemicals and the quantities they are used in that presents the big question — are your conveyor belts safe for the health of humans and the environment?
REGULATORY CONTROL Fortunately, there are very strong regulations in place in Europe designed to protect human life and the environment in the form of REACH (Registration, Evaluation and Authorisation of Chemical substances) regulation EC 1907/2006. The regulations stipulate that manufacturers must register information relating to the use of chemicals, preparations (mixtures) and substances used to manufacture their finished products in a central database in the European Chemicals Agency (ECHA) based in Helsinki. This especially includes
CONVEYING ADVICE
substances of very high concern (SVHC’s) which may have carcinogenic classifications (REACH article 57), mutagens and chemicals toxic for reproduction (CMR) as well as Persistent Organic Pollutants (POP’s) and short-chain chlorinated paraffin’s (SCCP’s). Short-chain chlorinated paraffin’s are commonly used, especially in Southeast Asia, to ‘super-accelerate’ the vulcanizing process. Of particular concern is the formation of nitrosamine gases, which are chemical compounds classified as probable human carcinogens based on animal studies, that are known to occur when certain types of vulcanization accelerators are used. The gases can release themselves from rubber belts, which could be hazardous if the belts are stored indoors.
AN OPEN DOOR Sadly, some European conveyor belt manufacturers have chosen to ignore
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REACH requirements, either completely or at least partially because of the impact on production costs. However, the biggest concern is that manufacturers located outside of EU member states and the UK are not subject to European regulations. Imported belting from Southeast Asia, primarily China, now dominates the European market. Competition is fierce and largely driven by the selling price. Raw materials make up more than 70% of the cost of producing an industrial conveyor belt so the incentive to minimize costs, regardless of risk to human life and the environment is huge. As with all markets, unregulated raw materials cost appreciably less than their much safer, strictly controlled compliant counterparts. This creates an extremely
significant selling price advantage for those who are not even subject to safety regulations in the first place. Although importing belts that contain materials that are controlled or forbidden in Europe is legally permissible, those who import belts from outside of Europe are responsible for regulation compliance. This effectively means that the manufacturers are free from responsibility and the consequences while the importers may be unaware of the risks that they are exposing their business to. Much worse is the fact that those who regularly work with conveyor belts such as conveyor maintenance staff and belt splicers, are exposed to potentially serious health risks, not to mention the untold damage to the environment. Unlike car tyres,
less than 10% of conveyor belts are recycled.
PLAY IT SAFE Always ask for written confirmation from the belt manufacturer or supplier that the belt you are buying has been produced in compliance with REACH EC 1907/2006 regulations. A certificate of origin is also helpful. At the same time, basic safety precautions should be applied. Firstly, wear gloves when handling belts. Secondly, it is advisable to wash your hands before drinking, eating or smoking. Lastly, those involved in activity that may cause rubber dust to be produced, such as grinding for example, should wear a mask to prevent inhalation of dust particles. Bob Nelson
step on Koch Solutions’ ongoing journey – combining excellent and concentrated BMH technology under one roof. With this acquisition, Koch Solutions has considerably strengthened its position in the bulk material handling market, supplying equipment from mines to ports and stockyards. With combined services, production and manufacturing, taking into account the new acquisitions, Koch Solutions continuously aims to provide its clients with customized individual all-in-one solutions.
SEPTEMBER 2023
with excellent Chinese infrastructure. The acquisition compromises knowhow and IPR such as port/terminal equipment, stockyard systems, pipe conveyors and various continuous surface mining equipment from both legacy FLSmidth and Mining Technologies (ex-TK) portfolios, references, facilities in Australia and Germany, employees and projects by 1 September 2023 for Bulk Material Handling and Mining Technologies. After the acquisition of FLS Wadgassen by Rainbow Heavy Industries under the flag of Koch Solutions in 2019, this is the next
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Koch Solutions acquires FLSmidth’s Bulk Material Handling business Koch Solutions GmbH has acquired the Bulk Material Handling (BMH) Business from FLSmidth A/S, including FLSmidth’s past acquisitions in the BMH area, previously known under ThyssenKrupp Fördertechnik and Sandvik Mining Systems. Koch Solutions GmbH is a German company whose roots reach back more than 75 years into the past and that has a globally unique set-up with its majority shareholder Rainbow Group having own fabrication facilities with erection and port facilities for fully assembled machines. It combines wellproven German know-how and engineering
ENGINEERING & EQUIPMENT
Wear a mask to avoid inhaling rubber dust.
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NEWS SEPTEMBER 2023
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ENGINEERING & EQUIPMENT
September 2023 sees more Rotainers commissioned in outback New South Wales
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Australian company Container Rotation Systems (CRS) is renowned for its container-emptying system, which offers an efficient solution to the problem of unloading bulk from containers. This is a concept that is gaining in popularity worldwide, and is in use internationally handling cargoes of vastly different properties, from alumina to coal. The company remains very active, with its concept becoming ever better known. This month has already seen the commissioning of several Rotainers. Since the delivery of the first Rotainer® Eurospec 38 RS (Reach Stacker) to its operations in Broken Hill over 12 months ago, production at mining company Tronox’s plant has increased dramatically. Therefore, a second unit was installed to assist with the high duty cycles while guaranteeing constant feed stock into the processing plant. Unit 1 is consistently cycling at over 1,200 containers per month. Both units are fitted with CRS’s newly developed, innovative, highly reliable, ‘Claw’ lid lifting system that works perfectly for generic style container lids and lock systems. These Rotainers are highly successful for CRS; being a standalone unit allows full functionality of the reachstacker while using all functions of the Rotainers operating systems for seamless operations. Operators feedback confirms the 180° rotation, away from the operators is the industry standard for safety, functionality and dust minimization.
with SENNEBOGEN material handlers
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Circular economy in the construction industry
The 840 E unloads bulk material arriving at the Port of Edouard Herriot in Lyon and ensures efficient and fast supply to PRADIER’s end customers and plants.
Electric material handlers 840 E & 855 E support efficient port handling CIRCULAR ECONOMY ALONG THE RHÔNE RIVER: FROM MONDRAGON TO LYON AND BACK
Starting in Mondragon, located in the department of Vaucluse, the company’s barges transport materials from the local quarries upriver towards Lyon. Here, the raw materials arriving at the port of Edouard Herriot are unloaded by the 840 E electric material handler and in this course supplied to various construction sites along the Rhône, the concrete plant and the precast plant of PRADIER in Lyon. Downstream, inert materials obtained from deconstruction and demolition operations from various contractors are transported back to Mondragon. After arriving at the site, the 855 E unloads the
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elements and blocks as well as mixed asphalt products and recycles inert materials obtained from demolition work. To increase the environmental friendliness of these processes, the company’s management spent years developing a logistics system in which the river acts as the centre of all business operations. The result is a circular economy principle that has been in place for several months now, according to which the company keeps various resources and goods circulating between the two sites along the Rhône by ship. The two electrically driven material handlers 840 E and 855 E serve as the hub and focal point of the processes, ensuring efficient and energy-saving material handling.
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The principles of the circular economy gain increasing importance in the construction industry and represent an important concept for companies’ sustainability efforts. In this context, resources should be returned to the cycle and reused in an environmentally friendly manner. The PRADIER Group, a French family-owned company located between the Rhône and Vaucluse departments, puts this principle into practice every day with the help of the SENNEBOGEN electric port material handlers 840 E and 855 E. The PRADIER Group is a manufacturer of materials for the construction and housing industry based in the Rhône valley in France. The family-owned company produces aggregates, precast concrete
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ENGINEERING & EQUIPMENT
The 855 E easily unloads the hull and feeds containers as well as the elevated hopper that pours onto the recycling plant’s conveyor belts. Thanks to the proven Green Hybrid energy recovery system, stored energy can be used efficiently during each lifting process.
barges and the material is processed at the recycling plant. The recycled materials are then shipped back to Lyon.
MACHINES SUPPORT THE OPTIMAL IMPLEMENTATION OF THE PROJECT THROUGH HIGH PERFORMANCE AND ENERGY EFFICIENCY
In order to find the optimal machines for the implementation of the circular economy, the Chairman of the Group Roland Pradier and Director of the Strategy Committee Maxime Cendres relied on the strong cooperation of SENNEBOGEN with the local service and sales partner SYGMAT, which delivered the material handlers to the Group. The machines had to fulfill the high requirements of the logistics scheme to be implemented and ensure a fast and efficient flow of materials between the sites in Lyon and Mondragon. In addition to a high
working radius, in order to be able to unload the ships safely and quickly from the jetties built above the shore, the machines had to work in a particularly energy-saving and environmentally friendly manner at the same time. The choice quickly fell on the two SENNEBOGEN electric material handlers 840 E and 855 E that meet the company’s high standards. Both machines are installed stationary on the docks and are supplied directly from the facility’s power grid. At the same time, the machines operate noise- and emission-free and ensure a pleasant working environment despite the demanding continuous operation. Equipped with the intelligent Green Hybrid energy recovery system, the additional hydraulic cylinder on the 855 E allows stored energy to be used in every lifting process, saving up to 30% in operating costs. During lowering of the boom, the
energy is stored in compressed gas cylinders placed in the rear of the machine. The energy is available again almost without any loss for the next lifting process. The system is especially convincing with the existing height difference to the river on the shore, which requires a certain reach depth and performance of the machine — an optimal opportunity to benefit from the sophisticated technology. Maxime Cendres is satisfied with the implemented principle of the circular economy: “Our ships now run regularly between Lyon and our sites in the Vaucluse. With their excellent level of serviceability and efficiency, the SENNEBOGEN machines fully contribute to overcome our environmental and logistical challenges. Ultimately, we can avoid daily truck traffic in the Rhône Valley and thus save significant amounts of CO2 emissions.” DCi
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In Mondragon, the 855 E unloads the material for further processing in the recycling plant.
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with bulk conveyor systems
specialist Leslie David explains why there can be a world of difference between belts made by one manufacturer compared to another.
around pulleys and drums. Belts with horizontal profiles such as cleats are rarely affected but belts with more longitudinal profile patterns such as chevrons are a very different matter.
THE MOST COMMON PROBLEM The most popular profiled belts used on steep incline conveyors are those with chevron-patterned profiles, which guide and control the flow of material. These range from 15mm up to 32mm in height above the belt surface. The most common problem is that the chevron profiles split and ultimately become completely detached from the base belt. One of the main causes of this is the constant flexing
THE BEST INDICATOR The reason why this occurs on one belt and not on another is very easy to explain and also applies to one belt needing much more frequent repairs and providing a much shorter operational lifetime. The answer is the quality and consistency of the rubber and the type of production process used to create the raised profiles. By far the best indicator of probable deficiencies
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When it comes to chevron profiled belting, appearances can be very deceptive. One belt may look virtually identical to another belt and the basic specifications may also appear to be identical. Therefore, it is perfectly reasonable to assume that the durability, repair and maintenance requirements and working lifetime will be roughly the same. In reality, nothing could be further from the truth. It is not unusual, especially with so-called ‘economy’ belts, to find chevrons as high as 25mm or 32mm starting to separate from the base belt and/or wearing almost completely flat within a matter of a few months and in some cases, weeks. Here, conveyor belt
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Chevron conveyor belts – the good, the bad and the ugly
ENGINEERING & EQUIPMENT
Moving into high gear
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ENGINEERING & EQUIPMENT
The good: made to perfection using a single compound and one vulcanizing process. (photograph courtesy of Dunlop Conveyor Belting).
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is when there is a significant difference in the asking price. This is because there is a direct correlation between the price and the quality of the rubber. There is no doubt that it is the quality of the rubber that has the biggest influence on performance, repair and maintenance costs and the costeffectiveness in terms of operational longevity. The rubber used for conveyor belts usually constitutes at least 70% of the material mass of a flat conveyor belt and even more so when it comes to chevron belting. It is therefore the single biggest opportunity for cost-cutting by manufacturers who want to compete for orders based on price rather than reliability and lowest lifetime cost.
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The rubber is the single biggest opportunity for cost-cutting by manufacturers who want to compete for orders based on price.
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TRICKS OF THE TRADE The two most common methods used to minimize the cost of the rubber are the use of recycled rubber of highly questionable quality and origin and the use of cheap ‘bulking’ fillers such as chalk to replace part
of the rubber polymers in the rubber compound. Another cost-cutting practice is the use of a cheap form of carbon black, which is a crucial ingredient of rubber. Cheap, low-grade carbon black can be created by burning disused car tyres. Some 20% of rubber compound is made up of carbon black so it has a notable impact on the overall cost of making a conveyor belt. Good quality carbon black is more costly because it is created by a process of burning oil in a strictly controlled, low oxygen environment so that combustion is incomplete. But burning used car tyres not only pollutes the atmosphere it also means that any oils and greases remain present within the ‘regenerated’ materials, which has a detrimental effect on the physical properties of the rubber. The net result of these practices is rubber that has very poor resistance to dynamic stress, wear and tear, including cutting and gouging of the surface, and the degradation caused by ground-level ozone and UV exposure. As you would expect, the combination of some or all of these factors seriously reduces the operational lifetime of the belt.
THE GOOD The essential requirements needed to manufacture a durable, low-operating cost chevron belt are two-fold. First is the use of a single rubber compound formula for both the base belt structure and the chevrons. This then allows the creation of a single, homogenous structure using a onestep vulcanization production process rather than the more common two-step process.
A completely homogenous structure can handle the dynamic stress forces created by the continual flexing around pulleys and drums much more easily. In fact, the whole structure is significantly stronger and more resilient against spreading damage or having profiles that split or shear off.
THE TWO-STAGE PROCESS To best appreciate the advantages of a single homogenous chevron belt structure, it is first necessary to understand the difference between the two production processes. The vast majority of chevron profile belts are created using a two-stage vulcanization process. This involves using a belt carcass consisting of layers of fabric reinforcing ply and covered by a layer of uncured rubber compound on the top and bottom surfaces, which is placed in the vulcanization press. A mould plate that has been filled with uncured rubber is then placed on top of the base structure. Alternatively, the mould plate is extracted, filled with uncured rubber and then replaced back under the base structure. In both cases, the complete structure is then vulcanized to create the finished belt. The key weakness with this method is that the uncured rubber compound used to construct the base belt structure cannot be the same as the rubber used on the top and bottom cover surfaces. This is because the rubber used to fill the chevron profile mould has to be more malleable and flow more easily so that it can completely fill the mould cavities. However, in almost all chevron belts that are made in this way, the
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The bad: constant flexing can cause dynamic stress fractures in conventionally produced chevron belts. contact point where the two different rubber compounds join instantly becomes a point of weakness because, as explained earlier, the chevron profiles constantly stretch and flex under significant tension each time they run around a pulley or drum. This means that unless the bond between the base belt carcass and the chevron profile is absolutely flawless then sooner or later dynamic stress fractures in the profile will begin to occur, eventually causing the profile to split and all too often completely part company with the rest of the belt. This problem is significantly magnified on mobile conveyor equipment with relatively small pulley diameters. The smaller the pulley then the higher the dynamic stress. Failure will happen even sooner if, as I touched on earlier, one (or both) of the rubber compounds are not fully resistant (as per ISO 1431 testing) to the effects of degradation (surface cracking) created by chemical reactions in the rubber caused by ground level ozone and ultraviolet light. Sad to say, as a consequence of the relentless pursuit of low prices, the vast majority of
A ‘single structure’ chevron belt needs a highly specialized rubber.
The mould plate used to make a ‘single homogenous structure’ chevron belt. manufacturers do not use rubber that contains the necessary antiozonants needed to protect it from ozone & UV damage.
MAKE IT ONCE, MAKE IT STRONG To create a single homogenous structure the base belt (at this stage comprising of only uncured rubber) is placed in the vulcanizing press between the base plate of the press and a chevron mould plate positioned immediately below it. The base belt will already have a specific quantity of uncured rubber on the top cover surface in addition to the volume of rubber needed to achieve the minimum thickness of the top cover of the base belt and create the chevron profiles following vulcanization. The actual amount of ‘extra’ rubber needed depends on the design and depth of the chevron pattern. The compression of the upper and lower plates then forces the additional rubber to flow into and fill the mould cavities. Vulcanization of both the
base belt structure and the rubber-filled moulds then takes place simultaneously to form a single homogenous unit. Because of the technical complexity and the higher costs involved, perhaps it is not surprising that apart from Dunlop Conveyor Belting, hardly any other manufacturer of note produces profiled chevron belt in this way.
MULTI-FACETED RUBBER An essential requirement of the one-step production process is having a single rubber compound that has been specially engineered for both the base belt structure and the chevrons and which can be vulcanized virtually simultaneously within the mould and the base belt structure. In addition to being sufficiently malleable to allow it to flow smoothly and evenly into the moulds, the rubber also needs to have all the physical properties mentioned earlier including being fully resistant to the effects of ozone and ultraviolet light. It also needs to conform to European REACH regulations so that the end-product is also safe for conveyor operators to handle. This may sound relatively straightforward but it is actually extremely difficult (and more costly) to produce such a versatile, multi-faceted rubber compound. This is due to the huge number of chemicals, polymers and additives that need to be used, which have to be very precisely balanced and mixed so that the final compound ‘cocktail’ possesses all of the necessary physical properties. Fortunately, the difficulties are hugely outweighed by the considerable advantages.
A MUCH SHORTER WORKING LIFE Although easier and cheaper to achieve, the biggest disadvantages of the two-step production process, is that two non-
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Leslie David.
The ugly: Chevrons as high as 32mm can wear almost completely flat in a remarkably short time. identical rubber compounds are vulcanized (bonded) together. One compound formula is used to create the base belt and a different, more malleable compound is used in the mould plates. The first big disadvantage is that the bond between the different compounds is naturally weaker and more prone to the effects of dynamic stress. The second big disadvantage is that the more pliable compound used for the mould plates invariably has a much lower resistance to cutting and abrasion. Research and experience has shown that the rubber used to make the chevrons in the two-step production process will almost certainly have a much lower resistance to abrasive wear than would normally be acceptable. It is not unusual, especially among so-called ‘economy’ belts imported from Asia, that even chevrons as high as 32mm can wear almost completely flat within a matter of a few months and in some cases, weeks. And while this is happening the efficiency of the belt steadily diminishes.
ABOUT THE AUTHOR After spending 23 years in logistics management, Leslie David has specialized in conveyor belting for over 17 years. During
Conveyor belt transfer points are a source of spillage and fugitive dust. Stop spillage and minimize fugitive dust, use SealTek. A brand new and unique skirting system. Features • Thanks to the overlapping design, SealTek forms a continuous seal • Perfect connection between side and tail skirt blocks • Wear resistant backing plate acts as an external wear liner • Each block can be individually adjusted • One tool adjustment • Very quick and easy replacement of worn-out skirt blocks • Only 135 mm installation height required • 60 mm wear life • Environmentally friendly due to the long service life and reduced waste
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CHEAP FOR A REASON The harsh reality is that chevron, and indeed conveyor belts in general, are often viewed as ‘sacrificial’ components. The aim seems to be to pay as little per metre as possible even though the need to regularly repair and replace worn and damaged belts is much more expensive both in terms of lost productivity and day-to-day running costs. A cynic might also say that for some manufacturers, belt suppliers and service companies, regularly replacing chevron belts is a highly lucrative business that would not be nearly so profitable if the belts were a lot more durable and lasted a lot longer. Fortunately, the high-quality European belt manufacturers and the service companies that represent them, do not think that way.
Make conveyor belt misalignment a thing of the past, use CenTrax. A permanent solution to keep your belt on track. Features • Excellent tracking characteristics • Wear resistant autoclaved tracker rollers • Fitted with a unique, fully sealed and maintenance free pivoting point • Suitable for reversible conveyor belts • Suitable for virtually any belt construction • Easy to install • Low maintenance • Long service life • Quick return on investment There is always a CenTrax solution for every situation!
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that time, he has become one of the most published authors on conveyor belt technology in the world.
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TBK Group’s wide bulk handling expertise includes conveying systems
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The TBK Group of companies offers great expertise in the bulk handling market. The group’s experience ranges across many different sectors, from mining and heavy industry to the feed and food industries. It delivers practical, innovative and sustainable solutions which minimize waste, pollution and dust emissions, and that convert waste streams into new, valuable raw materials. The group’s four divisions specialize in different angles of bulk handling, as detailed below.
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DCP BENELUX Sustainable customized solutions for industrial dust extraction such as filters, complete dedusting installations and central vacuum cleaning systems (CVC), including the possibility of undertaking the entire process, from engineering to commissioning. For more information, please see ‘Managing dust emissions with DCP Benelux’ on p119 of this issue. IFE BENELUX IFE Benelux offers customized solutions for conveying, screening, separating and reusing bulk goods and waste streams for both the bulk material processing industry and the recycling industry. Conveying and separation solutions as offered:
Customized vibratory feeders, sieve shakers, magnetic separators and recycling machines. TBK SPILLAGE CONTROL TBK Spillage Control has 65 years of experience in optimizing conveyor systems. Equipment and solutions as offered are based on conveyor belt systems optimization, more specifically on keeping the conveyor belt clean and on the right track, preventing spillage and airborne dust around transfer points and controlling dust nuisance near transfer points. Product
solutions are offered within several brand names: CenTrax, DusTek, ImpTek, ProTek, SealTek, Spill-Ex, StarClean, Shock-Blower. v Keeping a conveyor belt clean and on the right track: the two biggest problems with conveyor belts are carry back and mistracking. They cause unnecessary material waste, damage, excessive wear, high clean-up costs, unplanned downtime and an unhealthy and unsafe working environment. The CenTrax and StarClean are ideal in this role. v Preventing spillage and airborne dust around transfer points: transfer points are an essential component for clean, safe and trouble-free conveyor belt transport. However, they are also a source of spillage, wear and airborne dust. With TBK Spillage Control’s Clean Transfer point Technology — products developed in-house — customers are guaranteed lowspillage, low-dust and low-maintenance transfer points. CenTrax, ImpTek, ProTek and SealTek are excellent solutions. v Controlling dust nuisance near transfer points: when bulk material flow through a transfer point, the material stream brings air along with it. This airflow collects fine particles
ENGINEERING & EQUIPMENT
from the material stream, creating dust. The overpressure created during loading the belt blows this dust through every opening. Controlling the airflow reduces the amount of dust, and gives the airborne dust time to settle before the material stream leave the transfer point. In this situation, DusTek, ImpTek and SealTek are ideal.
ABOUT THE TBK GROUP
TBK Group is able to stay competitive in the market through:
TECHNICAL DEVELOPMENTS In terms of recent developments, TBK Spillage Control has developed an extraction unit, called DusTek. This extraction unit is specially designed for installation on a conveyor belt transfer point, with the option to connect standardized extraction units together for maximum flexibility in filtration surface and extraction flow rate. The extraction units can be supplied with or without a filter housing as desired. They are accessible for maintenance via the side of the overflow cabinet and the extraction units are available in accordance with ATEX 114 (directive 2014/34EU) for use in zone 22. DusTek extraction unit During loading of the belt, air is both displaced and simultaneously induced. Most transfer points are not properly designed for this. As a result, the air speed in the transfer point increases considerably, and the resulting ‘storm’ picks up fine particles from the material stream. This creates enormous amounts of dust. The airborne dust is blown out through all
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Commodities handled by the TBK Group include all sorts of bulk materials across many different sectors; from mining and heavy industry to the feed and food industries. These include: coal, ore, concrete, sand, household waste, compost, milk powder, bakery products, seeds and cocoa. Because TBK Group has multiple divisions, it is able to meet a broad demand. The group has supplied its services to a wide range of clients, many of which cannot be revealed due to confidentiality requirements. Those that can be mentioned include: v ArcelorMittal, the second largest producer of steel in the world — another (unnamed) huge producer of steel is also a major client. v Hoving Holland, a company based in the Netherlands that designs and produces custom-built machines and entire installations for mushroom culture and waste management. There are also many other waste management companies that are part of TBK Group’s customer base. v Sand and gravel sector. v Storage and transshipment sector
v combined product knowledge for optimized solutions; v customization: standard products can be customized for the specific situation; v competitive knowledge; v improving existing products and developing new products; and v optimizing requested products in tenders by advising the customer of the best solution.
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TBK SERVICES TBK Services supports the three business units; DCP Benelux, IFE Benelux and TBK Spillage Control and focuses on installation, inspection, measurements and maintenance such as assembling and maintaining on-site its equipment and its conveyor belt components. v Assembly: TBK Services assembles the equipment and components supplied by its three units. Its professionals are at home in many industry sectors, from mining to the fine food industry, and from bulk handling to recycling. v Inspections and audits: TBK Services carries out audits and inspects the performance of conveyor components, transfer points and dust filters. It analyses the causes of contamination and mistracking, and carries out system and dust emission measurements. It puts forward concrete proposals for sustainable improvements. v Maintenance: engineers carry out preventive or corrective maintenance, based on findings from the inspection
report. This includes cleaning, replacing parts and, if necessary, repairing, adjusting and fine-tuning. TBK Services records all activities in a maintenance report.
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available openings, with all the associated consequences. The DusTek dust control programme focuses on reducing and controlling the air velocity within the transfer point. This is done by using an active (extraction) and a passive method. In practice, it is often a combination of both methods. The DusTek extraction unit offers the following advantages: v TBK Spillage Control’s knowledge and experience of both conveyor belt and dust control technology. The division has years of practical experience in both conveyor belt systems and dedusting systems. Based on this expertise, its people are able to assess, reduce and control the volume of air that passes through a conveyor belt transfer point. v Special spot filter for the transfer point: this is specially designed for installation at a conveyor belt transfer point. Thanks to its integrated reverse jet cleaning system, the filter can operate 24 hours per day without interruption. The modular construction of the filter allows maximum flexibility in set-up, filtration area and suction flow rate. The filter is equipped with convenient 700 or 1,000mm-long filter elements. These can easily be replaced from the side of the transfer point. Naturally, DusTek can be built in compliance with ATEX 114 (directive 2014/34EU) for use in zone 22. v A combination of active and passive dust control: passive dust control
measures limit the amount of air that is induced along with the material flow during loading and reduce the air velocity in the transfer point. As a result, a relatively small spot filter is sufficient to reduce the air velocity further to below the critical value. In addition, the transfer point must be provided with an effective seal and the impact zone must be sufficiently supported. Sufficient length of the transfer point is important to ensure that the remaining amount of swirling dust can settle on the material stream. Currently TBK Group is working on another technological development but it’s still too early in the process to reveal anything about this now. More information will follow in the near future. COMPANY BACKGROUND Since 1956, TBK Group has been providing innovative solutions for companies in the mineral processing, mining, (animal) food bulk handling and recycling industries. Worldwide, it offers customers total solutions to the many complex problems they encounter during transport, sieving, separation, crushing, grinding and storage of bulk goods. Wijnand van de Vendel and Bart Kelderman worked together as managing director shareholders at TBK Group for many years, until Kelderman unfortunately had to step back from the company due to health reasons. In May 2022, Kelderman was succeeded by Stan Egging, the current co-director-shareholder.
In April 2023 TBK Group entered its next phase following the appointment of a new management team and with the participation of investment company Anders Invest. Of this development, Egging said: “Anders Invest is a participant that enables us to grow into the player that we are. They also have a preference for the manufacturing industry. We attracted this investment company because of their good growth strategy, which certainly does not include an exit strategy. The participation is an additional opportunity for us to realize the desired expansion also for international markets. This powerful party can now take that step more quickly.” As in previous years, the new management team will continue at the helm, leading a superb team of technical specialists, mechanics and engineers, who operate at the highest technical level thanks to regular training and courses, which enable them to produce exemplary work within a flat organization. TBK Group now has more than ten partners worldwide. This includes Europe, Australia, Africa, Canada and America. This means that its products can be used worldwide. Therefore, the company continues to expand its partnerships. IFE Benelux recently became a dealer of Lubas, leader in the production of polyurethane elastomers which offers a wide range of products used for the transportation of bulk material on conveyor belts such as Polyurethane (PU) screen covers and wear cladding. Due to this dealership it’s possible to supply complete sieving solutions from now on.
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Technology to move the world Recognized worldwide for our quality, we are committed to advancing the goals of ESG by providing durable, low-maintenance equipment that ensures unparalleled reliability, along with tangible environmental bene昀ts such as reduced airborne dust, lower noise, and superior operating ef昀ciency. Our mission extends beyond manufacturing - we actively strive to reduce waste, contain contaminants, and continually improve our manufacturing processes for greater ef昀ciency and environmental responsibility.
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Efficient installations & impressive results: Scrapetec’s partnership in Peru ISC Ingeniería del Sur SAC, the partner company of Scrapetec in Peru, has achieved an impressive feat. Within 24 hours, the company installed 108 metres of AirScrape and two DustScrape systems. The next day, it continued its pace and added an additional 56 metres of AirScrape and three DustScrape systems in just 16 hours. The results were remarkable, with effective dust control and spillage prevention at the material transfer points. These fast and efficient installations delighted the customer and showcased the excellence of that partnership in the industry. The results were nothing short of extraordinary. The AirScrape and DustScrape systems immediately proved their worth, effectively containing dust and eliminating spillage at the customer’s material transfer points. The improved working environment brought about increased productivity and enhanced safety for the employees. In conclusion, the story of Scrapetec’s partnership in Peru showcases the power of teamwork, expertise, and efficiency. With its AirScrape and DustScrape systems, Scrapetec is transforming material transfer operations, one installation at a time, and leaving a lasting impact on the industry.
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BEUMER Group: the ideal conveying solution The U-shape conveyor is able to cope with tighter curves than a troughed conveyor and transport larger mass flows than a pipe conveyor (all pictures BEUMER Group GmbH & Co. KG).
How can mining companies make their operations more sustainable in order to reduce their environmental footprint? One adjusting screw is the efficient transport of the mining material to the port, for example. Overland conveyors that can move large quantities of material over long distances are required. The BEUMER Group offers a very suitable conveying solution. Belt conveyors can be used to transport various bulk materials from and to the port. BEUMER Group supplies a variety of
solutions depending on the intended use. Troughed belt conveyors, for example, permit high mass flows. They have an open design and are therefore suitable for coarse materials and very large volumes. Pipe conveyors, by contrast, have other specific advantages. The idlers shape the belt into a closed tube. This protects the transported material against external influences and also protects the environment against emissions such as dust or material loss. Panels with hexagonal cutouts and idler rollers in an offset arrangement keep the
The pipe conveyor passes through the port: This is the final curved section before the transshipment tower for transfer to the port terminal.
tube closed. Pipe conveyors are able to cope with tighter curves and larger angles of inclination than are possible with an open troughed belt conveyor. Their enclosed design also enables them to handle various bulk materials securely without any danger of cross-contamination. They also protect the health of the people who work at the facility or live nearby — for example, when bulk metal concentrates are being transported. Lukas Paul, Head of Ports & Terminals at BEUMER Group remembers a project in Peru. To transport zinc, copper or lead concentrates mined by a number of different companies from the store to the terminal, the system provider installed a pipe conveyor measuring approximately 3,000 metres in length which transported more than 2,000 tonnes of this material per hour. However, there was a problem: the route passed through a military area with barracks for troops. The enclosed conveyor system reliably prevents the concentrates from coming into contact with the environment and conveys them to the ship’s holds without generating dust. The pipe conveyor is also equipped with filters, scrapers, a dust removal mechanism
Lukas Paul, Head of Ports & Terminals at BEUMER Group.
ADAPTING FOR IMPROVED PERFORMANCE Sometimes the bottleneck can be a transfer chute. The facilities are already designed to cope with large volumes of bulk materials, but the transfer chutes through which the material moves from one conveyor to the next are not. “That was true of one of our customers,” reports Paul. In this case, the experts at BEUMER were able to perform a DEM analysis which enabled them to adapt the chutes and eliminate the bottleneck. “When we talk to our customers and analyse the processes, we very soon see whether a technical solution to the problem already exists,” says Paul. An example? BEUMER Group supplied the conveyor technology for an iron ore terminal in Malaysia. “We were making a few small changes to improve plant
performance when we discovered a new problem related to conveying iron ore in a particular condition,” recalls the BEUMER expert: during the rainy season, the material that is to be transported can sometimes become wet and sticky. In this state, material sticks to the conveyor belt and over time is distributed along the complete conveyor route. There was no suitable solution for keeping the belt clean available on the market. “We had tried a
number of different belt scrapers but that didn’t really help,” says Paul. BEUMER’s technical experts developed a prototype that cleans the belt using very-highpressure water. “In this way, we were able to remedy a problem for which there had previously been no solution.” The U-shape conveyor was developed against a similar background. The challenge was to combine the advantages of open troughed and enclosed pipe conveyors: the transported material had to be protected against outside influences such as wind, rain or snow — while the environment had to be protected against potential escaping material and dust. The solution had to be equally suitable for coarse material as well as very fine material. And all this was made even harder by the sometimes complex routing. “In our U-shape conveyors, a special idler roller configuration forms the belt into a U-shape. This is how the bulk material is transported to the discharge station,” explains Paul. A similar idler roller configuration to that used in troughed conveyors is used to open the belt. In this way, BEUMER Group has extended the possibilities for providing the best bulk material transport solution based on the specific need of the individual project.”
ENGINEERING & EQUIPMENT
and a control system, making the need for any transfer points superfluous. “Our belt conveyor systems are an economical and environmentally friendly alternative to truck transport,” says Paul. “They allow operators to automate their processes and remove the burden of the manual work from their employees. This solution also reduces energy consumption.”
ENGINEERING & EQUIPMENT
Conveyor systems in various fields: achieving best results Conveyor systems are widely used across various industries to automate material handling processes and achieve optimal efficiency and productivity. The team at CONVIR believes that every company, industry and project require custom solutions, by creating unique conveyor systems to maximize efficiency of the manufacturer. In all industries, the use of conveyor systems can result in several benefits, including increased throughput, reduced labour costs, improved product quality, enhanced safety, and better inventory management. To achieve the best results, it's crucial to design and implement conveyor systems that are tailored to the specific needs and constraints of each industry and facility. At JSC “CONVIR” the company tries to always keep up with the latest technologies and create conveyors as efficient as it can get in a certain situation. As of today it specializes in three main categories of belt conveyors.
1. MOBILE CONVEYORS
SEPTEMBER 2023
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Mobile conveyors are a type of conveyor system designed to be easily transportable and versatile, making them ideal for various industries and applications. These conveyors are mounted on wheels or tracks, allowing them to be moved to different locations within a facility or even between job sites.
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KEY FEATURES OF MOBILE CONVEYORS: Mobility: mobile stackers and conveyors are designed to be easily moved within a facility or between job sites. They often have wheels or tracks that allow them to be transported and positioned quickly. Adjustable heights: these systems typically have adjustable heights for both the input and output ends, allowing operators to adapt to different material handling scenarios and loading/unloading requirements. Variable speeds: mobile stackers and conveyors have adjustable speed controls, allowing operators to control the rate at which materials are moved, stacked, or conveyed. Telescoping boom: many mobile stackers feature telescoping booms or conveyors that can extend and retract, reaching different lengths to accommodate various stacking or conveying needs. Compact design: these systems are designed with a compact footprint to maximize space efficiency when not in use or during transport.
Self-propelled: mobile stackers and conveyors can be self-propelled, meaning they have their own power source (e.g., diesel engine or electric motor) for mobility. This eliminates the need for external towing or pushing. Remote control: some models come with remote control options, allowing operators to adjust height, speed, and other parameters from a distance for added convenience and safety. Durability: they are built to withstand rugged environments, making them suitable for industries such as mining, construction, and agriculture, where equipment may be exposed to harsh conditions. Customizable: mobile stackers and
conveyors can often be customized to meet specific application requirements, including belt type, width, and length, as well as loading and unloading options. Environmental compliance: some models are designed with features to minimize environmental impact, such as dust suppression systems, which help control dust emissions. JSC “CONVIR” is currently providing mobile conveyor solutions for mining, quarry, wood, sugar industries and ports.
2. STATIONARY CONVEYORS Stationary conveyors provide a versatile and cost-effective solution for material handling and transportation needs within
ENGINEERING & EQUIPMENT
industrial facilities. Their flexibility, ease of installation, and adaptability make them valuable assets in optimizing production processes and enhancing overall operational efficiency. One of CONVIR’s flagship products is modular stationary conveyors. The hallmark feature of modular stationary conveyors is their modularity. These systems are constructed from individual modules. This modularity allows for easy customization and reconfiguration to meet changing needs. Modular conveyors are designed for easy installation and assembly. They often feature bolted connections, which simplify setup and reduce downtime during installation. Also the modular design enables scalability. Users can easily extend or modify the conveyor system by adding or removing modules to accommodate changes in production volume or layout as they can also be configured in various shapes, including straight lines, curves, or complex layouts, depending on the specific material flow requirements of the facility. These conveyors can accommodate different types of conveyor belts to suit the characteristics of the materials being transported. Modular conveyors can be equipped with a wide range of accessories, including diverters, chutes, sensors, and
guides, to enhance their functionality and adapt them to specific applications. The main clients of CONVIR in this area of specialization are sugar factories, quarries, mines and others. Naturally, this wide range of industries requires a high level of customization, starting from the belt type and ending with unique shapes of the transporter.
3. NON-STANDARD CONVEYORS & PRODUCTION
In order to discover solutions to previously undiscussed/covered problems,
CONVIR’s team is also always ready to collaborate with its clients in order to find unique solution. This could include for example the safety metal constructions and bridges or port loaders/unloaders that require the most attention to detail. The best part of working with conveyors is that no two projects are the same, so JSC “CONVIR” works closely with its clients to successfully implement any of the three solutions in any kind of application or to create a conveyor system that intercepts mobile and stationary conveyors with new non-standard solutions.
ENGINEERING & EQUIPMENT
Second Doppelmayr RopeCon® system to transport wood chips at Lenzing AG’s premises Like the first RopeCon® at the Lenzing plant, the second installation also impresses with high availability, wind stability and its ability to cross high-density plant infrastructure without any problem. As a consequence, the RopeCon® creates an optimal link between the raw materials storage facility and the digester house. For the planned expansion of wood chip transport between the storage area and the digester house at its cellulose processing plant, LENZING AG, a leading company in the field of the production of fibres made from the raw material wood, contracted a second
TECHNICAL DETAILS
SEPTEMBER 2023
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Length: Vertical rise: Capacity: Speed: Motor rating, continuous:
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630m 33m 350tph 2,65m/s 60kW
since then, the system has proved to be a reliable and efficient solution for supplying the digester house. As the system is raised off the ground, it makes light work of crossing the existing infrastructure on the premises.
ABOUT DOPPELMAYR TRANSPORT TECHNOLOGY GMBH
RopeCon® conveying system to ensure sustainable raw material supply. The system has to cover a length of roughly 630m between the wood storage area and the digester house, passing right across the existing plant infrastructure. In addition, the system had to guarantee high availability in order to allow optimal integration into the production process and reliably deliver the 350 tonnes an hour to their destination. The second RopeCon® installation has been built to run alongside the existing RopeCon®, which has been transporting beech wood chips since 2003. In the time
Doppelmayr Transport Technology GmbH is a 100% subsidiary of the international Doppelmayr Group with headquarters in Wolfurt, Austria. Within the group, Doppelmayr Transport Technology is the point of contact for the transport of goods and materials. Doppelmayr is a technology leader and pioneer in ropeway engineering and is also present in other lines of business. Apart from material transport systems the group also designs, plans, and manufactures passenger ropeways for winter and summer tourism as well as for the urban transit sector, rope propelled APMs (e.g., the systems currently operating at the airports of Toronto and Mexico City) or fully automatic high-rise warehouses.
Innovation out of tradition It pays to talk to a specialist!
TAKRAF multi-commodity portal scraper reclaimer with a capacity of 1,100 t/h in Japan.
TAKRAF bulk material handling and storage solutions TAKRAF is recognized as a world leading technology brand when it comes to bulk material handling solutions, with a specific focus on high-capacity and/or complexity. Our solutions are tailored to your individual requirements and include all forms of conveying, stockyard & disposal facilities, loading & unloading equipment and more. Scan the QR-code to learn more about our bulk material handling cababilities.
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Challenge your material limits Nothing should stand in the way of your productivity – least of all the materials you move. With our compact Hägglunds direct drive systems, you can adapt easily to the job at hand, taking advantage of full torque at an infinite range of speeds. And should an overload try to stop you, the drives’ low moment of inertia and quick response will keep your machines protected. We’ll support you too, with an agile global network and smart connectivity to bring you peace of mind. Driven to the core.
Hägglunds is a brand of Rexroth. www.hagglunds.com
replacing a fleet of trucks. This overland conveyor, rated at 1,600tph (tonnes per hour) travels downhill from the mine site to the stockpiling area, following a negative slope with a height difference of –250m and an aggressive trajectory including a combination of four horizontal curves and vertical curves. This downhill configuration sees electrical power being generated at a rate of a few hundred kilowatts when material is conveyed. Thanks to state-of-the-art frequency converters, this generated power feeds other electrical consumers, and the overland conveyor belt can be controlled in any material loading configuration. RBL REI’s depth of experience in this field includes a hydraulically controlled braking system allowing, in case of a power shutdown, to stop this very long conveyor in fewer than ten seconds. The second phase of the installation includes a set of conveyors and transfer towers connecting to the existing
stockyard system. This will allow for an increase in loading capacity from 2,500tph up to 4,000tph (design capacity), integration of a material product sampling system and another transfer tower to direct the enriched manganese ore. RBL REI has designed a specific solution to integrate the new equipment with a minimum production downtime. Thanks to an embedded real time tracking device, RBL REI and the end-user can remotely monitor the performance of the conveying system and predict any upcoming maintenance operation. From initial concept creation to final system commissioning, RBL-REI provides its clients with comprehensive engineered solutions that utilize the latest industry design tools to ensure maximum efficiency. RBL REI’s team of highly qualified engineers is mastering the art of handling any kind of solid bulk material and is involved in the ports, mining, quarry, tunnelling, environment and energy industries.
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Environmental considerations and a desire for more cost-effective solutions are pushing mining and exporting companies to find alternatives to transport their bulk material. The Gabonese company, COMILOG (part of French global mining and metallurgy group Eramet), faced this exact challenge while implementing a project to increase its production. COMILOG specializes in the extraction and processing of manganese ore. Due to an increase in demand, the company is now producing over 5mt (million tonnes) per year. COMILOG mines, processes, transports and ships the ores using an existing combination of conveyors, train wagons, stockyard and shiploader. This existing system, working on a daily basis, was designed and implemented more than three decades ago by France-based company RBL REI, and has been operating successfully since then. Thirty-five years after the system was set up, COMILOG showed its trust in RBL REI when it decided to improve operational efficiency and cost-effectiveness of the existing installation, for which RBL REI offered its most advanced solution. RBL REI is world-renowned for the calculation, design, manufacturing and construction of bulk handling systems, and has been in operation for almost 50 years. Moreover, some of the company’s installations — which are present on the five continents — were achieved in the most challenging and extreme environmental conditions. The first phase of the project was successfully commissioned over the summer. The new ore transport system supplied by RBL-REI includes a package of belt conveyors at the Moanda mine site. The longest of these is an overland conveyor measuring more than 6.5km,
ENGINEERING & EQUIPMENT
RBL REI offers green and cost-effective solutions for bulk conveying
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KEEP A GOOD THING MOVING
EMERGENCY STOP SWITCHES
ACCESSORIES
In the bulk goods industry, the brand KIEPE is well known for proven premium-quality products "made in Germany" for monitoring and controlling conveyor systems. Roughly 80,000 km of conveyor systems all over the world have been equipped with KIEPE products. Our customers’ appreciation of our products is reflected in our leading position in the market.
SPEED MONITOR DEVICES
POSITION SWITCHES
Kiepe Electric GmbH Kiepe Industry Electric GmbH Kiepe-Platz 1 · 40599 Düsseldorf Telefon + ( ) info@kiepe-elektrik.com www.kiepe-elektrik.com
Pipe conveyors offer several advantages when compared with conventional conveyors: the ability to easily overcome obstacles with curves; the absence of need for transfer points; absence of material spillage; and very limited environmental impact. Pipe conveyors (PC) are environmentally friendly applications used to handle almost any type of material avoiding material emission and spillage. Moreover, PC technology reduces the necessity for dust suppression systems, which means saving the energy usually required to operate them. Further, this system has no drops between conveyors which is a waste of energy and is totally useless for the process. Without transfer towers, it is possible to save a lot of steel, foundation works, and erection activities, thus reducing the carbon footprint of the plant and the environmental impact. The use of enclosed belt conveyors ensures that the material is handled in a completely sealed way, all along the conveying path. The need for dedusting equipment is reduced to its minimum — and often eliminated. This kind of conveyor allows for dust-free operations (as the product is completely sealed by the rubber belt), extremely reduced costs in terms of supporting steel structures and galleries. This is thanks to the reduced section and weight compared with a standard belt conveyor — with full layout flexibility, transfer towers are not necessary for changes of height or direction of the conveyor. Bedeschi can provide pipe conveyors with vertical curves, horizontal curves and vertical and horizontal curves combined. The belt is the key element of pipe conveyors; Bedeschi supplies steel-cord or textile belts with a very similar structure as on a troughed conveyor. Carcass and rubber belt covers are the same as the conventional ones. The only difference is the reinforcement in the edges to provide a better overlap seal. The belt is also manufactured with a ‘memory’ to roll into a tube. This facilitates the tube forming and also reduces the transition zone — the distance from the loading point to the point where the belt is rolled into a pipe. The pipe belt, going around a curve, is compressed on the inner side and tensioned or stretched on the outer side. These different tensions introduce a rotational force into the pipe belt, which can rotate the belt overlap out of its central position. For this reason,
Bedeschi’s R&D team has developed and tested at its workshop in Italy a system to avoid belt rotation. The principle of this aligning station is based on the self-aligning training idlers on conventional troughed conveyors. By rotating the idler station around its centre axis, the belt is shifted to the left or right. With a pipe conveyor belt, this sideways movement is converted into a rotating motion — clockwise or counterclockwise. The three rolls on top of the conveyor are fixed, they do not move. The three rolls on the bottom move around their central axis. Each one of these rolls has a concave shape to increase the contact area with the belt. This arrangement consists of three training panels in series, actuated by one electro/mechanical actuator. The three panels are mechanically connected and move together. Rotating these three lower idler roll sets will rotate the pipe belt. This automatic training panel has been developed by Bedeschi’s R&D team, as well as the overlap position detecting station. Overlap feedback position is continuously detected by ultrasonic sensors managed by Bedeschi’s in-house-
developed software driving the turning panels. The position of the belt overlap is monitored by a series of sensors mounted around the belt pipe. The sensors monitor the position of the overlap and initiate corrective action, if required. Other designs are based on manually adjustable individual idler rolls, but these systems once adjusted, have to be manually readjusted with any variation of friction between the idler roll and belt. This can be due to weather changes (dry – wet – ice – snow), or different belt loadings. As mentioned before, pipe conveyors have a very limited environmental impact. Bedeschi’s commitment to lowering CO2 emissions in the cement industry is reflected in the study and research, with its R&D team, to offer its clients the best ecofriendly solutions for each project. The company is extremely proud to work closely with its clients in projects aimed to use alternative fuels to limit the use of fossil-type fuels, as well as reduce plant power consumption. This is the case of the SECIL Group which has awarded Bedeschi with a contract for the supply of a new pipe
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ENGINEERING & EQUIPMENT
Bedeschi Conveying Projects – The Secil Group Conveyor Project
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3D design of the pipe.
conveyor to handle different kinds The pipe during the cold of alternative fuels at the Outão commissioning phase. Cement Plant in Portugal. This project further strengthens the co-operation started with SECIL more than 20 years ago and it is part of the major R&D Clean Cement Line (CCL) Project which aims to develop and demonstrate a new cement production technology. The CCL project aims to bring the Outão cement plant to the forefront of energy efficiency and the lowest CO2 emissions among European cement producers. The project is partly funded by the Portugal 2020 government incentives programme, and it aims to develop a new concept of cement production. Bedeschi’s delivery to SECIL Group will contribute to eliminating the dependence on fossil fuels. The concept of Industry 4.0 will become essential for the plant’s management for improving efficiency and optimizing the processes, therefore a digitalized system will be integrated into the whole plant. The pipe conveyor has a diameter of 250mm and conveying length of 350m and will grant safe and clean transportation of alternative fuels at a rate of 300m3/h. It has been designed with vertical curves to fit with the layout constraints curves to follow the ground profile and to without intermediate transfer points. The overtake obstacles and with horizontal belt forms a closed tubular section both in
the carrying and return path; the conveyed material is protected from wind and rain all along the route. Bedeschi’s engagement in this project is among the activities implemented by the Italian company to contribute to reaching some of the sustainable development objectives, especially environmental protection, as established in the Agenda 2030 by the United Nations and one of the achieving goals present in Bedeschi’s sustainability report. Thanks to research and development in green technology, Bedeschi is able to design and produce machines and turnkey installations reaching the highest environmental standards. All involved are committed to the fundamental aim: guaranteeing a sustainable model for the future. Bedeschi designed and supplied the complete pipe conveyor system, delivering the structure in pre-assembled transportable modules to allow a smooth and trouble-free installation process. The pipe conveyor solution has been selected for this application being a modern and environmentally friendly transport system solving numerous problems associated with conventional conveyor systems and transportation of difficult materials.
RETAINS
DUST THE DUST FILTER CONCEPT FOR DUST REDUCTION AND PRESSURE REDUCTION AT TRANSFERS HIGHLY EFFECTIVE AGAINST DUST FORMATION The special filter medium of the DustBox retains dust particles that are generated due to material movement, and at the same time is permeable for the circulating air. The air escaping through the filter medium reduces the air pressure in the transfer, which is distorted by material movement. Used in combination with the AirScrape, the DustBox unfolds its special properties and increases the efficiency of the ScrapeTec dust removal system. Dust and spills are thus completely avoided.
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REPA CE’s manufacturing capabilities consist of three large modern factories based in China, employing approximately 470 employees. The third factory was acquired in 2018 and is purely focused on HDPE and PU products which has room for expanding operations threefold once the demand in the market picks up. v first factory (200,000m²): for pulleys and idlers; v second factory (87,000m²): for idlers, idler stations and structural steelwork; v third factory (9,701m²) : HDPE idlers, belt scrapers, PU/ HDPE components. All factories have a full complement of modern and well maintained equipment fit for purpose, consisting of the following: v profile cutting equipment and hydraulic plate rolls (pulley shells);
SEPTEMBER 2023
REPA CE offers wide range of conveyor components for bulk applications
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REPA Conveyor Equipment B.V. (REPA CE) based in the Netherlands specializes in producing high quality pulleys, idlers and idler frame for customers worldwide. REPA CE is a member of the REPA Group, which has been in the belt conveyor business for over 27 years. The company has recently relocated to new spacious office and warehouse facilities in Alkmaar, the Netherlands.
CAPABILITIES REPA CE has a strong in-house engineering capability that provides tailor-made designs. It selects and optimizes the best engineering solutions to meet specific customer demands, and environmental conditions for a large range of industrial applications that include but are not limited to the following: bulk materials handling (coal, cement, etc; mining; minerals; recycling industry; poultry industry; food industry; mushroom industry; palletizing industry; and agriculture industry. It also supplies custom made rollers to all kinds of industries. REPA CE’s product range includes; v pulleys and idlers (for all belt conveyor systems including trough conveyors and pipe conveyors); v pulleys up to 20 tonnes maximum (shell & shaft combined); v pulleys (cylindrical/crowned — ceramic/ rubber/PU lagging); v thermally controlled heater pulleys; v belt guide rollers/re-tracking idlers and frames; v steel rollers to (DIN, CEMA, SANS, GB etc. standards); v HDPE rollers/belt scrapers; v carrying and return training idlers; v rope pulleys & wheels; v idler/trough frames; v steel structures; and v canopies/covers.
ENGINEERING & EQUIPMENT
v hydraulic brake presses/ bending and punching machines (structural steelwork); v the latest welding technology (qualified operators & procedures to AWS/ EN standards); v robotic welding line for structural steelwork and idler frames; v heat treatment facilities; v Non-Destructive Testing (carried out by certified level II NDT technicians); v a full range of conventional and CNC horizontal lathes, boring and milling machines (shell, end discs, shafts); v rubber vulcanizing, including autoclave and high quality corrosion protection facilities (including powder coating); v dynamic and static balancing; v PU/ HDPE extrusion and CNC machining centres (third factory); and v zinc plating and hot dip galvanizing are carried out by approved sub-suppliers under strict quality and environmental controls. All operations are supported by a qualified and dedicated QC department which includes a full time resident engineer (expat), operating in all factories, providing technical support, inspections and assistance on manufacturing processes. This is further enhanced by in-house inspection and testing facilities, non-destructive testing and mechanical/chemical analysis laboratory in accordance with and certified to: v ISO 9001:2015 Quality Management Systems. v ISO 14001:2015 Environmental Management Systems. v ISO 18000:2007 Occupational Health & Safety Management Systems. v ISO 3834-3 – Quality Standard for Fusion Welding and Metallic Materials.
SEPTEMBER 2023
These two manufacturing facilities combined are capable of producing approximately 2,000,000 high quality energy saving idlers annually.
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Customers are provided with Inspection & Test Plans (ITP) prior to commencement of work (if required) for approval and final manufacturing data book (MDR) consisting of inspection, test reports, material certification and welding documentation are compiled progressively until final completion. Weekly progress and inspection surveillance reports complete with photographs are issued on a weekly basis throughout manufacture upon request as part of REPA’s total commitment to its quality and customer satisfaction programme. Idlers are designed and supplied by REPA CE in accordance with: v DIN 22112-3 – Testing Requirements. v Strict T.I.R. control according to DIN 221122. v Dynamic Balancing – Class G40/G16 according to ISO 1940:2005.
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ENGINEERING & EQUIPMENT
4B Group launches innovative digital rotary encoder ‘ENCODER-FLEX 1024’ 4B Group has introduced the Encoder-Flex 1024, a configurable multi-function encoder designed for monitoring position or speed. The Encoder-Flex 1024 has many applications and is very well suited to monitor the position of rack and pinion gates, angular position of distributors, as well as shaft speed for rotating machines such as bucket elevators and conveyors. The new, ATEXapproved Encoder-Flex 1024 has numerous industrial applications in one design. With a compact, stainless-steel design, the Encoder-Flex 1024 provides the robustness for harsh industrial environments. The fully sealed body has an innovative local calibration facility that does not require opening the unit; simply apply an external magnet briefly to calibrate. Providing even more flexibility, resolution can be programmed for one to 1,024 pulses per rotation. In addition, the Encoder-Flex 1024 provides 4–20mA, quadrature-pulsed and
Modbus RTU outputs in one single model, giving the user the versatility and flexibility to connect many different controllers and displays. “We have already identified numerous applications for the Encoder-Flex 1024 in our core markets. One example is to monitor slide gate position; this gives complete visibility to the plant process control system for maximum efficiency and early warning of any issues,” says Sam Payne, 4B Group CTO for Electronics. “One of the key benefits of the EncoderFlex 1024 is the configurability for multiple applications. End users and OEM’s do not
have to worry about configuring their encoder/tachometer requirements at the order stage; one part number suits all applications.” According to Payne, “The Encoder-Flex 1024 is a robust yet compact unit that takes up very little space. Unlike string potentiometer gate monitors that are mechanical devices prone to failure and require maintenance, the Encoder-Flex 1024 is easy to install and calibrate. It features outputs of 4–20mA, Quadrature Pulse (speed/relative rotation), and RS485 Modbus RTU to meet customer needs.” “This product is simple to install and operate and features elegant calibration,” explains Payne. “Compared to competitive products, it’s less bulky and more robust with fewer limitations. The resolution can even be set in the field from one to 1,024 pulses per revolution to suit virtually any application.”
SEPTEMBER 2023
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Martin Engineering highlights safe conveyor equipment design
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Conveyors are among the most dynamic and potentially dangerous equipment in bulk handling. The operational basics of belt conveyor systems regarding the hardware installed and the performance required from the components are too often a mystery to many employees. This knowledge gap also creates a safety gap. Since personnel are the single most important resource of any industrial operation, to meet workplace safety standards, the consensus among safety professionals is to design the hazard out of the component or system, which historically yields more cost-effective and durable results. Designs should be forward-thinking. This means exceeding compliance standards and enhancing operators’ ability to incorporate future upgrades costeffectively by taking a modular approach. This method alleviates several workplace hazards, minimizes clean-up and maintenance, reduces unscheduled downtime and extends the life of the belt and the system. Before the drafting phase, designers should: v establish the goals of reducing injuries and exposure to hazards (dust, spillage, etc.);
v increase conveyor uptime and productivity, and; v seek more effective approaches to ongoing operating and maintenance challenges.
COMBINING SAFETY & PRODUCTIVITY To meet the demands for greater safety and improved production, some manufacturers have introduced equipment designs that are not only engineered for safer operation and servicing but also reduced maintenance time. An example is the Martin® QC1™
Martin® Guarding is designed to protect workers from reach-in injuries in unauthorized areas (all photos: ©Martin Engineering 2023).
Cleaner HD/XHD STS (Safe-to-Service) primary cleaner and the Martin SQC2S™ STS secondary cleaner, designed so the blade cartridge can be pulled away from the belt for safe access and replacement by a single worker. The same slide-out technology has been applied to impact cradle designs. Systems like the Martin Slider Cradle are engineered so operators can work on the equipment safely, without breaking the plane of motion. External servicing reduces confined space entry and eliminates reach-
in maintenance while facilitating faster replacement. The result is greater safety and efficiency, with less downtime. An example of a safer belt cleaner is the CleanScrape®, which received the Australian Bulk Handling Award in the ‘Innovative Technology’ category for its design and potential benefits. The revolutionary patented design reduces the need for bulky urethane blades altogether. It delivers extended service life, low belt wear, and significantly reduced maintenance, which improves safety and lowers the cost of ownership. Unlike conventional belt cleaners that are mounted at an angle to the belt, the
CONCLUSION
The track-mounted Martin® Slider Cradle can be serviced quickly and safely, with no reach-in maintenance.
LOW-BID PROCESS AND LIFE CYCLE COST
price, the benefits are often short-lived, and costs increase over time, eventually resulting in losses. In contrast, when purchases are made based on the lowest long-term cost (life-cycle cost), benefits usually continue to accrue and costs are lower, resulting in a net savings over time.
ABOUT MARTIN ENGINEERING
Martin Engineering has been a global leader in bulk material handling for more than 75 years, continuously developing new solutions to make high-volume conveyors cleaner, safer and more productive. The company’s series of Foundations™ books is an internationally recognized resource for safety, maintenance and operations The CleanScrape® training — with more than 22,000 forms a 3-D curve print copies in circulation around the beneath the discharge world. The 500+ page reference that conforms to the books are available in several pulley’s shape. languages and have been downloaded thousands of times as free PDFs from the Martin website. Martin Engineering products, sales, service and training are available from 17 factory-owned facilities worldwide, with wholly-owned business units in Australia, Brazil, China, Colombia, France, Germany, India, Indonesia, Italy, Malaysia, Mexico, Peru, Spain, South Africa, Turkey, the USA and UK. The firm employs more than 1,000 people, approximately 400 of whom hold advanced degrees.
SEPTEMBER 2023
Although the policy is generally not explicitly stated by companies, the ‘Low-Bid Process” is usually an implied rule that is baked into a company’s culture. It encourages bidders to follow a belt conveyor design methodology that gets the maximum load on the conveyor belt with the minimum compliance to regulations using the lowest price materials, components and manufacturing processes available. When companies buy on
Engineering safer conveyors is a long-term strategy. Although design absorbs less than 10% of the total budget of a project, Engineering/Procurement/Construction Management (EPCM) services can be as much a 15% of the installed cost of a major project, additional upfront engineering and applying a life cycle-cost methodology to the selection and purchase of conveyor components proves beneficial. Safety-minded design at the planning stage reduces injuries by engineering hazards out of the system. The system will likely meet or exceed the demands of modern production and safety regulations, with a longer operational life, fewer stoppages and a lower cost of operation.
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CleanScrape is installed diagonally across the discharge pulley, forming a threedimensional curve beneath the discharge area that conforms to the pulley’s shape. The novel approach has been so effective that in many operations, previously crucial secondary belt cleaners have become unnecessary, saving further on belt cleaning costs and service time.
ENGINEERING & EQUIPMENT
This Martin SQC2S STS secondary cleaner allows for safe external maintenance by a single worker.
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ENGINEERING & EQUIPMENT
Port conveyors: belt wear isn’t just from salty air Most conveyor belts in ports are considered operating in ‘severe duty’ and typically don’t just wear out, writes R. Todd Swinderman, President Emeritus, Martin Engineering. Yes, they’re exposed to raw material and punishing weather conditions. But even though the salty air can erode components quickly, more often, the belt experiences a shortened life from catastrophic events like a significant impact, splice failure or piercing damage. Or they suffer from chronic issues such as mistracking or frozen idlers. In addition to correcting such problems to extend belt life, a concern to many bulk material
Engineered chutes control and centre cargo flow on the receiving belt to match the belt’s speed and avoid over shifting and mistracking (all photos ©Martin Engineering 2023).
Properly positioned inspection doors along the length of the system allow maintenance and monitoring of belt health.
improvements of 40–300% from using DEM to optimize chute designs.[1] The primary objectives of chute design are to direct an uninterrupted flow of the bulk solid from the chute to the receiving belt, centred in the direction of belt travel and as close as possible to the speed of the receiving belt. While the interaction between the belt and the bulk material is complex, in general, troubleshooting belt wear caused by chute design can take advantage of some simple relationships. The first is the general relationship between material impact angles and the wear rate of rubber. Figure 1 shows that as the impact angle increases, the wear generally decreases. The second fundamental principal that
handling operations is the damage from loading, belt wear from cleaning devices and the difficulty of cleaning damaged belts.
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BELT WEAR FROM LOADING
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Since the belt is a major cost element in the process of conveying bulk materials, much attention is focused on reducing wear and damage. In general, loading wear occurs over a long period of time from the discharge of material onto the belt and from contact with conveyor components such as idlers and belt cleaners. Belt wear from loading includes both impact damage and frictional wear. Damage to the belt can be a single event, such as that from tramp metals or oversized lumps in the material flow stream. Such sudden damage can result in catastrophic failure that requires immediate attention, demanding a system shutdown. The negative effects of long-term wear are less dramatic, and replacement can generally be scheduled for planned outages to avoid affecting conveyor availability. One key to understanding belt wear
from loading is the chute. The development of Discrete Element Modelling (DEM) as applied to conveyor loading chutes has given the industry a valuable tool for verifying chute designs and predicting conveyor belt wear. A survey of the literature yields evidence indicating belt life
can be applied to chute design to minimize belt wear is the speed of the bulk material stream, which is affected by friction and 1. Minimizing Belt Wear and Damage from Optimized Chute Design; (2014) Jason Aldrich, Yijun Zhang; Conveyor Dynamics Inc.; Bellingham, Washington, USA, pp.3-7.
acceleration due to gravity as the load falls to the belt. The coefficients of friction between the bulk material, chute and belt are important parameters that are utilized in DEM programmes to optimize the shape of the chute, producing the desired exit velocity and direction of the discharged bulk material. Common chute configurations include rock boxes, inclined flat chutes and curved
Three different chute design approaches
Comparison of loading velocities and vertical component Vey.
loading velocity vectors. Vey is the bulk material stream velocity perpendicular to the belt and is the primary factor in belt wear. The wear of the belt is proportional to the magnitude of Vey, so minimizing this component through chute design is a focus of a DEM analysis. Figure 2 is a generalization, it but shows that the exit velocity of a curved chute is the lowest of the three design choices. This is due in part to the force resulting from the curved chute, which tends to reduce the impact velocity ( Vey) relative to a flat chute, even if the basic discharge angles are similar. Rock boxes may reduce chute liner wear but can create significant belt wear due to the relatively high vertical velocity and the resulting shearing action between the bulk material and the belt as the load gets up to belt speed.
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A single scratch can contain significant carryback.
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chutes, as shown in Figure 2. Ve is the exit velocity of the bulk material stream from the chute, and Vb is the belt speed. Other factors to consider when designing the optimum chute for a given application include drop height and preferred liner materials, but in general, belt wear from the choice of chute design is greatest with rock boxes, which do little to slow the material’s velocity and introduce a large amount of disruption as the load cascades from one shelf to the next, then
lands on the moving belt at a nearperpendicular angle. Flat inclined chutes help shift the load in the general direction of the receiving belt’s travel, but can involve even greater impacts than a rock box, depending on the drop height. The violent landing takes a constant toll on the belt, often creating significant amounts of fugitive material in the form of dust and spillage. Belt wear from loading impact is generally minimized when using curved chute designs, as the bulk material stream’s velocity can be most closely matched to that of the belt with curved chutes. Figure 3 shows the relative differences in
ENGINEERING & EQUIPMENT
General wear of rubber based on impact angle.
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Innovative cleaner design reduces belt wear and eliminates the need for re-tensioning.
a system for rating the difficulty of the belt cleaning application and for desired levels of carryback exiting a cleaning station to aid users in specifying belt cleaning performance, rather than making decisions based on brand preference or price alone.
CONCLUSIONS v Curved chutes are effective in minimizing belt wear from loading. v Belt cleaners do wear the belt, but at a much lower rate than loading. v Rather than focusing on extending the life of sacrificial wear materials, making service of wear materials easier and faster should be the goal of design and maintenance engineers.
ABOUT THE AUTHOR
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While belt wear is the main concern, a significant amount of attention should be paid to the selection of liners to prolong chute life. Given the relative cost of the belt compared to the chute in most applications, the wear liners should be considered sacrificial components, and attention would be better spent on improving chute design, selecting lower friction liners and making the liners easier and quicker to change. Some manufacturers have engineered new designs for liners that can be serviced from outside the chute, for example, eliminating the need for confined space entry and drastically reducing replacement time.
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CLEANING OF DAMAGED BELTS Cleaning efficiency is related to the material properties extracted from the quarry, number of belt cleaners, the mechanics of a particular belt cleaner design and the belt surface, among a host of other variables. It’s a common expectation that a conveyor belt can be cleaned with an efficiency approaching 100%, but even a brand new belt has macro and micro defects that make cleaning close to 100% practically impossible. These imperfections can result in as much as 60g/m2 of carryback passing a belt cleaner station 2. Basic Parameters of Conveyor Belt Cleaning; C.A. Rhoades, T.L. Hebble, and S.G. Grannes; U.S. Dept. of the Interior, Bureau of Mines; Pittsburgh, PA; 1989.
with a new belt. When the belt surface is damaged, the amount of carryback that can be shielded from belt cleaning in scratches and gouges can be even more significant, on the order of 100 to 200g/m2. Figure 4 shows how much carryback can be contained in a single scratch measuring 2mm wide by 1mm deep in the belt top cover. The US Mine Safety and Health Administration (MSHA) estimates that 85% of all conveyor problems — including wear — come from fugitive materials. Fugitive materials are those that escape the conveyor other than at the discharge, including spillage, dust and carryback. Since carryback is a significant source of fugitive materials, which in turn contribute to belt and component wear, it makes sense to focus on adequate belt cleaning. Cleaning damaged belts is best accomplished using water in combination with mechanical scrapers. In severe cases, brush cleaners are effective in removing material from damages such as skirtboard grooves, but brush cleaners require more frequent adjustment and replacement than mechanical scrapers. With a belt in good condition and professional maintenance, a belt cleaning station can usually control carryback to within 10–100g/m[2]. The Conveyor Equipment Manufacturers Association (CEMA), in its seventh edition of Belt Conveyors for Bulk Materials, has established
R. Todd Swinderman, President Emeritus/ Martin Engineering, earned his B.S. from the University of Illinois, joining Martin Engineering’s Conveyor Products division in 1979 and subsequently serving as V.P. and General Manager, President, CEO and Chief Technology Officer. Swinderman has authored dozens of articles and papers, presenting at conferences and customer facilities around the world and holding more than 140 active patents. He has served as President of the Conveyor Equipment Manufacturers’ Association and is a member of the ASME B20 committee on conveyor safety. Swinderman retired from Martin Engineering to establish his own engineering firm, currently serving the company as an independent consultant.
ABOUT MARTIN ENGINEERING Martin Engineering has been a global leader in bulk material handling for more than 75 years, continuously developing new solutions to make high-volume conveyors cleaner, safer and more productive. The company’s series of Foundations™ books is an internationally recognized resource for safety, maintenance and operations training — with more than 22,000 print copies in circulation around the world. The 500+page reference books are available in several languages and have been downloaded thousands of times as free PDFs from the Martin website. Martin Engineering products, sales, service and training are available from 17 factoryowned facilities worldwide, with whollyowned business units in Australia, Brazil, China, Colombia, France, Germany, India, Indonesia, Italy, Malaysia, Mexico, Peru, Spain, South Africa, Turkey, the USA and UK. The firm employs more than 1,000 people, approximately 400 of whom hold advanced degrees.
ENGINEERING & EQUIPMENT
Go harvest! Customers demand reliability from bulk grain conveyors — all day, every day
AGI Hi Roller conveyors serve as a standard-bearer with customers for efficiency, reliability and safety (photo provided by AGI).
A LEGACY OF RELIABILITY Since 1982, AGI Hi Roller has been manufacturing commercial enclosed, dusttight and self-reloading conveyors, designed specifically for installation in grain handling facilities, soy and corn processing operations, and industrial operations. The conveyors eliminate explosive grain dust emission and minimize housekeeping and maintenance costs — issues prevalent in the industry. AGI Hi Roller specializes exclusively in the design and application of enclosed belt conveyors, which contain dust and spilled materials and automatically reload that material back onto the belt’s carrying surface. With reduced dust emissions, isolated bearings and higher capacities, the AGI Hi Roller series deliver safety along with efficiency. v The AGI Hi Roller — with capacities
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high capacity — all day, every day. “Today’s customers move grain 24/7. So, they demand dry bulk handling systems to convey grain with consistent and reliable performance. AGI’s enclosed belt conveyors are built for that purpose,” says Mike Hand, AGI Vice President, North America Commercial. “AGI’s Hi Roller® and Hi Roller®HiLife® conveyors are workhorse products with a great design. While they have not undergone a major redesign, AGI makes small behind-the-scenes changes to enhance the user experience, improve durability or ease assembly for customers — things like increasing the robustness of welds and setting new standards of excellence for quality control. These slight changes add to the alreadyrobust reliability of our enclosed belt conveyors.”
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What is the one thing a commercial grain operation can never reclaim? The answer is time. As September ends, farm combines across North America are well under way with corn and soybean harvest. But the truth is — around the globe — crops are being harvested all year long. And, for commercial operations, which process, ship and market those bulk grain commodities, time is everything. Ag Growth International (AGI) knows this. That is why AGI — based in Toronto, Canada, with manufacturing, engineering and customer service, sales and support operations worldwide — is focused on supplying the agriculture and food industry with high-quality, durable grain handling solutions that can swiftly and reliably move huge volumes of bulk grain commodities at
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AGI Hi Roller conveyors at a port terminal (photo provided by AGI). up to 3,800 metric tonnes per hour — is optimal for moving bulk products like grains, pulses and feeds that have low moisture levels or products that require gentle handling. The belt conveyor is totally enclosed, reducing the dust emissions typically found with
open belt conveyors. Built with rubber flippers that attach to the tail pulley, they work to lift and direct spilt material against a stationary deflector that then reloads onto the carrying surface of the belt. v The AGI Hi Roller Hi Life — the
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With capacities up to 3,800 metric tonnes per hour, AGI Hi Roller conveyors are optimal for gently handling bulk products like grains, pulses and feeds (photo provided by AGI).
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heaviest duty, highest capacity and longest life enclosed conveyor — is ideal for handling large capacities and continuous plant feed applications that run 24 hours a day, seven days a week. Resembling a conventional conveyor idler, the AGI Hi Life idler is much
buy our products,” said Hand. AGI Hi Roller conveyors have replaced open belts or chain conveyors worldwide, delivering higher capacities to existing facilities with their smaller trunking widths. From multi-million-dollar port terminals to feed, food and flour processing mills, AGI has custom-installed more than 10,000 conveyor systems in facilities around the world.
“AGI’s bulk conveyors appeal to those customers who simply cannot afford any down time or interruptions. These include big grain traders and terminals in which efficiency and reliability are the expectations,” said Hand. “While this is not a huge shift in the marketplace; we do see customers push for lower operational costs. So, increasingly, they are willing to invest in the right equipment to provide longevity, minimal maintenance, customer service, and return on investment.”
SETTING STANDARDS
SERVING CUSTOMERS WORLDWIDE For more than 40 years, the contributing factors behind the success of AGI Hi Roller conveyors are consistent construction, quality control and a focus on customers. “Simply put, we listen to the people who
While AGI Hi Roller conveyors serve as a standard-bearer with customers for efficiency, reliability and safety, AGI’s people-behind-the-product are, also, setting their own standards for manufacturing. “Internally, one of the biggest things that we’ve worked on is partnering with AGI’s local and global engineering teams on design for manufacturability — that means improving design to allow for production efficiencies on the shop floor, reduced scrap, and better workflow,” said Len Homelvig, AGI Plant Manager. “We have also improved collaboration across teams, streamlined roles and responsibilities, expanded leadership and safety training, and improved overall output.” AGI’s focus on productivity, responsiveness, timeliness, customer service, and
attention to detail are factors that matter to customers. "Over the previous year, we have made significant gains in productivity and efficiency,” said Homelvig. “Every day that we come to work, our goal is to deliver a quality product on time with exceptional customer service after the sale. Our ongoing challenge, however, is: how do we do that even more effectively?” In the end, both Hand and Homelvig say that the AGI Hi-Roller’s mission is to help customers solve their greatest challenges. Homelvig put it this way: "We are trying to help customers make better decisions by offering them information for an equipment solution that best meets their needs, while minimizing the cost and impact for everybody involved.”
ENGINEERING & EQUIPMENT
thicker, the bearings are much larger and there are no brackets or bearings exposed to the internal atmosphere of the conveyor housing. Hi Life is considered one of the industry’s best conveyor for gentle handling of bulk products. v AGI’s Hi Roller series also offers the Mini Roller and Lo Roller for smaller jobs.
ABOUT AGI AGI is a major provider of equipment solutions for agriculture bulk commodities including seed, fertilizer, grain, feed, and food processing. With manufacturing facilities in Canada, the United States, Brazil, India and Italy, these facilities and teams work to deliver the right combination of conveyors, storage, technology, and any other relevant equipment required for the project.
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Innomotics: a trusted partner for the mining industry Innomotics is a prominent supplier of end-to-end solutions for the mining, cement, and other industries. The company effectively meets its customers’ challenges at each process stage, from extraction to transportation to beneficiation with its comprehensive portfolio of solutions. With eight factories on three continents as well as service staff in 49 countries, Innomotics can provide equipment and support its customers wherever they are in the world. Through electrification, automation, and digitalization, the company wants to help its customers build the mines of the future that will contribute to the global fight against climate change. Whether the customer needs to move minerals a few metres or tens of kilometers, Innomotics can design, implement, and support the operations of conveyor belts able to move thousands of tonnes per day. When it comes to the transportation of bulk materials, Innomotics can power the mine winders, conveyor belts and electrified truck-trolley systems which can move minerals efficiently and sustainably from pit to port. In 2012, working in partnership with ThyssenKrupp, Innomotics commissioned a gearless drive for the conveyor belt at the Antapaccay copper mine in Peru, one of the first such systems to be installed outside of Germany. Located around 4,200 metres above sea level, the 6.5km belt can move around 5,000 tonnes per hour of ore, using just two bearings per drive, compared with more than 20 in a conventional drive. This means greater availability, reduced maintenance downtime, and lower operating costs. As mining companies and others strive to reduce their carbon emissions, new technologies for the transportation of bulk materials will play a key role in these efforts. For example, Innomotics continues to offer its Electrification TruckTrolley system which can be an efficient means of reducing fuel consumption in mine haul trucks, especially on steep uphill slopes.
However, given that the trucks themselves account for around 60% of the weight that they have to move — and therefore of the energy they consume — Innomotics believes that conveyor belt systems offer a much more efficient and sustainable method for moving bulk materials. As well as providing the power to move bulk materials, Innomotics strives to offer technological solutions to help customers manage their processes more efficiently, sustainably and in greater safety. The company already offers a range of products and services in this space. Innomotics’ Short Interval Control (SIC) platform helps mine managers stay on top of critical constraints that could hinder operations, using real-time information collected via sensors or entered by operators onto mobile devices. Whether the issue is related to personnel, materials, or equipment, once a constraint is detected, the system assesses feasible options and presents them to management for a final decision. The company’s MAQ technology for advanced stockyard management allows operators to continuously monitor their inventory of bulk materials. With real-time 3D models that display both the quantity and quality of stockpiled material, users can track its movements from the time it is stacked to when it leaves the yard. The Digital Twin technology allows customers to simulate the design and
operation of their processing system before it is even built, experimenting with different designs and operating methods which can result in huge savings in capital expenditure, operating costs, and maintenance downtime. A Digital Twin for a conveyor system allowed the owner to identify several potential problems which it was able to resolve in time to ensure a smooth commissioning. Digital Twins can also be used for training purposes. For example, operators at an iron ore plant in Turkey have used their digital twin to learn how to respond rapidly and effectively to unscheduled stoppages. Innomotics has pioneered the use of Artificial Intelligence to help companies use its machinery more efficiently. In India, a mining equipment supplier has equipped its wagon tippler system with Innomotics’ Smart Mining Anomaly Detection solution, which provides customers with advanced warning of potential issues with the hydraulics. Better able to plan preventative maintenance and service work, customers estimate that the technology has led to energy savings of around four hours per week. From giant systems for handling bulk materials to cutting-edge technology for managing a business better, Innomotics is a trusted name for the global commodities industry.
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For more than 50 years, Polish company Sempertrans has been manufacturing highquality steel cord and textile conveyor belts to help customers accelerate their operational performance. With production facilities in Poland and India, Sempertrans is one of the largest and most technologically advanced conveyor belt manufacturers in the world. Its far reaching experience, state-of-the-art technologies and high production capacity, as well as extensive conveying expertise have made it one of the most reliable conveyor belt suppliers in the world, providing excellent quality in terms of products and services. Sempertrans is part of the Semperit Group, which has been a worldwide leading supplier of natural and synthetic rubber products for more than 190 years. Sempertrans sees itself as a partner, and it helps its customers to find the optimal conveyor belting solutions for their applications. Everything it does is guided by one clear goal in mind: it creates added value by making the customer’s entire
ENGINEERING & EQUIPMENT
Sempertrans boasts over 50 years of conveying expertise
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conveyor system as safe, efficient and reliable as possible. Besides the supply of conveyor belts with excellent cost-tobenefit ratio, Sempertrans offers critical support at all stages of its projects. It stays at the side of its customers anywhere and anytime to provide them with tailored technical consulting and field services.
FACTORY IN FOCUS
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Sempertrans has a major manufacturing facility — the largest in Europe — where it makes its cables, mixes rubber, manufactures belts, packages its own products and transports them to customers all around the world. All factory operations are carried out to the highest standards, and employ high-tech solutions to ensure that its products are of the highest quality. It has a very advanced laboratory, where its carries out all manner of tests, and puts its products through all the relevant testing — heat, stress, strength, and so forth — so that it can be confident that everything that leaves its manufacturing facilities is reliable, longlasting, safe and as environmentally friendly as possible.
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The De Cecco pasta-making cleaned very rapidly and easily, thus GL rollers for light conveyors where company has managed, thanks to its lowering operational costs, above all maximum economy is requested — and determination to preserve and for the purposes of processing food for not too dusty, wet or dirty maintain the great tradition of pastaproducts. The 135 series pinionenvironments. making (much appreciated worlddriven rollers were used for this wide) while optimizing its project because they enable any engineering and technological number of combinations, providing resources, from both the production maximum conveyor Flexibility and and logistics angles. A visit to the installation modularity. Idle rollers in plant in Ortona in Italy shows how steel — which roll on pre-lubricated challenging and competitive the and sealed radial ball bearings — globalized world is, and how we can were used because they are respond — via innovative solutions particularly smooth-running with a arising out of impressive, typically high load capacity, while tapered Italian, capabilities in the design and rollers in steel were used for the manufacturing fields. driven curves, relatively free of The De Cecco plant in obstacles, thus ensuring that the The 113LS Drum Motor, with Ortona (operational 24/7) packs can be moved smoothly steel helical gearbox for high use opened in 1997. The along also at these points. light- and medium-duty conveyors. approximately 230 employees are deployed in three shifts. The BENEFIT 12 functioning lines have a Rollers, drives rollers and drum production capacity of about motors provide added-value for 4,000 quintals/day, for an overall the entire line. The new quantity of 1,100,000 quintals conveyor system is based on a per year. The fresh semolina is Compac project using products all ground at the Fara San from Rulli Rulmeca, that were Martino mill, and is kneaded ‘gleaned’ from among the top with water from the companyproducts that this company owned spring, of the Maiella from Bergamo can place on the aquifer, at an ideally low goods handling market. The temperature. The water is solution entailed adoption of used to produce very many differing box conveyor systems Rulmeca’s 135 pinion pasta formats subjected to the on various overhead lines, sprocket rollers P1C – P2C: traditional process of bronzeplaced at heights of four to five polyamide or steel pinion wire drawing. The fresh pasta metres, so that operatives and sprockets, steel or PVC tube. then undergoes a stage that the already existing machines shows what De Cecco and the below encounter no obstacles. Italian art of pasta-making Given the load-bearing really mean. In fact, this stage structure of the building, the consists of slow, lowsolution was to provide temperature drying. Usually, support from above, anchor the story ends here. It is as point heights notwithstanding. though packing and conveying This project enabled input thousands of boxes didn’t play from the 12 production lines a part in the struggle to keep to the advanced automatic production levels high. De systems for palletizing, Cecco, instead, understood wrapping and transport to the that its policy of uncompromising Rulmeca. The drum motors of the LS range warehouse. The project includes 11 preservation of traditions required are motorized for light loads with the systems for raising the boxes (four of one innovation, precisely there where the reduction gear in steel. It was decided to kind and seven of the other), and hundreds products leave the factory, on their way to use these drum motors for the conveying of metres of overhead conveyors of various any number of destinations. system constructed at the De Cecco kinds that can accumulate the products in factory because these items are totally the event of a downstream stoppage and SOLUTION protected (hermetically sealed) and are release them as and when required. The solution adopted at the De Cecco therefore ideal for processing and Rulmeca’s products enabled construction factory entails use of 113LS 0.37kW transporting food products. The use of of the required conveyors, tailored to 0.32m/s series drum motors, 135 diam. 50 drum motors is indicated in normal and needs and deploying motorized rollers, series motorized rollers, KRM diam. 58 damp environments and where washing drum motors, clutch rollers, idler drums on series tapered rollers, and GL diam. 50 takes place frequently (IP66/69), as in the the back of the belts, and components in series idle rollers, all manufactured by Rulli Ortona warehouse. Drum motors can be general.
ENGINEERING & EQUIPMENT
The pasta tradition meets high technology
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More than one way to convey — DSI offers innovative ways to transport bulk materials DSI Fully Mobile high angle conveyor shiploader in the Port of Adelaide in Australia.
There are many ways to convey bulk materials, and no one knows that better than Dos Santos International. Dos Santos International is the foremost authority on high angle conveyor applications and design of sandwich belt type high angle conveyors. The flagship system is the DSI Sandwich Belt high angle conveyor. This system sandwiches materials between two belts with a gentle, yet firm, hugging pressure. Materials can be elevated to the highest of angles (to 90° vertical), through ‘C’ and ‘S’ shapes, and other unique profiles. Not only is the system versatile, it has proven to be economical, mobile and ‘green.’ Join us in counting the ways.
DSI SANDWICH BELT HIGH ANGLE CONVEYORS
Twenty years ago, ‘going green’ wasn’t quite the popular phrase that it is today.
However, that is when Joseph Dos Santos, President of Dos Santos International was presented with a challenge to go green like no other. The challenge was to use the least amount of space possible to process and separate one of Earth’s greatest treasures…diamonds. The picture on p85 shows the surface facilities of Canada’s first completely underground diamond mine, Snap Lake. Snap Lake was the motivation for the DSI Sandwich Belt Conveyors in the Northwest Territories. The Snap Lake ore body is a dyke that dips an average of 12-15° from the northwest shore down under the lake. Kimberlite, the diamond bearing ore, is brought to the surface to a processing facility where the diamonds are extracted. Due to the hostile environment, the facilities must be enclosed and heated. A smaller footprint for the plant was
determined to be the optimal way to minimize environmental impact and cost. This led to pursuit of the DSI Sandwich High Angle Conveyor because of its designed space saving features. In the process building, the kimberlite must be elevated then discharged into the various crushing, screening and sorting functions. The original concept was to use a multitude of DSI Sandwich conveyors to minimize the facilities. This was ultimately rationalized to require only two sandwich conveyors, which now define the facility’s minimal footprint. The DSI Sandwich Belt Conveyor’s ability to convey at any high angle made it ideal. The gentle, yet firm hugging pressure allowed these precious gems to be elevated at high angles without damage. The Snap Lake project incorporates two sandwich conveyors, each travelling to
DSI Sandwich high angle conveyors used in diamond mines.
ENGINEERING & EQUIPMENT
opposite ends of the building. The units were standardized at 36” belt width to simplify spare parts inventory. Design of the units included provision for future upgrade, from 275tph (tonnes per hour) to 524tph, merely by increasing the belt speed. By operating at the lower speed until the upgrade is required the conveyors optimal energy efficiency is preserved. The success of the Snap Lake system then led to the incorporation of DSI Sandwich conveyors with confidence into the Victor Project in Northeastern Ontario. Ontario’s first diamond mine incorporated three DSI Sandwich belt units.
DSI FULLY MOBILE HIGH ANGLE CONVEYOR SHIPLOADER
Moving on to expanded mobility, there is no better example of the versatility of a DSI Snake than Australia’s first DSI Snake Sandwich High-Angle shiploader at the Port of Adelaide on Australia’s southern coast. Australia’s first Snake shiploader elevates a variety of high value ores from trucks to ship. Conventional conveyors would not have fit the limited dock space which required a smaller footprint. Dos Santos International, being the world’s foremost authority on high angle
DSI fully mobile Sandwich Belt shiploader being driven on the dock to the ship hull by remote control.
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conveying was able to fit the space easily by being able to elevate at a 50° angle. If fitting the space weren’t enough, DSI went a step above and created a mobile shiploader to elevate the materials with ease. Materials for export are trucked to the dock and dumped onto a special trap loader type feeder. The ore is fed continuously and uniformly onto the mobile Sandwich Belt’s receiving chute. The Sandwich Belt shiploader elevates the bulk over the ship’s deck to the hatch where it is discharged into the ship’s hold. At the Sandwich Belt’s discharge, a special telescoping chute, with rotating, pivoting spoon, facilitates even and complete filling of the holds. The mobile Sandwich Belt is carried on a tripod of twin rubber tyres. Each set of twin tyres is mounted at a vertical kingpin and can rotate 360° about the vertical axis. Thus, without repositioning, the
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Sandwich Belt shiploader can set up to travel in any direction. With the tail tyres fixed, the front tyres can be oriented and travelled for a slewing motion. The unit was complete in November 2006. This first DSI Sandwich Belt shiploader for Australia has set the pace for
months into its operation. Against this background, M3 Engineering was tasked with developing an alternate conveying route quickly since all haulage was now by truck and very expensive. The logical, most direct and economical path was over the same hill (rather than under).
TB29, downhill, with horiz curve
TB26 elevating, with horiz curve
TB27, downhill, multi-tripped agglomerator
What could have been – Original design for DSI GPS.
TB30, downhill
TB32 to the leach pads
TB28, downhill, with horiz curve
TB25, from the crusher house
TB31, spans the haul road
CONVEYOR ON THE EDGE: the multi-flight overland system follows the haul road on the edge of a steep drop-off many more high volume high-angle installations at materials handling docks and yards throughout the world.
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DSI OVERLAND CONVEYORS
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There can be no finer example of DSI’s ability to exceed all customer requirements than the system at Goldcorp’s Los Filos gold mining site. This gold mining project, located in the Nukay mining district of central Guerrero State in southern Mexico is one the largest gold mines in the world. Los Filos is a heap leach operation. The ore size is reduced at the crushing plant and then it is hauled to the valley where it is stacked on engineered pads. A chemical solution is sprayed onto the ore, which extracts and absorbs the gold as it trickles through the ore. To regulate seepage rate, agglomerate (cement) is mixed into the ore for optimal ore exposure to the solution. Ultimately, the solution is directed to the plant where the gold is precipitated out. A previous short-lived system conveyed the ore from the crushing plant to the leach pads via a glory hole ore pass and an underground conveyor, through the hill. An agglomeration drum mixed in the agglomerate before final delivery to the leach pads. This conveying system experienced material flow problems right from the start, especially during heavy rains. The sticky ore tended to plug up the ore pass. Geological instability ultimately collapsed the ore pass, putting the transport system out of service only four
The path required a down-hill high angle conveyor; thus, Dos Santos International was approached about its DSI Sandwich Belt high angle conveyor. Being the best solution, DSI was awarded the contract in March 2009 for a downhill high-angle conveying system which it dubbed the DSI G.P.S. (Gently Pressed Sandwich) high angle conveyor. Concerns with geological instability remained, especially along the path of the DSI GPS. Further geological scrutiny led to abandoning this path altogether, thus abandoning the DSI GPS as well. M3 was again tasked with developing an alternate conveying path. This time a conventional conveyor system was developed, following the already developed truck ramps. Dos Santos International again submitted its proposal for the project, now an overland conveyor system. The project was awarded to DSI May 19, 2009. The Dos Santos International proposal included two important commitments solely for the customer’s benefit: v DSI would maximize use of the conveying equipment and structure, already at the mine, from the collapsed and abandoned through-the-hill conveying system; and v the awarded ten-flight system appeared to be a candidate for further rationalization and cost reduction, using horizontal curves to amalgamate successive conveyor flights. The DSI proposal included an amalgamation
study as the first order of business. Both commitments were fulfilled reaping substantial cost savings to the customer. In the former case, the conveyor dubbed, ‘TB25’, was engineered to use all existing conveyor equipment and structure. Though the arrangement is entirely new, the equipment and support steel are reused from the previous system. The head drive terminal is the only component of TB25 that has new equipment. New steel at the support bents, minor framing, and a new discharge chute make up only a small portion of the total structure. In the latter case, the amalgamation study revealed that six conveyor flights could be reduced to three when joined with horizontal curves. The ten flight system was reduced to seven flights. TB26, TB28 and TB29, each with a horizontal curve, are products of the study. The DSI expertise thus proved particularly advantageous using the horizontal curves to simplify the system and to reduce both capital and operating and maintenance costs. Additionally, the third conveyor flight, TB27 is especially engineered to accomplish the agglomeration by mixing through five intermediate tripped transfers. The en-route agglomeration, conceived by Goldcorp, results in substantial savings by eliminating the need for the additional agglomerating drum. The overland conveying path is
Looking up TB26.
ENGINEERING & EQUIPMENT
Looking up the Overland Path: From TB25 to TB26.
Looking down TB28.
Looking down the Overland Path: From the tail of TB27, the agglomerating conveyor.
IPCC, OPCC – WHAT’S THE DIFFERENCE? IPCC is the popular acronym for In-Pit Crushing and Conveying. There is no popular acronym for Out-of-Pit Crushing and Conveying though it is quite more prevalent in the mining industry. The proper acronym in this case would be OPCC. In any case, from an equipment standpoint, in principle there are no differences. The mined product, ore or waste rock, is primary crushed to a conveyable size then it is conveyed to its respective destination, primary ore storage
IPCHAC, OPCHAC Though to a much lesser extent, Dos Santos Sandwich Belt high angle conveyors have been used as part of IPCC systems and OPCC systems, hence the proposed
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We count these but a few of the many ways
we can convey bulk materials. Still, Dos Santos International continues to explore and expand the range of materials handling methods like no other in the industry. DSI remains at the forefront of bulk solids handling.
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predominantly downhill. While this presents the normal controlled starting and stopping problems, it also presents great savings opportunities. The downhill flights are decisively regenerative. The drive motors, now generators, feed power back into the grid that powers the other mine equipment. These carefully engineered conveyors are equipped with variable frequency drives to ensure operation at maximum efficiency. This is another example of DSI’s commitment to ‘green’ conveying. How do we convey thee? v steeply, firmly, gently; v curving, vertically and horizontally; v tripping, agglomerating; and v elevating and lowering.
at the plant or waste dump. Practically, the implementation does differ. Generally the crusher of the OPCC system is strategically, permanently located. The crusher of an IPCC system is located in the pit, sitting on the ore body. It must be moved periodically as the mine expands. So the crusher must be relocatable or mobile depending on the mine plan. The inpit conveying system must likewise be relocatable or mobile. The high angle conveyor advantage in this case is undeniable. It offers complete conformance to the mine slopes requiring no special excavation or rehandling and because it offers the shortest distance between the two end points (receiving to discharge) it is compact and more easily made relocatable or mobile.
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new acronyms IPCHAC and OPCHAC. The high angle advantage is greatest in the pit. The advantage was exploited at the Majdanpek Copper mine in Serbia throughout the 1990s. The system had significant features including 2,000mm-wide belts continuously elevating 250mm coarse ore at 4,000tph. The net elevating height was 6 x 15-metre benches; 90 metres. The total lift was 93.5 metres which included the transfer height at discharge. The system scaled the benched mine wall at a mere 35.5° without any special excavation to accommodate the system. The system was a resounding success and fulfilled its technical and economic objectives: v it precluded tripling of the truck fleet; v it precluded the need for 4km of haulage ramps, 3.5km of which would be at constant ascent; and v it saved US$12 million per year. Despite the resounding success Dos Santos Sandwich Belt high angle conveyors have not again been incorporated into an IPCHAC system though many were installed at OPCHAC systems and underground mines handling the same primary crushed ore and rock product. It is against this background that we present the study of high angle versus conventional conveying at an Eastern European copper/gold mine.
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STUDY OF HIGH ANGLE VS CONVENTIONAL CONVEYING AT EASTERN EUROPEAN COPPER/GOLD MINE
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A study was conducted by Dos Santos International in a copper mine located in a mountainous terrain in southeastern Europe. The mine plan locates the primary ore crusher at the pit perimeter and the processing plant more than 300 metres of elevation above the crusher. The customer recognized this to be an ideal route for high angle conveying. To optimize the high angle conveyor system the customer turned to the expertise of Dos Santos International. The general design parameters are summarized in table 1. The system is to use a conventional sacrificial conveyor from the crusher to the start of the high angle conveyor system then the high angle conveyor system to the Sacrificial conveyor from primary crusher to high angle conveyor system.
Developed copper mine pit with primary ore crusher at lower left and conveyor system leading to the processing plant at the upper left. Waste rock is spoiled into the valley behind the pit.
ore stockpile at the plant. DSI first addressed the issues of belt width and belt speed for the types of conveyors envisioned: v conventional troughed belt sacrificial conveyor; v Sandwich Belt high angle conveyor with steel cord-reinforced belts; and v Sandwich Belt high angle conveyors with multi-ply fabric reinforced belts. Driven by the material size more than by the modest volumetric design rate, DSI chose the appropriate belt widths and belt speeds: v 1,400mm BW at 2.0m/s for the sacrificial conveyor; v 1,800mm BW at 2.5m/s for the Sandwich Belt high angle conveyors with steel cord belts; and v 2,000mm BW at 2.5m/s for DSI Sandwich Belt high angle conveyors with fabric belting. Belting and equipment recommendations follow including 12.7mm Grade 1 ore carrying covers, CEMA E6 idlers, shaft mounted drive arrangements and VFD starting and load sharing control. Take-up systems are automatic hydraulic. First, DSI conceptually designed and specified the conventional sacrificial conveyor and provided a technical and capital cost summary. From that point came the main purpose of the study — optimizing the high angle conveyor system. At this copper/gold mine, the great advantage of the sandwich belt high angle
TABLE 1 Design parameters, ore conveying system, primary crush to stockpile Material Copper, gold ore Bulk density 1.75t/m3 Size 250mm minus Capacity: 1,665tph Design capacity: 1,870tph
conveying system is its ability to follow closely the natural topography, requiring minimal earthwork or elevated structure, as there is no limitation in conveying angle. The overall slope of the high angle path is actually very modest. The first exercise compared a single flight main high angle conveyor against two multi flight options — a two flight and a three flight system. The single- and twoflight systems required steel cord belts for the high belt tensions developed. Because of the high elastic modulus, this precluded the tight transition curves that are possible with fabric belting. The large curves could challenge the system’s ability to conform closely to the natural topography. The results of this comparison showed the three flight system to be most conforming to the topography but also the most expensive. This is largely owed to the wider and very costly 2,000mm belts required. The steel cord belt options, because of their larger curves, did require some elevated structure but this was minor compared to the overall length.
Because of the less expensive, lower strength belting and its consequence, the two flight system proved to be slightly less expensive than the single flight system despite the additional terminal equipment. The work to that point was presented to the customer. Based on the options presented, despite the minor cost premium, the customer chose the single flight system for its advantages of reduced transfers and location of all major equipment at the terminal ends where easy access for maintenance exists. For convenience, the previous comparison did not deal with the complications of the material stacking over the stockpile. All systems also utilized GPS (gently pressed sandwich) pressing rolls over the entire length of the cover belt. Pursuant to the additional optimization, Dos Santos International first investigated the need for GPS rolls over the full length. This revealed that it was possible to eliminate about 67% of the GPS rolls without negatively affecting other aspects of the design.
DSI adjusted the design accordingly, then proceeded to the stacking system optimization. DSI first considered four stacking variations, but quickly reduced these to two — taking the main high angle conveyor directly to discharge over the stockpile or taking the main high angle conveyor only to the pile base, there discharging onto a separate high angle stacker that delivers the material up to the stockpile. In order to keep the drives at grade level, the former required additional high tension pulleys at each belt. These, along with their implications, resulted in a more expensive solution, compared to a less expensive version for the latter main high angle conveyor with independent high angle stacker. Besides the favourable economics, the latter system also may have the advantage of a material escape option if implemented by diverting the material flow to a side stacker. In this light, the customer chose the latter arrangement, a main high angle conveyor with an independent stacker to the
stockpile. This is depicted in the figure above. The above combined with the sacrificial conveyor determines the complete conveying system from the primary crusher to the ore stockpile. The total system is summarized technically in Table 2 below. The final system consists of the sacrificial conveyor, a main GPS high angle conveyor to the base of the ore stockpile, and an independent GPS high angle stacker. A final meeting and inspection of the ore conveying path from the crusher location to the ore stockpile location revealed what was expected from the drawings and the path developed. Thus DSI believes that the Sandwich Belt high angle conveyors system developed will have the favourable technical and economic characteristics that were presented in the study and report. The customer has agreed and the final high angle conveying system in incorporated as an integral, vital part of the mine plan that began in 2018.
ENGINEERING & EQUIPMENT
Main high angle conveyor flight with five separate cover belts along the length.
TABLE 2 Technical summary, total conveying system from primary crusher to ore stockpile Sacrificial Conveyor W10202-0000 Sacrificial Conveyor
1,400mm 2.0m/s Varies to 14.5° 31,640mm 229,915mm
Steel ST 1250
DSI GPS Stacker
2,996kW 3,300kW 1,650kW 1,650kW Steel ST 4500
324kW 370kW 185kW 185kW NN 3 x 455 = 1365
GPS 10B2
2,000mm 35° 41,963mm 85,840mm
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241kW 315kW
DSI GPS Main Flight W10202-0010B GPS 10B1 Copper, Gold Ore 1.75t/m3 250mm minus 1,870tph 1,800mm 2.5 m/s Varies to 26° 340,527mm 1,331,688mm
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General Drawing Conveyor flights Material Bulk density Size Design rate: Belt width: Belt speed: Conveying angle: Lift: Length: Drive power: Calculated: Selected total Top belt: Bottom belt: Prelim belt selection
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Fabrication and installation of DemcoTECH AeroConveyor™ at a titanium miner in Mozambique (and below).
www.drycargomag.com SEPTEMBER 2023
A 73m DemcoTECH AeroConveyor™ has been installed at a major titanium mining operation in Mozambique, following an assessment by engineering and project-focused company DemcoTECH Engineering of the existing in-plant materials handling equipment, which was not performing as required. Found to be a perfect application for the AeroConveyor and based on the success of this installation, the client has contracted DemcoTECH to retrofit four more AeroConveyors in other parts of the plant. The AeroConveyor can transport the product up an incline of up to 18°. In addition, to the benefits provided by fully enclosed conveying, the system utilizes a standard scraper at the head end, standard take-up pulleys and return idlers, as well as a small fan to introduce air into the system. As a result, it is both easy and cost-effective to maintain, as well as being compact. “The unique DemcoTECH AeroConveyor™ offers the same benefits as a traditional pipe conveyor in terms of fully enclosed conveying, protecting both the environment and product from mutual contamination,” notes DemcoTECH Engineering General Manager, Paul van de Vyver. “But, unlike the pipe conveyor, it is also suitable for short distances, can convey material at steep inclines and is very energy efficient. “This tried-and-tested technology, which has been in use for over 40 years for conveying products that are dusty, of low bulk density and often difficult to convey, represents the ideal solution for certain applications. “For example, the development of the AeroConveyor was a breakthrough for the diamond industry, where its ability to be easily and securely enclosed enables the kimberlite ore to be transported without risk of theft.” This is due to the fact that air, which provides the ‘cushion of air’ necessary to support the belt and product, comes from outside of the trough structure and, since no idlers or rollers are required on the carrying side, personnel do not need to access the enclosed conveyor for any reason whatsoever. In addition, as the design of the AeroConveyor is based on the hovercraft principle with a bed of air below the belt conveyor, it does not experience the rolling motion or wave effect of idlers, making it highly suitable for conveying precious minerals and metals. As a result, some 20 DemcoTECH AeroConveyors™ have been installed on diamond mines to convey kimberlite, gravel, diamonds and diamond tailings. It has also found wide acceptance in other mining industries. with installations to convey material
ENGINEERING & EQUIPMENT
DemcoTECH AeroConveyor™ makes inroads across wide range of industries
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from coal, crushed limestone and vermiculate to furnace feed and slag and manganese. In addition to a wide range of general industrial applications, conveying products from woodchips to soap noodles, fertilizer, salt, animal feed and ash, the AeroConveyor has made significant inroads in the sugar industry, with machines supplied for actual sugar plants and sugar mill-related products. For the port handling industry, the AeroConveyor is deployed on the wharf, both to feed shiploaders and to carry products from ships to silos.
BENEFITS OF THE DEMCOTECH AEROCONVEYOR™ Traditionally used over short distances and at high inclination angles, the modern DemcoTECH AeroConveyor™ offers high capacity conveying at greater belt speeds, over longer conveying distances. “Besides the environmental benefits, which include reduced noise pollution, other benefits of the AeroConveyor include its reliability, long belt life and minimal maintenance requirements,” says van de Vyver. “It is also easy to install as fewer supporting structures are required due to the fact that the AeroConveyor can easily span 12m, enabling installations to take place in difficult to reach areas such as roofs. Walkways are not necessary since the idlers have been eliminated on the carrying-side. The DemcoTECH AeroConveyor™ has no moving parts along the carrying side and is fully enclosed.”
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HOW DOES THE AEROCONVEYOR WORK?
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The DemcoTECH AeroConveyor™ is an enclosed troughed conveyor, which eliminates idlers by supporting the conveyor belt on a cushion of low pressure
Turnkey Petronas RAPID project in Malaysia (and below). air. A continuous belt is driven around a head and tail pulley using the normal motor drive, however with one major difference — the trough section is used as the structural support of the belt. The air cushion is supplied by means of a centrifugal fan, which blows into the plenum chamber and enters the conduit area via holes positioned along the length of the trough. An air film or cushion is thus created, lifting the belt off the steel trough and providing a smooth surface for the product.
RESPECTED SUPPLIER IN CONVEYOR DESIGN AND ENGINEERING
DemcoTECH provides, in addition to the AeroConveyor, a comprehensive range of advanced conveying technologies, including overland and in-plant belt conveyors, pipe conveyors and stacking, shuttle, mobile and grasshopper conveyors, and feeders. Recent awards from India for an upgrade on an existing 4.6km pipe conveyor, as well as for a number of overland conveyors, have added to its
extensive track record in the supply of pipe and belt conveyors, which includes downhill, extendable and inclined systems. In line with its total solutions approach, DemcoTECH also provides a full range of supporting and auxiliary equipment, including trippers, stackers and load-out equipment. Offering services from conceptual design through to project completion, DemcoTECH’s project services are tailored to the needs of small to mega contracts. “Our projects demonstrate the flexibility of our services, ranging from providing a shuttle conveyor and installing it during a plant shut of seven days working 24 hour days for a miner in South Africa, through to a massive four-year contract for Vale’s multimillion-dollar iron-ore import/ export facility in Malaysia. We also completed a turnkey project in Malaysia for the prestigious Petronas RAPID project, with the main feature of our system being a 2.2 km pipe conveyor,” concludes van de Vyver.
ABOUT DEMCOTECH DemcoTECH Engineering is a specialist bulk materials handling and niche process plant company, offering services from concept design through to project completion to the power generation, cement, mining, metallurgical, manufacturing and port handling industries. Services include conceptual design, feasibility studies, design, engineering, procurement, expediting, construction and commissioning. After-sales services include spares, maintenance, refurbishments and operational readiness packages covering procedures, systems and workplace tools required to successfully operate and DCi maintain a new or upgraded plant.
mobile equipment plays a valuable role in the bulk industry
ENGINEERING & EQUIPMENT
A movable feast?
Revolutionizing ports: the advancements in mobile harbour equipment INNOVATIVE SOLUTIONS FROM SAMSON MATERIALS HANDLING
INNOVATIVE SOLUTIONS BY SAMSON MATERIALS HANDLING
SEPTEMBER 2023
Shiploaders: SAMSON’s shiploaders redefine efficiency in bulk cargo handling. These highly automated systems ensure seamless loading of materials onto vessels, reducing turnaround times and increasing operational throughput. With precise control over loading rates and material
distribution, shiploaders optimize cargo loading while minimizing spillage and environmental impact. Stormajor systems: Stormajor systems provide a unique solution for effective stockpiling and reclaiming of bulk materials. These systems use an innovative air cushion technology to create and maintain stockpiles, allowing for controlled and dustfree material reclaiming. Stormajor ensures consistent material flow, eliminating the need for heavy machinery and reducing both energy consumption and environmental pollution. Eco-Hoppers are designed with sustainability in mind. These advanced hoppers feature a dust-controlled enclosure, preventing material spillage and minimizing airborne pollutants. By incorporating state-of-the-art dust extraction systems, eco-hoppers improve air quality and reduce health risks for port
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In the rapidly evolving landscape of global trade and logistics, the significance of efficient cargo handling at ports cannot be overstated, writes Petar Karaivanov, SAMSON Materials Handling. Mobile harbour equipment has emerged as a pivotal solution, transforming the efficiency, safety, and sustainability of port operations. With a focus on innovation, SAMSON Materials Handling has introduced a range of cuttingedge solutions, including mobile shiploaders, Stormajor systems, mobile eco-hoppers, and mobile material feeders. These advancements have redefined the way ports manage their cargo, offering unparalleled benefits. This article delves into the revolutionary advancements in mobile harbour equipment, with a special emphasis on the transformative solutions provided by SAMSON Materials Handling.
Static cranes were once the mainstay of cargo handling at ports, but their limitations prompted the evolution of mobile harbour equipment. This category of machinery combines mobility with advanced cargo handling capabilities, leading to improved port efficiency. Since the 1960s, SAMSON’s solutions, including shiploaders, Stormajor systems, ecohoppers, and material feeder sections, have significantly elevated the efficiency and sustainability of port operations.
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personnel. This sustainable approach aligns with global environmental goals and regulations. Material feeders: the material feeder section is a critical component of port operations, and SAMSON’s innovative solutions enhance its efficiency. These sections enable seamless material transfer between various stages of cargo handling, reducing bottlenecks and optimizing overall port productivity. The incorporation of advanced automation and control systems ensures precise material delivery, minimizing wastage and operational delays.
ADVANTAGES OF MOBILE HARBOUR EQUIPMENT
The adoption of such solutions as stated above offers a multitude of advantages for modern port operations like optimized cargo handling processes, leading to faster vessel turnaround times and increased port throughput. v Improved safety: the advanced automation and safety features integrated into AUMUND’s solutions reduce the risk of accidents, ensuring a safer working environment for port personnel. v Sustainability: SAMSON’s ecofriendly approach, evident in solutions like eco-hoppers, promotes environmental responsibility by minimizing dust emissions and spillage, ultimately contributing to cleaner air and water in port areas. v Leveraging cutting-edge technologies, such as automation, AI, and data analytics, to enhance operational efficiency, reduce downtime, and enable predictive maintenance.
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CHALLENGES AND FUTURE OUTLOOK
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While the benefits these solutions are substantial, challenges such as initial investment costs and compatibility with existing infrastructure remain. However, the long-term gains in efficiency, sustainability, and operational cost
reduction often outweigh these challenges. The future prospects for mobile harbour equipment are promising. As technology continues to advance, further integration of automation, data analytics, and remote monitoring will lead to even more efficient and streamlined port operations.
CONCLUSION Mobile harbour equipment has transformed port operations worldwide,
and SAMSON’s innovative solutions have taken this transformation to new heights. The introduction of shiploaders, Stormajor systems, eco-hoppers, and material feeders, showcases SAMSON’s and AUMUND’s commitment to revolutionizing bulk cargo handling, improving efficiency, enhancing safety, and promoting sustainability. As ports continue to adapt to the demands of the modern global economy, solutions like those will play a pivotal role in shaping the
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Cable Festoon • Corrosion-resistant, long-life rollers; precision sealed bearings • Systems customized for the application • Preassembled option, for easy installation
Conductix-Wampfler has one critical mission: To keep your bulk material handling operations running 24 / 7 / 365. You need proven, worryfree energy solutions - and Conductix-Wampfler has them. Our systems provide reliable electric power and water to stacker/reclaimers, barge and ship loaders/unloaders, bulk conveyors, tripper systems, and gantry cranes. Conductix-Wampfler systems are rugged, low maintenance, and timetested in tough, dusty environments. All products are backed by the largest sales and service network worldwide! www.conductix.com
Slip Rings • Allow infinite rotation • Combined power, control and media (water, air, oil, vacuum, other) • Available with ATEX and SIL 3 certification
BulkEx 23 echn cal on erence is taking place on 17th and 18th October 2023 at Chesford Grange in Warwickshire. The 2-day conference boasts a program full of influential speakers who will address current technical issues, sustainability within the sector and emerging projects, subjects covered will appeal to professionals and organisations from across the bulk materials handling industry. In addition, both days will host a supporting exhibition, with around 40 companies showcasing their products and services. This highly-anticipated event is the perfect opportunity to showcase your business to a captive audience and establish critical connections, attendees are sure to benefit from extensive networking opportunities. The event will include our Gala Dinner and Excellence Awards ceremony on the evening of the 17th of October, celebrating the best in materials handling along with Rory Underwood as our After-Dinner Speaker. Rory holds the record for scoring 49 tries for England in a stellar rugby career, so I’m sure he will have plenty of interesting anecdotes to share during the evening. Awards categories are: • Apprentice of the Year • Project of the Year • Engineer of the Year • Supplier of the Year • Innovation Award • Sustainability Award (New for 2023) • Exporter of the Year (New for 2023) • The Harold Wright Lifetime Achievement Award
or o er 80 ear the ater al andl n En neer oc at on E ha u orted the techn cal and co erc al ntere t o and o coer ea an e u l n and u n bulk handl n e u ent If your business supplies or uses bulk and handling e uipment, then strengthen your position by enjoying the advantages of HEA membership. embership allows you to tap into a uni ue technical marketing knowledge base, plus a range of benefits including industry seminars and site visits to companies. or ore n or at on: el: 01257 412635 E a l: ecretar @ hea co uk Web: www hea co uk
MATERIAL HANDLER REPLACES TWO MACHINES IN THE PORT
Tomakomai Futo Co., Ltd. originally used four ship-unloaders and one crane to discharge feed raw materials. One of these had an outdated pneumatic system and needed to be replaced. With the environment in mind and the need for a port material handler with low fuel consumption, low CO2 emissions and the ability to work quickly and efficiently, the choice was the
SENNEBOGEN 860 E with its intelligent Green Hybrid System. “We currently use three ship-unloaders and the SENNEBOGEN 860 E to discharge the majority of our cargo. Thereby the SENNEBOGEN 860 E replaces one shipunloader and one crane. As the frequency of operations requiring cranes has decreased, we have also been able to save costs,” explains Seiji Hayashi, Executive Officer and General Manager of the Feed Silo Division. www.drycargomag.com
Left to right: Seiji Hayashi (Executive Officer and General Manager of Feed Silo Division, Tomakomai Futo Co., Ltd.), Jason Ang (Marketing Manager SENNEBOGEN Asia Pacific) and operator of the SENNEBOGEN 860 E, Tomakomai Futo Co., Ltd.
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The port of Tomakomai handles large quantities of animal feed and raw materials such as foodstuffs from different regions of Japan and the rest of the world. With the commissioning of the SENNEBOGEN 860 E in 2020, Tomakomai Futo Co., Ltd. aims to make material handling more efficient while reducing CO2 emissions for a sustainable society. Tomakomai Futo Co., Ltd. is a comprehensive logistics company contributing to the development of the food industry in Hokkaido, based on the management philosophy of ‘contributing to the community and society as a logistics enabler’. An enabler refers to an entity that is indispensable to development and problem solving in the regions and for customers, an ‘unsung hero’. The company’s services include general warehousing, cold storage, raw material silos and oil terminal operations. In addition, the company operates sites in and outside Hokkaido that form a logistics network and contribute to the development of the food industry in Hokkaido. Raw materials from Japan and overseas are temporarily stored in the yard’s 190,000-tonne silos, the fifth-largest silo storage facility in Japan, before being resold to feed manufacturers.
ENGINEERING & EQUIPMENT
Environmentally friendly material handler replaces ship-unloader in Japan
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SENSITIVITY OF THE MACHINE ALLOWS SAFE AND PRECISE LOADING IN THE CARGO HOLD
“With the SENNEBOGEN 860 E, it is possible to unload the material while looking directly into the cargo hold from the driver’s seat. I feel much more confident in my work when I can check the surroundings myself, rather than taking instructions from the signalman,” explains the person responsible for the cargo handling system and the operation of the SENNEBOGEN 860 E. Thanks to its sensitivity and large reach depth, the material in the cargo hold can be placed and gripped particularly precisely.
ENGINEERING & EQUIPMENT
SENNEBOGEN 860 E operator (top row) with Jason Ang, Marketing Manager, SENNEBOGEN Asia Pacific (bottom row, first from left) and Iwahana, Branch Manager, Hakkaido Sales Office, Sun Earth Co., Ltd (bottom row, second from right).
“This is very helpful for safely guiding other machines and personnel in the cargo hold. It saves time and increases safety in the workplace for everyone.” The port material handler is equipped with a mobile undercarriage that allows it to move and work independently on the quay. This has also increased the degree of freedom in assigning ships in the port. Currently, the SENNEBOGEN 860 E is operated by three people, with two more being trained. Thanks to the machine’s ease of use, new operators can be trained quickly and easily. In this way, the operation can be maintained continuously and the supply of forage to Hokkaido can be kept stable.
ENVIRONMENTALLY FRIENDLY MACHINE SUPPORTS CO2 REDUCTION
“By using the SENNEBOGEN 860 E, we have been able to significantly reduce our fuel consumption. In addition, its lower energy consumption also decreases our CO2 emissions, which is a high priority for Tomakomai Futo Co., Ltd. “In the beginning, the SENNEBOGEN 860 E was mainly used for unloading, but now we use it for both loading and unloading. We have also increased the variety of loading and unloading methods,” says Seiji Hayashi, Executive Officer and General Manager of the Feed Silo Division.
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Streamlining port operations: the dynamic world of dry bulk material mobile ship-unloading
SEPTEMBER 2023
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In the intricate tapestry of global trade, ports are crucial nodes facilitating the movement of goods across international borders. Within the multifaceted landscape of port activities, unloading dry bulk materials from ships occupies a central position. These bulk commodities, encompassing products like coal, grains, ores, and dry bulk powders, constitute the cornerstone of the global economy. Every year, millions of tonnes are loaded and unloaded within ports worldwide. The efficient handling of these materials hinges on utilizing specialized equipment and meticulously executed techniques for (mobile) ship-unloading. This article delves
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into the bustling activities that revolve around unloading dry bulk powder materials (like cement, fly ash, alumina, etc.) from ships in ports, encompassing the operational dynamics and technological innovations that shape this critical process.
THE DYNAMICS OF DRY BULK MATERIAL UNLOADING
Unloading dry bulk materials from ships is a multifaceted process that requires precision, expertise, and specialized equipment. The complexity of the task is rooted in the diverse nature of the materials being transported. As such, a variety of unloading methods have been
devised to cater to the unique characteristics of each cargo. The mobile ship unloading process encompasses several vital stages: 1. Vessel arrival and berthing: the process commences with the arrival of ships at the designated port. Skilful navigation and berthing are crucial for the vessel’s safety and optimizing cargo transfer efficiency. 2. Unloading equipment setup: ports are equipped with an array of machinery tailored to handle distinct types of dry bulk powder materials. These include (mobile) unloaders such as mechanical
ENGINEERING & EQUIPMENT www.drycargomag.com SEPTEMBER 2023
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grab cranes, mechanical ship-unloaders or pneumatic ship-unloaders. These unloading systems are strategically positioned to facilitate efficient cargo transfer. 1. Cargo discharge: the selected unloading equipment is employed to extract the cargo from the ship’s hold. Grab cranes utilize mechanical grabs to hoist and transfer materials to designated storage areas or conveyors. Mechanical shipunloaders employ a continuous bucket chain or conveyors for cargo transfer. Pneumatic conveyors, on the other hand, leverage air pressure to transport bulk materials to storage facilities. 4. Material transportation: following the unloading process, the bulk materials are conveyed to storage facilities within the port premises. Conveyors, trucks, and rail systems are frequently employed to facilitate this transfer.
5. Quality control: ports often implement rigorous quality control measures to ensure the delivered materials meet specified standards. Samples are extracted and subjected to testing to verify parameters such as moisture content, particle size distribution, and chemical composition. 6. Storage and distribution: the unloaded materials are then stored in silos, stockpiles, or other designated storage structures within the port. These materials can be further distributed via trucks, trains, or ships to their final destinations, depending on market demands.
CHALLENGES AND INNOVATIONS While the activities surrounding dry bulk material mobile ship-unloading are essential for global trade, they are not without their
challenges. Adverse weather conditions, mechanical breakdowns, and environmental considerations can all impact the efficiency of the unloading process. To mitigate these challenges, the industry is increasingly embracing technological innovations: v Automation: automation and remote control systems are becoming integral to the operation of unloading equipment. These advancements enhance efficiency by optimizing processes and reducing the need for constant manual intervention. v Data analytics: the integration of advanced data analytics and sensor technologies enables real-time monitoring of the unloading process. This proactive approach allows for predictive maintenance, streamlined workflows, and data-driven decisionmaking.
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v Environmental concerns: ports are keenly aware of the environmental impact of their operations. To address this, they are adopting eco-friendly and dust-free technologies to minimize dust emissions, noise pollution, and energy consumption. Dust suppression systems and noise reduction measures contribute to sustainable practices.
LION BULK HANDLING: REVOLUTIONIZING DRY BULK MATERIAL UNLOADING
One prominent player in the realm of unloading equipment is Lion Bulk Handling, a manufacturer at the forefront of developing cutting-edge solutions for dry bulk material handling. With a commitment to innovation and excellence, Lion Bulk Handling has significantly contributed to enhancing the efficiency and sustainability of the unloading process in ports.
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COMPANY BACKGROUND Lion Bulk Handling is a pioneer and expert in maritime and portside material handling. It designs and engineers its key components, adding other proven technologies from leading manufacturers to form its integrated systems with more than 55 years of design and engineering experience in equipping dry bulk ships, barges, supply vessels, harbour loading and unloading equipment, cement terminals, drilling rigs and floating terminals. Lion Bulk Handling’s business brands, Kintec, H.W.Carlsen, Ruyter Offshore and
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Bulk Academy, offer a wide range of reliable and sustainable systems and products in the field of material handling. Together with its business brands, Lion Bulk Handling has hundreds of excellent references worldwide. Lion Bulk Handling is part of the Lion Marine Group. INNOVATIVE & DUST-FREE SOLUTIONS Lion Bulk Handling’s product portfolio includes a variety of state-of-the-art dry bulk conveying (loading and unloading) systems designed to address the challenges posed by various dry bulk materials (such as cement, fly-ash, alumina, barite, bentonite, lime, etc.).
Lion’s unloading equipment for ports include: v Ship-to-silo unloaders or pneumatic ship unloaders (PSU): Lion’s PSUs require a pipeline connection to handle the entire conveying process from ship to store. These highly efficient pneumatic ship-to-silo unloaders are available in road mobile, dock mobile, gantry mobile, barge mounted and stationary configurations. Next, all configurations are available with a manipulator arm for open hatch (option 1) unloading or delivered with a flexible hose connection for closed hatch (option 2)
v Ship-to-truck unloaders or continuous suction pumps (CSP): ship-to-truck unloaders are ship and barge unloaders for unloading directly into bulk trucks. Due to the continuous suction pump (CSP) system included in each unit, a long line of simple, flexible and nonexpensive installations are available. The ship-to-truck unloaders are used as dry bulk mini terminals in several ports and terminals and are available in road mobile, dock mobile, gantry mobile, barge mounted and stationary configurations. Next, all configurations are available with a manipulator arm for open hatch (option 1) unloading or with a flexible hose connection for closed hatch (option 2) unloading. The closed hatch unloading option can only be used with a fluidized floor vessel and can be operational in any weather condition.
components, aligning with the industry’s green initiatives, are part of Lion’s conveying solutions. MAINTENANCE AND SPARE PARTS Downtime and reduced productivity are a nightmare for any user of ship-unloaders. Lion understands the challenges of carrying out maintenance and repairs. Lion’s mission is to provide its customers with a seamless shopping experience. All the equipment displayed around the unloader are spare parts, which Lion offers through its webshop, and are used in unloaders. Customers looking for spare parts for its ship-unloaders should head to the company’s webshop, or contact the technical support team.
CONCLUSION The bustling activities surrounding the mobile ship-unloading of dry bulk materials in ports are pivotal for the seamless flow of global trade. These activities, driven by precision and technological innovation, enable the efficient transfer of commodities that underpin economies worldwide. As the industry continues to evolve, companies like Lion Bulk Handling stands at the forefront, shaping the future of dry bulk material handling with its advanced and environmentally conscious unloading equipment. Through a harmonious blend of operational excellence and technological integration, the dynamic world of dry bulk material (mobile) ship-unloading is poised for continued growth and transformation.
327T | Tilting Top Lift Spreader
TECHNOLOGICAL INTEGRATION Lion Bulk Handling stands out for its integration of cutting-edge technologies into its bulk handling equipment. The company’s unloading systems are often equipped with highly advanced automation and remote monitoring capabilities, allowing for remote operation, real-time performance tracking, and immediate issue resolution. This integration enhances safety and efficiency and reduces operational disruptions. These technological developments are part of Lion’s larger vision to implement the Industry 4.0 philosophy within every bulk handling system. ENVIRONMENTAL COMMITMENT Lion Bulk Handling recognizes the importance of environmental sustainability in modern port operations. Its equipment is designed to incorporate dust suppression mechanisms for reliable and dust-free ship-unloading; from picking up the product in the ship’s hold to discharge at the storage facility, the entire unloading process is enclosed, ensuring dust-free operation. Also, other aspects like noise reduction technologies and energy-efficient
One of our hard-working spreaders Dedicated Top Lift Spreader with tilting function for bulk material handling. Meet the rest of the team at elme.com
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unloading. The closed hatch unloading option can only be used with a fluidized floor vessel and can be operational in any weather condition.
ENGINEERING & EQUIPMENT www.drycargomag.com
Longwater Gravel celebrates its partnership with Hitachi
As UK producers of quality aggregates, Longwater Gravel has invested in an expanding fleet of Hitachi construction equipment to work across its three quarries at Coxford Abbey, Horstead and Wymondham in Norfolk. Celebrating its platinum anniversary in 2022 and ongoing partnership with Hitachi Construction Machinery (UK), the Costessey-based company has purchased the first two ZW310-7 medium wheel loaders in the UK for the Coxford Abbey site near Fakenham. The impressive new machines have been added to Longwater Gravel’s expanding line-up of Hitachi wheel loaders: two ZW310-6s, a ZW220-5 and a ZW220-6 at Coxford Abbey; a ZW310-6 and a ZW220-6 at Wymondham; two ZW220-6s at Horstead; and two ZW180s servicing the stockyard at its Costessey headquarters. In addition, the company has a ZX210LC-6 medium excavator working as the main production machine at each of the quarries.
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PRODUCTIVITY AT COXFORD ABBEY
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As an example, the two ZW310-7s and ZX210LC-6 at Coxford Abbey help to achieve an annual production of 120,000 tonnes of sand and shingle, type 1 sub-base, natural shingle, and recycled, decorative and specialist aggregates. Once excavated and loaded on to an articulated dump truck, the raw materials are hauled to the production plant.
One of the wheel loaders feeds them into the hopper and on to a dry screening process. This separates the large (25mm and bigger) from the fine materials, with the former being crushed and the latter being moved along to a washing barrel, which separates the sand and cleans the stone. The stone then emerges from a wet screen into the bays for 10 and 20mm gravel, as well as coarse and soft sand. The water from the process is recycled into a lagoon, with the silt being periodically removed by an excavator. The new Hitachi wheel loaders are also used for loading trucks, material handling and creating stockpiles.
MORE PARTNER THAN SUPPLIER Simon Smith, Longwater Gravel’s Operations Director says, “Our Hitachi fleet has been reliable over the past eight years. The machines work well and there’s minimal downtime. In addition, the allimportant support we receive from HCMUK is excellent. “As a relatively small business, we can’t afford for our machines to stop working. So, we must have an immediate response from an engineer or the urgent delivery of a spare part when required. The feeling we have is that Hitachi really cares, and as a result it is more of a partner than a supplier to Longwater Gravel.”
IN A LEAGUE OF THEIR OWN Longwater Gravel’s Quarries Manager Rupert Jarvis is also an experienced operator, and therefore has a qualified view on the company’s range of Hitachi construction machinery. “I like Hitachi machines in comparison with other brands, as they do exactly what it says on the tin. They have a high level of availability, an impressive work rate and guarantee excellent productivity. “The ZW wheel loaders are reliable and robust — none of the other brands work as well as Hitachi machines. They will outperform anything else in the market. In addition, Zaxis excavators are in a league of their own. “There’s more than enough power to drive the unique Hitachi three-pump hydraulic system, which means that they are agile and precise. They can out-dig better than anything else and load a truck so quickly. The ZX210LC-6 is one of the best excavators ever built, and the engine and undercarriage cannot be beaten.”
ENGINEERING & EQUIPMENT
After impressive trial, Rubner Holzindustrie buys the L 580 LogHandler XPower® ith the L 580 LogHandler XPower®, Liebherr offers the timber industry a very special wheel loader. Liebherr has recently revamped this model and has optimized numerous aspects of the wheel loader in the course of the revision, such as the lift arms and the associated grabbers developed for log handling. A model of this latest generation has now been in operation for six months at the family-owned company Rubner Holzindustrie in Rohrbach an der Lafnitz, Austria. The new features of the L 580 LogHandler XPower® were first tested at Liebherr's Bischofshofen plant over a period of several months. The Liebherr special wheel loader was so convincing that Rubner Holzindustrie decided to buy it right away. A challenging environment where different work had to be carried out was the ideal situation for testing the improvements in the lift arms and grabber. At the timber yard, the Liebherr special wheel loader feeds the logs into the debarking and sorting system, and then transports the logs — grouped by diameter — to the respective storage location. The lift arms, which were specially developed for log handling, feature manipulation heights of up to seven metres and a reach of almost four metres, and offer optimum conditions for rapid material handling. The 360° rotatable grabber with a capacity of up to 4m² enables versatile and time-saving transportation from the storage location to the company's own sawmill.
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L 580 LOGHANDLER XPOWER® PUTS ON AN IMPRESSIVE PERFORMANCE AT RUBNER HOLZINDUSTRIE
LIEBHERR'S CUSTOMER SERVICE IS A UNIQUE SELLING POINT
“We have never experienced customer service of this level before,” Karner exclaimed. “A specially trained Liebherr expert taught us how to operate the machine directly at our site and it was the ideal start for us with our new Liebherr L 580 LogHandler. Thanks to this service, all our employees are well trained in handling the new machine, which ensures smooth processes for us and saves time and costs.” And Liebherr not only offers reliable service at the beginning of the business relationship. With its extensive service network, Liebherr Customer Service is reliably on hand should repairs or maintenance be required. Downtimes are thus kept to a minimum for maximum productivity.
Firmly rooted in the densely forested region around Rohrbach an der Lafnitz in Austria, Rubner Holzindustrie GmbH relies on regional wood from sustainably managed forests. With 130 employees, the
ABOUT THE LIEBHERR GROUP The Liebherr Group is a family-run technology company with a highly diversified product portfolio. The company is one of the largest construction equipment manufacturers in the world. It also provides high-quality and user-oriented products and services in a wide range of other areas. The Liebherr Group includes over 140 companies across all continents. In 2022, it employed more than 50,000 staff and achieved combined revenues of over 12.5 billion euros. Liebherr was founded in Kirchdorf an der Iller in Southern Germany in 1949. Since then, the employees have been pursuing the goal of achieving continuous technological innovation, and bringing industry-leading solutions to its customers.
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ABOUT RUBNER HOLZINDUSTRIE
company specializes in the production of glulam beams as well as premium-quality solid construction timber. Rubner Holzindustrie is one of 19 subsidiaries of the family-run Rubner Group, headquartered in South Tyrol. The passion to get the best out of the versatile and renewable raw material wood has been driving the company for almost 100 years. This commitment makes the Rubner Group one of the most important timber construction companies in Europe. www.drycargomag.com
Rene Karner, Technical Manager at Rubner Holzindustrie, summed up the experience in a very positive way: “This is the first Liebherr wheel loader that we have tested in our sawmill, which meant that the operation was new and somewhat unfamiliar to us at first. However, once we got used to it, we liked the machine so much that we bought it immediately after testing it. We were also particularly impressed by the new grabber and the new lifting arms.” Rubner Holzindustrie spans a 14hectare operating area, and the special wheel loader from Liebherr often covers a distance of more than half a kilometre per loading cycle. With the powerful, powersplit XPower drive, which Liebherr equips as standard, and a top speed of up to 40km/h, these handling runs can be carried
out very efficiently. The numerous optional assistance systems increase safety on site. These systems include the active rear personnel detection, which warns of dangers in the rear area and automatically reduces speed with its brake assistant as soon as the sensors detect any danger. “The intuitive and simple handling of the special wheel loader was particularly impressive. The steering-wheel-free operator's cab with easy to operate joystick steering offers sufficient space in the operator's cab and ensures a comfortable working atmosphere,” said Rene Karner. He continued, “When we directly compared this machine with a competitor, we observed fuel savings of about two litres per operating hour. In addition, the hydraulic-mechanical braking effect of the drive results in less tyre wear and virtually no brake wear. These features of the L 580 LogHandler XPower® provide us with significant economic and service advantages in our day-to-day work.”
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ENGINEERING & EQUIPMENT
GENMA wins high praise from Brazilian client for mobile harbour crane
ENMA® (a major brand and part of Nantong Rainbow Heavy Machineries Co., LTD [RHM]) has received a commendatory letter for its mobile harbour crane from Brazilian customer PSB (PORTO SUDESTE DO BRASIL S.A.). The customer stated in the letter that GENMA®’s mobile harbour crane (MHC) would strongly improve the unloading process, reducing operational downtime, increasing the unloading reliability and growing the business, allowing more vessels with more capacity. PSB is proud to receive and operate the first GENMA® MHC in Brazil, manufactured and delivered by Rainbow Heavy Machineries. In May this year, a GENMA® 150-tonne MHC designed and built by RHM was officially delivered for PSB. The MHC is equipped with two working options: hook and grab. With the hook, the maximum lifting capacity can reach 150 tonnes; using the grab, the maximum working efficiency can reach 1,000 tonnes per hour. The MHC can simultaneously meet the needs of customers for unloading bulk materials
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such as coal and lifting breakbulk cargo. To date, the GENMA® MHC has successfully unloaded 70,000 tonnes of coal, and has demonstrate excellent performance during operations. Mr Gustavo, business manager of the client company, praised the MHC not only for its exquisite appearance, but also for its reliable performance and excellent efficiency. GENMA® provides professional and high-quality solutions for the lifting and bulk loading and unloading of the terminal. GENMA®, a brand under RHM, has always been customer-oriented, providing customers with a one-stop solution which includes integrated high-end equipment design, R&D, fabrication and service. In addition to meeting the multifunctional needs, efficiency, stability, safety and environmental protection are also important attributes of GENMA® MHC.
MEETING THE NEEDS OF HIGH-INTENSITY AND COMPLEX WORKING CONDITIONS
The GENMA® MHC delivered to PSB in Brazil uses a highly advanced hydraulic
slewing system and hydraulic cylinder luffing system, as well as the latest electric drive dual winch design form, which can ensure stable, reliable, safe and efficient performance of the equipment while fully meeting the customer’s high intensity and complex working conditions. “In order to ensure the efficiency of unloading operations, the terminal facilities need to work 24 hours without interruption, with people working in relays, which require high quality of the crane. During the coal unloading process, the GENMA® MHC can work continuously 432 hours, with stable performance and always maintaining high operating efficiency. The quality of GENMA® products is very reliable.”
MEETING THE NEEDS OF ECONOMY AND ENVIRONMENTAL PROTECTION
In terms of power system, the GENMA® MHC is using a pure electric power configuration for the first time. By using shore-based power supply instead of traditional diesel power generation, it has
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significant advantages in energy conservation and emission reduction. “This crane is very environmentally friendly, and there is no black smoke or noise at the site. We are very grateful to GENMA® for creating a clean and tidy working environment for us,” says Gustavo. He adds that the GENMA® MHC meets his expectations for an environmentally friendly crane.
MEETING THE REQUIREMENTS FOR SAFE OPERATION
delivery of the MHC, GENMA® sent the after-sales engineers in time to provide us with professional technical guidance, which makes me feel the professionalism and rigour of GENMA®’s entire service system,” he said. Driven by customer demand and aiming for maximum customer satisfaction, Rainbow Heavy Machineries, as a professional provider of material handling total solution, is committed to providing customized products and services to fully meet its customers’ varied needs. In the future, Rainbow Heavy Machineries will continue to accelerate the pace of internationalization, insist on technology research and innovation, lead by technology and implement customercentric approach, continuously exporting ‘GENMA® solutions’ to domestic and foreign customers, and continuously creating value for global customers. DCi
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‘Safety’ has always been an important component of GENMA® brand genes. To fully ensure the safety of equipment, designers at GENMA® have focused on optimizing the design of key parts of the crane. By adjusting the position of the oil cylinder, which is designed to support the equipment, above the jib, combined with a
landing jib design, the GENMA® MHC not only improves the overall structural stress performance and its daily use safety, but also gives the ability to flexibly cope with typhoon weather. In addition to the jib design, the cab has a panoramic window and transparent bottom plate, ensuring that the driver has an excellent panoramic view, which combines convenience, safety, and aesthetics. It is worth mentioning that the structure, mechanical, electrical, and other aspects of the GENMA® MHC are designed in accordance with local safety certification standards in Brazil, and the crane has safety certifications such as NR12 in Brazil. This shows that GENMA® MHC safety technology has successfully integrated with the Brazilian market. In addition to the product itself, GENMA®’s professional after-sales service is also praised by Gustavo, “After the
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ENGINEERING & EQUIPMENT
Dust emissions management don’t mess with the best
Jay Venter
Wuvio: expert in dust control
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KEEPING YOUR OPERATIONS DUST FREE WITH WUVIO’S TECHNOLOGIES
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Dust-free operations and storage of bulk good can be a challenge. Dust emission is a well-known side effect of the storage of bulk goods in ports, steel mills or other storage areas. The wind is present at these locations; stocks of coal, ores or sand, can blow apart and cause dust emissions in the wider area. A traditional way of capturing dust around large stocks of bulk goods is the use of water. Unfortunately, water has no binding properties and is often a shortlived, ad hoc solution. This solution also requires continuous input of labour and resources.
A CRUST FORMER IS AN IDEAL SOLUTION TO EFFECTIVELY REDUCE DUST EMISSIONS
EcoCrust S is an ideal solution for dustfree dry bulk handing and storage. Wuvio’s crusting agent does have binding properties, which means that the use of its crusting agents reduces water consumption by about 80% compared with the traditional method. This solution forms a thin layer that closes off the top layer of the stored bulk goods. After application of the crust, dust formation is reduced by more than 90%.
If desired, the crust can be made in colour. White or green are most used, these colours form a signal effect to the environment. In this way, employees or local residents can recognize that preventative work is being done to reduce dust formation by using crust formers.
READY TO USE CRUST FORMING AGENTS Dry bulk storage and handling companies want an effective solution that saves time and money, will be easy and quick to prepare and apply. The ideal solution is the use of EcoCrust S technology, this crust forming product will be prepared in dedicated mixing installation locally or will be supplied ready to use. The mixture is sprayed as a thin layer over the bulk goods, so that a nice, thin and well-adhesive crust forms when it dries. Eco Crust S needs to be sprayed with a water tanker equipped with a spraygun, with throw of 40–50m. The transparent alternative to EcoCrust S is Freko-Crust. This crust former contains no fibers but has the same binding and protective properties. The crust is colourless (transparent) and can simply be applied with a (mobile) spray gun. The life of the crust depends on the requirement and site conditions. If desired,
the crust can be prepared to protect the dry bulk storage up to six months, application ratios can be adapted to match site throughput and turn around times. Crust is unaffected by harsh weather conditions such as strong winds, heavy rain, hail or snow. Wuvio’s crust formers are 100% biodegradable and harmless to the aquatic environment.
ADVANTAGES WUVIO’S CRUST FORMING AGENTS: the crust will last up to six months; offer more than 90% dust reduction; save more than 80% on water; are easy to prepare and apply; reduce loss of product during storage or transport by 90%; v are 100% biodegradable; and v are 100% safe for people and environment. v v v v v
COMPLEMENTARY SOLUTIONS While crust former is an effective solution on stockpiles, it could be less sufficient in other situations. To support customers in finding the best solution for dust control, Wuvio has developed other techniques: v Freko-Foam: captures the dust on conveyor belts & in transfer points;
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ABOUT WUVIO
OWN IN-HOUSE LABORATORY Wuvio has its own fully equipped laboratory at its headquarters in Maasdijk. Its chief-chemist leads a team of laboratory technicians focused entirely on dust and odour control. With Wuvio’s own
laboratory, it has the best grip on product development and improvement. Here, through test setups, situations — encountered in field — are simulated. However, the interfering variables that Wuvio encounters in the field are eliminated as best the company can in the lab or are almost completely under control. In its laboratory, Wuvio deals with general projects, with generic solutions to dust and odor challenges, but we also work on very customer-specific problems in this area. Using samples, samplings of specific products, Wuvio develops the most optimal solution for each dust problem.
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Wuvio is a Dutch company, founded in 2007 and is highly respected in the field of industrial dust control. With a team of experts, Wuvio operates worldwide and are available day and night to help its customers with dust or odour problems. On-site, Wuvio analyses the client’s dust challenges and then works with them to find the most optimal and sustainable dust
control solution from both an economic and operational perspective. Wuvio manufactures and sells additives developed in its own laboratory, as well as dust control system, ensuring that clients always receive the solution that suits them best. From its headquarters in the Netherlands, Wuvio works worldwide with its customers and partners to enable a dust-free environment.
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v Freko-Humidifier (via fog cannon or misting installation): makes water up to ten times more effective; and v Road Dust Solution: keeps the road dust free (suitable for paved and unpaved roads).
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ENGINEERING & EQUIPMENT
Innovative dust minimization with ScrapeTec ScrapeTec Trading GmbH is a major player in the field of dust emission control during bulk material handling. Based in Kamp-Lintfort, Germany, ScrapeTec serves customers worldwide across various markets.
KEY MARKETS ScrapeTec focuses on several growing and crucial markets, including South America, Indonesia, Europe, North America, and Australia. These regions offer significant opportunities in the bulk material industry, and the company strategically allocate its resources to provide innovative solutions.
effectively minimizes dust emissions during the handling process.
THE INTELLIGENT BELT GUIDE ROLLER — WITH SENSOR MEASUREMENT TECHNOLOGY, MONITORING, AND DATA TRANSMISSION
Furthermore, ScrapeTec is developing an intelligent belt guide with an integrated monitoring system. This technology will
enable operators to monitor the status of their equipment in real time and proactively address potential issues, further enhancing efficiency and reliability. The E-PrimeTracker answers this question simply and comprehensively. Equipped with additional sensors, it works remotely and sends its data on the belt running status to monitoring systems.
ScrapeTec’s DustScrape operates without the need for additional energy.
MARKETING AND INNOVATION The company’s success is built on several key factors. It has established successful collaborations and partnerships that enable it to stay at the forefront of technology and continuously enhance its products. Innovation is deeply ingrained in ScrapeTec’s corporate culture, and it invests heavily in product development to offer its customers new and differentiated solutions. The company’s new products boast low-maintenance features and substantial benefits for its clients. ScrapeTec is currently working on exciting projects that will soon hit the market.
CUSTOMER-CENTRIC APPROACH ScrapeTec’s strategy also encompasses a special focus on customer service. The company highly values proximity to its customers and collaborate closely with its partners on the ground. This allows it to provide tailored solutions that meet the specific needs of its clients.
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INNOVATIVE PRODUCTS
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An outstanding example of ScrapeTec’s innovation is its DustScrape dust control system. This innovative solution operates without the need for additional energy and
Use on the conveyor belt in conjunction with the AirScrape.
DustScrape at the transfer point behind the calming zone.
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Golden West Industries boasts over three decades in dust controlled bulk handling Managing fugitive dust has long been a struggle for material handling in mining and all types of industries — including maritime movements. Golden West Industries has been successfully treating problematic situations for 3+ decades in ocean transport and delivery of material that is proven to be efficient at both the loading and unloading aspects. “Our products and services are guaranteed to help with such situations,” says Jason Pierce, Vice President, Golden West Industries, Inc. – USA, and this, he adds, “allows the client to perform without the risks of dusting factors internationally.” Foaming agents are known to reduce dust while adding minimal moisture and with minimal effort. “Systems can be installed on the vessel or at the port to reduce dust emissions into the 90% range, and in some instances above, allowing you to focus on material movement that is in compliance with industry standards.” according to Pierce.
USING GOLDEN WEST’S PRODUCTS WILL HELP:
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v lower dusting emissions for internal cleanliness making clean up simple and effective; v compliance issues with regulatory authorities; v lower water usage; v reduce or eliminate carry-back and chute clogging; v reduce lost material; v ensure safe dust levels for personnel both on vessels and at port; and v provide a cost-effective solution for all materials.
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“Our systems are custom designed for your needs including application points and system placement allowing for uninhibited use in any environment.” Most applications require minimum points of foaming agent, allowing more space to perform the tasks at hand. Installations are straightforward and can usually be installed in house by the client, with professional direction for our expert staff. “Our client roster extends internationally with a number of groups using our system(s) on self-unloading vessels and arrival ports. Many clients utilizing both for added dust control measures onshore. “Foaming agents are simple and effective. Small amounts of water per tonne are mixed with air in our system creating a shaving cream appearance dust control measure,” says Pierce. The bubbles created work to encapsulate the fugitive dust particles allowing them to travel with the material downstream instead of becoming airborne. This allows for trouble free offloads and limited loss of material. Low voltage electricity is used to power the system for automated on/off functions allowing worry free application during treatment cycles and low cost. Golden West Industries is always willing to work with clients to design bespoke systems, explains Pierce: “We encourage our clients to provide us with their internal schematics to allow us to custom build the proper system for their needs. Once this is complete, a system designed specifically for them is initiated and built to specifications.”
ENGINEERING & EQUIPMENT SEPTEMBER 2023
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Simple, autonomous solution to a complex problem
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A complex problem that has plagued the bulk handling industry for years, the creation and management of fugitive dust, has previously been an overlooked and somewhat neglected side effect of bulk loading activities. However, over time, the impact of this often-hazardous airborne menace has become quite clear, both from a health and safety perspective as well as an environmental one. Most companies that participate in bulk loading activities, whether it be ship, rail, truck or yard loading will find themselves with an unfortunate dust situation at some point, often drawing the ire of local communities and health and safety or regulatory bodies, as well as just ending up with an extremely poor working environment, with very low visibility and air quality. “Industrial dust control measures require simple, practical solutions,” says DSH Systems General Manager Jason Whaanga. “Complicated equipment that requires a specialist to develop, install and maintain only makes the control of fugitive dust more expensive and the results are not always ideal and sometimes deteriorate over the life of the equipment.” These side effects Whaanga mentions are numerous. From the obvious issues to worker health and wider communities, to the plain horrible problem of dust coating the environment, trucks and other vehicles
or sneaking into ventilation and clothing. There is also the potential for loss of product, and therefore, profit, when the fine particles of product get carried away by the wind, as well as the wider issues caused by low visibility and poor worker health. The installation of DSH’s hoppers has resulted in a dramatic decrease in airborne dust during loading and transfer operations at those locations. There are many benefits to using a DSH system, including: better air quality and visibility; a healthier and safer working environment; a reduced risk of dust explosions; faster and cleaner loading processes; significantly lowered product loss during loading; reduced maintenance; dust disposal and cleaning costs; and the removal of air from products can increase storage capacity. One customer reported that its site, which loads soybean meal, has seen a 70% reduction in cleaning requirements since the DSH system was installed. This is where DSH Systems thrive. Developed in 2004 by Trevor Schwass, DSH’s dust suppression hopper is a simple, autonomous system that requires minimal utilities, maintenance or expertise to install, “Our hoppers were specifically developed to reduce and control dust when bulk loading dry, granular freeflowing products” says Schwass, “The hopper is used under a central feed point,
and condenses the product into a reduced volume stream, which lets it fall freely through the air into any loading container with minimal dust.” A revolutionary invention, DSH’s hoppers require no services to function, can be installed into both new and existing sites, and maintain the integrity if the product mix even as the stream cascades through the air in a dense column. Since its inception, the company has grown its systems to include all manner of products and flow rates, and it has handpicked agents for its worldwide distribution network. Since 2004 DSH has thousands of DSH systems installed across the globe, from ports in Japan to quarries in France, and everywhere in between. “We offer a turnkey solution with regards to dust suppression systems which makes us a bit of a one stop shop. We all share an office, the marketing, engineering and sales team and everyone gets involved and has a real practical knowledge of our hoppers and their functions, even our marketing team are able to help diagnose issues and suggest hopper systems!” Whaanga laughs, “Our engineering team is spectacular, with a huge working knowledge of bulk handling systems and materials and our sales team is second to none. We aim to make sure that our systems are available to anyone, regardless
Cleveland Cascades Ltd Global leader in bespoke dry bulk loading chutes
Ship Loaders
Silo Loaders
Truck Loaders
Cleveland Cascades are Specialists in the design and manufacture of bespoke dry bulk loading chutes. Our bespoke solutions are designed to meet each customer’s specific requirements from a tool kit of proven components, utilising the expertise of a team of specialist in house design engineers.
Tanker Loaders
We lead the loading chute industry & set the standard for dust emissions and environmental pollution control in dry bulk handling. Our worldwide reputation is built on high quality, well-engineered, robust, high performance chutes, backed up by excellent customer service and global lifetime product support.
Contact Cleveland Cascades Ltd Unit 22, Dukesway, Teesside Industrial Estate, Thornaby, Stockton-on-Tees, Cleveland, TS17 9LT, United Kingdom Tel: +44 1642 753260 | Fax: +44 1642 753270 E-mail: enquiries@clevelandcascades.co.uk | Website: www.clevelandcascades.co.uk
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of locale or language, which is why we work so closely with our distributors, and we often travel to sites and trade shows and have personal and long-lasting relationships with our clients and distributors — all of the team at DSH really make an effort to have those face-toface conversations with them, which is something that we are very proud of,” he comments, adding that, DSH has been actively involved in the bulk handling industry for almost 20 years, not even including all of the expertise of its many representatives. The year 2023 has so far proven to be an exciting one for DSH. After weathering the storm of Covid-19 (as well as few literal storms that wreaked havoc in New Zealand), two new team members came on board early in the year, and along with the existing team have revamped DSH from the inside out. “We’re currently exploring a lot of research and development to ensure that every hopper that goes out the door is 100%,” Whaanga says. New spring testing rigs and ship loading designs are in the pipeline, as well as a totally new support package from the marketing team. “We’ve been introducing some of the new updated branding over the past few months and are looking forward to a new website and installation packs very soon. “Trevor recognized that there was a gap in the market for this simple, easy system that just speaks for itself, and that was back in 2004! It really is an amazing product, and we are looking forward to being able to share that” Most recently, DSH visited Phu My Port in Vietnam, where two polyethylene and two steel hoppers were installed some months ago. Since the installation, ground operation employees at the port have reported a dust reduction of up to 85%, and one employee stated that the DSH “needs very minimal maintenance and it is a very efficient system” and that they “are very satisfied with the system and hope to install more.” With every hopper installed, DSH contributes both to better worker health as well as environmental protection, all whilst ensuring a clean and efficient loading method. By limiting dust generation, a DSH hopper minimizes the amount of fugitive particles escaping into the air, preventing the pollution of precious oceans, waterways and urban areas, and minimizing health hazards for both humans and animals associated with the inhalation of dust. At DSH, the company strives to offer
exceptional products and service, all whilst being proudly Kiwi-owned and operated. “Knowing we are a company that, with every hopper sold, contributes to better health outcomes to operators, drivers and other site staff is something the team at
DSH do not take for granted.” Whaanga says, “We at DSH truly believe in our systems and seeing the difference that these hoppers can make to a site and its surrounds is an awesome thing which we are very proud of.”
Dust is inevitably created during conveying, processing and storage of bulk goods. The dust that is released is harmful to health, is environmentally damaging and causes pollution. Dust can also create a very real risk of explosion. DCP Benelux, part of the TBK Group of companies, is a specialist in managing dust emissions. With sustainable and customized industrial dedusting solutions, it reduces the impact that production processes have on people and the environment. It ensures a clean and safe working environment. Dust Control Partners (DCP) provides v a thorough analysis of all dust issues; v tailor-made solutions; and v control of dust emissions.
DEDUSTING Dedusting is applicable to all branches of industry. All production processes have their own specific requirements, so every dust issue requires an individual approach. DCP Benelux analyses its customers’ dust issues.
ANALYSIS
COMPLETE SYSTEMS
and excellent manufacturing quality. If required, the filters can be manufactured entirely in SS304 or SS316. v Suitable for ATEX zone 22 and explosive substances: DCP Benelux’s dedusting filters, fans and rotary valves can, of course, be manufactured to comply with ATEX 114 (directive 2014/34EU) for use in zone 22. If explosive substances are extracted, the filters are reinforced to withstand a reduced explosive pressure of max. 0.5 bar (o). In addition, they are fitted with safety components such as explosion relief plates or flame arrestors, ATEX isolation valves in the inlet — and clean air duct, and a flame and pressure-resistant rotary valve. DEDUSTING SYSTEMS DCP builds complete dedusting systems, including piping and all other components such as control valves, rotary valves and the like. It takes care of the entire process from design to commissioning. Naturally, it also provides all necessary manuals and certificates in accordance with the applicable ATEX and CE directives. CENTRAL VACUUM CLEANING SYSTEMS DCP designs, supplies and installs industrial vacuum cleaning systems. Each system is designed customer- and product-specific. CVC installations suck up dust or material that is released during production processes or cleaning activities with a high under pressure. Large distances can be bridged with one system. The system can be switched on and operated simultaneously at different positions. Because the air velocity is high, both light dust and larger amounts of heavy material can be vacuumed and transported. A CVC system consists of a blower, dust filter and piping including control valves, bends and vacuum components.
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DCP Benelux supplies filters, complete dedusting installations and central vacuum cleaning systems (CVC). These are specially designed and built for the customer’s specific requirements by Czech partner, Cipres Filtr s.r.o. DCP Benelux is not limited to only supplying the appropriate dust filter, it is able to undertake the entire process, from engineering to commissioning.
DUST FILTERS DCP Benelux’s dust filters are compressed air-cleaned cloth filters. Their operation is simple. Dust-laden air is passed through the filter cloths. The dust collects on the outside of the filter cloth and the cleaned clean air leaves the filter through the exhaust duct. DCP’s compressed air cleaned envelope filters can be broadly divided into three main groups: cased filters; insertable filters; and spot filters. Thanks to the integrated reverse jet cleaning system, these filters can be operated 24 hours per day without interruption. Reasons to choose DCP Benelux’s dust filters include: v Low compressed air consumption during cleaning: the needle-felt envelope filter bags slide over steel filter frames, which are fitted with specially shaped openings. The cleaned air flows through the openings into the clean air chamber, from where it is extracted to the outside air. The filter elements are periodically cleaned by compressed air being injected against the direction of the air flow. During this compressed air injection, a large volume of additional ambient air is induced through the same openings — thanks to the resultant venturi effect. This creates a brief but powerful reversal of the airflow direction, which cleans the envelope filter bags. The venturi effect means that the volume of compressed air required is low. v Customization and quality: thanks to modular construction and flexible production, each filter can be tailored exactly to the customer’s requirements. This allows DCP Benelux to supply customized products at standard prices. Its filters are recognized for their solid construction
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DCP Benelux identifies all the areas that require dust control, analyses the required extraction rates and flow distribution, and produces a duct resistance calculation. It can also collaborate with customers to determine any ATEX requirements they may have. Based on all this information, it can then establish which type of dust filter, filter medium and fan is required.
PRODUCTS OFFERED
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Managing dust emissions with DCP Benelux
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Creating an effective dust management plan A dust management plan (DMP) is very specific to the industry and application. For example, a quarry’s needs may look vastly different from that of a port, writes Michael Kelley, President, BossTek. First off, quarries produce a disproportionate volume of dust and often operate in contrasting environments from ports (rural vs. urban/suburban). This doesn’t necessarily mean a quarry’s DMP is thicker and more complicated. Due to the wider variety of raw materials handled and greater exposure to variable weather conditions, a port’s DMP might have a larger scope with several regulatory variables that can make it considerably more involved. Upon creating a DMP, operators will realize that there is no one-size-fits-all approach to dust control. However, incorporating atomized mist technology into a DMP implemented by strategically placed dust control cannons and accessories has proven to be the most effective method to achieve compliant air quality and airborne particle suppression.
UNDERSTAND THE OPERATIONAL
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ENVIRONMENT
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Prior to creating a DMP, operators are strongly encouraged to first get a detailed environmental assessment from a reputable specialist. The environmental assessment will inform the dust control plan by first relaying what kind of hazardous substances the operation is/could be emitting, the regulations around this activity, and the potential impact on both staff and the surrounding ecosystem. Although the environmental assessment might provide recommendations, it will likely not provide a comprehensive DMP. A dust management plan takes a deeper dive into specific permit requirements, seasonal weather patterns, particle sizes, causes of emissions, workplace safety, community safety, and specific dust-related environmental impacts. The first step is understanding dust and emissions.
DUST SIZES AND THE SLIPSTREAM EFFECT Dust particles or ‘Particulate Matter’ (PM) are measured by diameter in microns (μm), which is a fancy word for micrometres (1,000,000th of a metre). To remain suspended by normal ambient air currents, particles can be as large as 200μm. The smaller they get, the less visible they are to the naked eye, becoming barely visible at 100μm. At the size of <PM10 (the regulated size threshold for airborne
Figure 1 – Dust size comparisons. Air Cannons are common in ports for the ability to capture airborne dust with less runoff than hoses (©BossTek® copyright 2023). crystalline silica particles), the dust is able to avoid the body’s natural defences, penetrating deep into the lungs and causing chronic lung diseases (Fig. 1). Airborne suppression of outdoor emissions is typically accomplished using water. Tests conducted over two decades reveal that droplets need to be approximately the same size as the airborne particulates to be effective. Hoses and sprinklers create droplets between 200μm and 1,000μm, compared to atomized mist which is sized in the range of 15μm to 200μm. Droplet sizes greater than 200μm are only adequate for wetting surfaces, but don’t offer airborne dust suppression. This is due to the slipstream effect. The mass of the falling droplet creates a swift air current that moves around it called a slipstream. Particles get caught in the slipstream and either move around the droplet, avoiding it altogether, or it could
give the smallest particles lift, worsening the issue. In contrast, atomized droplets travel on air currents with the particles, absorbing them, and the collective mass drives both to the ground.. (Fig. 2). What makes droplets from hoses and sprinklers so large? These methods depend on water pressure to propel the droplets long distances. A massive volume of water pushed through a narrow space is needed to propel the water and this volume creates larger droplets. An atomized misting cannon relies on a powerful fan to propel tiny droplets created by misting nozzles, using far less water and offering more complete coverage.
INDUSTRY CONSIDERATIONS FOR DUST MANAGEMENT PLANS
Formulating a dust management plan is wholly dependent on where the emissions are produced, the travel distance, and who/what is affected. In the United States, for example, there are several regulatory bodies that oversee different parts of the operation. The Occupational Safety and Health Administration (OSHA) is the regulatory body for workplace air quality
WHAT IS A DUST MANAGEMENT PLAN? Simply assigning a person to hose down dust-generating activities is not a plan. A DMP is a comprehensive document that states the causes, compliance requirements, testing measures, control methods,
Tower-mounted mist cannons allow for total coverage of tall storage piles. © BossTek® 2023 copyright and policies for a specific operation. These standards are often set by government agencies such as the U.S. Mining Safety and Health Administration (MSHA) or a reputable trade organization like the Conveyor Equipment Manufacturers Association (CEMA).
The dust management plan demonstrates to regulators that the operator has done their due diligence in good faith. It also provides resources — both internal and contracted — to inform, train, and track all operations that might affect air quality. The creation and administration of the
ENGINEERING & EQUIPMENT
and the safety of workers. These regulations also extend to the Centers for Disease Control (CDC), which oversees dust emissions from a health perspective (chronic lung diseases). The Environmental Protection Agency looks at dust emissions as air and water pollutants. These agencies work in tandem and running afoul of any of these standards can result in violations, fines, and potential downtime. Enclosed/underground — the clean air intake system could be contaminated by tunneling and mining activities, so consider airflow and particle movement. Suppression of dust at the point of emission can mitigate airborne particulates using non-mechanical misting heads or misting rings that don’t violate restrictions on electrical or moving parts. Enclosed and naturally ventilated — manufacturing (wood products, aluminium casting, etc.), processing (recycling/MSW, crushing, sifting, etc.), and production plants (cement, fertilizer, etc.) generally depend on a system of open windows/ doors and roof vents to pull heat and dust out. This category includes storage warehouses with massive tripper conveyors and reclaimers. However, this doesn’t control circulating dust within the enclosure, creating a workplace hazard. Compact cannons can help circulate the air, directing heat and airflow while suppressing airborne dust. Bulk handling and storage — the use of tall stacker conveyors and storage areas is common for bulk handlers from ports to smelting to scrap yards. Tower-mounted dust suppression cannons and misting rings are preferred for these applications to ensure complete coverage over tall storage piles and to control emissions from conveyor cargo discharged high in the air onto piles. Open operations — even using natural barriers like trees and structures, open operations such as quarries, landfills, ports, and sowing of arid crops (grains, root veg, etc.) may require extensive wide area dust suppression with no runoff or pooling during operations. Larger dust cannons are designed for large, exposed areas. In regions with periodic high winds or applications in need of the reach, seek cannons with the option of distributing a pressurized stream, as well as atomized mist.
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Trailer-mounted units can run up to 48 hours without needing to refuel which minimizes downtime. © BossTek® copyright 2023
Figure 3 – Hierarchy of Dust Control Methods. © BossTek® copyright 2023 DMP requires ongoing contributions from many stakeholders within the organization, but oversight largely falls on the Environmental Manager.
THE RESPONSIBILITY OF OPERATORS AND ENVIRONMENTAL MANAGERS
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Operators are responsible for ensuring that site environmental management requirements are met. In most cases, oversight will rest with the Environmental Manager (EM) to uphold the standards stated in the dust management plan. Make sure staff and contracted personnel are trained on the DMP and are familiar with the procedures and their roles/responsibilities in dust prevention. Cutting corners or ignoring protocols shouldn’t be tolerated. The EM needs to ensure monitoring requirements are being met on all operations. It helps if contracted partners with large construction or operations projects appoint their own environmental representative to oversee that project. In some cases, monthly or quarterly reports are required on environmental impact, ensuring that independent auditors or inspectors appointed by the regulatory agencies (OSHA, CDC, EPA, etc.) are provided with detailed and up-to-date information.
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SECTIONS OF A DUST MANAGEMENT PLAN In the range of 10–50 pages long, depending on the size of the site and the scope of the project, the dust control plan is a report directed by an environmental specialist and maintained by internal resources. It is comprised of several different parts. v Summary — an overview of the goals, findings, and solutions. People should be able to get a good idea of what is in the report and get a positive impression that all parts are being proactively addressed. v Acknowledgments — a list of contributors and external resources used to create the report. v Contents — an index of the entire report with page numbers. v Introduction — a narrative for the
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report from an environmental and workplace safety perspective. State the nature of the operations and the organization’s air quality goals. Highlight the collection of data and reasoning behind the chosen solutions. Project/site contacts — the names and contact information to whom regulators can direct questions. Project/site introduction — an introduction comprised of a short history, a description of the surrounding area, nearby communities, obstacles, and industrial activities around the site that may contribute to lower air quality. Environmental evaluation — an examination of the existing air quality and contributing sources of particulate load on the air shed. It also covers several topics such as geology, soil quality, ecology, water quality, seismology, weather, and an environmental impact statement. Policy evaluation — from an air quality standpoint, the DMP offers more detailed fugitive particulate data, regulatory policy, permit details, and assessment methodology than the environmental assessment. Dust control measures — a wide range of industries refer to the Hierarchy of Control Methods, which are listed from least effective to most effective when determining what methods and measures to implement. The CDC defines Eliminate by Design as “removes the hazard at the source”, which is what mist cannons are designed to accomplish by suppressing airborne particulates at the point of emission (Fig. 3). Monitoring — this section defines what is being tested, the testing methods, and frequency on a chart also showing ongoing testing results. It should, on a regular schedule (quarterly, bi-annually, or annually), provide insight into the effectiveness of the measures and offer recommendations.
v Conclusion — closing thoughts and updated addenda. v References — Any other links or source materials used to create the report. v Glossary — A glossary of terms or abbreviations. Note that this can also be placed before or after the index.
DMP UPDATES AND CHANGES Operations and attitudes toward air quality change as sites expand and communities grow around them. Operators should always keep the safety of staff and the surrounding community as their priority. However, companies also have an obligation to address the needs of customers and investors. Greater production demands can increase the volume of bulk material processed/handled and increase a site’s operating hours. The invariable result is a dramatic increase in the volume of dust. This will require significant changes to the DMP. Here are some things Environmental Managers should consider: v Pinpoint the new dust-emitting sources. v Identify dust response triggers (wind, disruption, blasting, etc.). v Define changes in the properties of emissions (size, hazard, etc.). v Record the current and potential effects. v Make a hypothesis on the impact. v Implement PPE and administrative controls to mitigate the impact on staff during the evaluation period. v Monitor the sources and the effects for a short period to test hypotheses. v If dust control measures are in place in anticipation of the change, create a control test to monitor effectiveness. v Create contingency plans for changes in weather conditions. v Monitor sensitive receptors (ecological health, community health) when possible or partner with local groups to get updates. v Train staff on dust management and assign responsibilities for updating the plan.
EQUIPMENT
Dust control methods can be an investment. Some methods such as hoses and sprinklers may seem like a low initial expense but end up costing more in labour and water usage. Here are some questions when choosing a dust control solution: What is the required water source? Dust control solutions, for the most part, use water to suppress or control airborne emissions. Most DustBoss cannons can use city water with a standard 1.5 inch hose run through a booster pump to operate. If hydrant water is available, less pressure and volume is needed compared to standard hoses and sprinklers. What is the required coverage area and can dust be controlled at the source? This determines the size and type of mist cannon needed. The best practice is to stop dust before it becomes airborne or
close to the point of emission. What is the power source? Solutions like hoses and sprinklers that use pressure instead of power are less effective against airborne dust. However, operations without a power source do have alternatives such as mist cannons on self-contained road-worthy trailers with diesel gensets. What are the rules around standing water, pooling, and wastewater runoff for this site? The DustBoss family of cannons uses only 7-10% of the water volume of hoses, sprinklers and tanker trucks, saving hundreds of gallons of water per minute and thousands of dollars in water bills per annum. How much labor and maintenance does the dust control solution require? Often, hoses, sprinklers and tanker trucks require labor to operate, adding to the cost. Mist cannons are autonomous. They are positioned, turned on, and left alone.
Companies who bought DustBoss Systems often comment on the rugged construction and ease of use, as most models are accompanied by a remote control that can be operated from the cab of a vehicle or from a safe distance. Quality is why some of the first units sold decades ago are still in operation today.
CONCLUSION Dust control plans take time and resources to create, but the cost of fines, negative public relations, and potential lawsuits is far pricier in the long run. Dust control experts can work with internal resources (EMs, project managers, etc.) to show where and how operators can integrate atomized mist technology with operations to control airborne fugitive emissions and improve suppression. This insight will go a long way in producing a comprehensive dust management plan.
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CHOOSING THE CORRECT DUST CONTROL
Port sector - conveyor belts project in Motril, 2023
CHIA DUST SUPPRESSORS
addition, as there is less air trapped in the materia, the space available for loading material increases. The firm and solid dematerial column allows direct loading in confined openings. CHIA’s dust suppressors do not contain mobile internal components, nor do they require connection to an electrical supply. Other features of the dust suppressor are the reduction of maintenance costs and cleaning costs. Additionally, it reduces the degradation of materials and reduces the need to capture and dispose of dust.
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CHIA’s dust suppressor system can achieve significant reductions in fugitive dust emissions and dust explosion hazards. The dust suppressor system is installed under a power point. As the products flow, a natural agitation occurs that helps separate the dust particles from the material. Once the material falls by gravity, a solid column is created that facilitates unloading into trucks, wagons, storage tanks, open spaces, etc. Its better resting angle increases the storage capacity. In
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In 2023 CHIA manufactured and installed a 52m-long ecological iron ore conveyor belt in the Port of Motril. This custom-made conveyor will be loading iron ore onto ships in Spain and Europe in an ecological manner. The belt is completely closed and has a system of aspirations that eliminates the generation of dust in the environment. Trucks unload the iron ore into the chain feeders installed on both sides of the conveyer, from where the iron ore then gets transported by conveyor into the ship holds, thanks to a telescopic sleeve. The load capacity is 750 tonnes per hour. This ecological conveyor was specially designed for the port of Motril, with the intention of reducing the environmental impact as much as possible during the cargo activities of the ships. This new project will give initiative to the export of iron ore to Asian countries, thanks to the partnership between the cosignatory agency Consignaciones y Estibas Motril, SL and the Alquife Mining.
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Dust suppression system with mineral oil for silos and grain terminals
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Before (left) and after (right) installation of ICCE’s dust suppression system.
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Dust is a common issue in grain handling facilities, and it can lead to a range of problems and challenges. Some of the key problems associated with dust in grain handling facilities are: v Health hazards: dust can contain allergens, mold spores, and fine particulate matter. Prolonged exposure to grain dust can lead to respiratory health issues. v Fire and explosion risk: grain dust is combustible, and can lead to fires and explosions. This presents a significant safety risk to both workers and the facility itself. There is the potential to cause catastrophic damage and loss of life. v Reduced visibility: excessive dust in the air can reduce visibility within the facility. Increasing the risk of accidents and collisions involving vehicles and equipment. v Premature wear and tear: dust particles are abrasive and can cause faster deterioration of machinery. This results in higher maintenance and replacement costs. v Operational inefficiencies: dust accumulation leads to operational inefficiencies. Blockages and reduced equipment performance can disrupt the flow of grain. Thus causing delays and productivity losses. v Product contamination: by developing contaminants, impurities, and molds, dust can degrade the quality of the grain. This is particularly problematic for the grain intended for human or animal consumption. v Environmental impact: dust emissions can have environmental consequences on local wildlife and communities. Dust particles have a negative impact on nearby vegetation,
air, soil, and water bodies. To address these problems, a dust suppression system must be implemented. This system is essential for creating a safer and more efficient handling system. ICCE has developed a system that uses mineral oil as an agent for dust suppression. The system can reduce the dispersion of dust particles during grain processing and storage operations. Some of the key advantages are: 1. Improved air quality: mineral oil helps reduce airborne dust. Thus improving the air quality and minimizing respiratory health risks. 2. Dust emission reduction: by binding to dust particles, mineral oil reduces dust emissions. Which is crucial for regulatory compliance and environmental responsibility. 3. Equipment protection: minimizing dust extends the lifespan of machinery and equipment. 4. Fire prevention: mineral oil dust suppression can reduce the risk of fires and explosions in grain facilities. 5. Personnel safety: enhanced safety measures result from reduced dust levels. Lowering the risk of accidents and respiratory issues for workers. 6. Environmental responsibility: mineral oils align with environmentally friendly practices. 7. Cost effectiveness: mineral oil dust suppression systems has proven to be more cost-effective compared to the other solutions. ICCE offers a complete solution. From the design to the supply, start-up, and maintenance of the installed system. The entire solution includes following the specific processes and considerations: v Identification of dust generation
points: determine the key areas within the handling facility where the dust is generated. These points can include conveyor belts, chutes, transfer points, and loading/unloading areas. v System design and installation: ICCE designs a dust suppression system with the corresponding documentation. The design considers the facility layout, airflow patterns, and specific dust areas, thus, ensuring effective dust control. v System supply: ICCE provides and installs a complete system on a turnkey or supervision basis. v Personnel training: this includes understanding the system's operation, maintenance procedures, and safety protocols. Mineral oil application — installation and functioning of the system is as follows: 1. Spray nozzles or misting systems are placed in dust-prone areas. Mineral oil is automatically sprayed onto surfaces where dust is generated. The fine mist of mineral oil particles helps bind with dust particles, making them heavier and less likely to become airborne. 2. Control and monitoring: the system includes a control and management system for managing the operation of the dust suppression system. The system manages the frequency and intensity of mineral oil spray. This is based on dust levels and operational needs. 3. Maintenance and refilling: routine maintenance of the system is essential to ensure effectiveness. This includes cleaning nozzles, checking pipelines for blockages, and refilling mineral oil reservoir.
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Spraystream removes dust particles from the air when handling grain
Spraystream fog cannons have become increasingly popular in recent years due to their effectiveness in suppressing dust and reducing fire risk in grain handling applications. The Spraystream machines emit a fine mist of water droplets that can capture dust particles and prevent them from becoming airborne, which is especially important in industries where dust is a significant hazard.
A SAFER AND HEALTHIER ENVIRONMENT FOR WORKERS
In addition to their dust suppression capabilities, Spraystream cannons can also be effective in reducing fire risk in grain handling facilities. Grain dust is highly combustible and can ignite very easily, leading to fires and explosions. By reducing the amount of dust in the air, Spraystream cannons can lower the risk of ignition and reduce the potential for fires.
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SPRAYSTREAM REDUCES THE RISK OF FIRES
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Grain handling facilities, in particular, can benefit greatly from the use of fog cannons. These facilities handle large volumes of grain, which can produce a significant amount of dust during the handling process. This dust can be a major health hazard for workers and can also create a risk of explosions and fires. In addition, the dust can settle on equipment and machinery, causing them to malfunction or break down. By using fog cannons, grain handling facilities can significantly reduce the amount of dust in the air, creating a safer and healthier environment for workers. Spraystream cannons can also reduce the risk of fires and explosions by preventing dust from accumulating on surfaces and equipment. The effectiveness of Spraystream cannons is due to the fact that they produce very small water droplets. These droplets are so small that they can float in the air and capture dust particles as they pass through. As the mist settles, it pulls the dust out of the air and onto the ground, where it can be easily cleaned up.
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SPRAYSTREAM FOG CANNONS: A HIGH-QUALITY SOLUTION Spraystream offers an extensive range of fog cannons with various options. These machines create a micro-droplet mist curtain with a range of up to 150 metres, in part thanks to the use of high-quality materials: v The patented cone shape is aerodynamic and made from a composite. This high-quality material creates lighter machines, has an attenuating effect, and has a lower risk of corrosion. The cone shape leads to a maximum range with a minimum capacity and water. v Spraystream also uses GRUNDFOS maintenance-free pumps of the highest quality. v The company’s intuitive machines are also very easy to use and can be controlled remotely. v The Spraystream machines have a default electrical oscillation and the fans can withstand high performances. v The wind guides make sure that a turbulent air flow is converted into a laminar air flow. This leads to minimum water flow losses and thus to more targeted and more efficient atomizing. v The atomizers can be replaced easily because Spraystream uses rapid-lock systems.
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FIXED NOZZLE SYSTEMS AND CUSTOMIZATION
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Not every dust problem can be solved in the most efficient way with standard machines. That is why Spraystream also provides customized systems. This can range from minor adjustments to standard machines, or completely customized installations. This way Spraystream can perfectly meet the customer’s needs and budget. A team of engineers has the knowledge and experience to develop custom-designed atomizing systems. An assembly and maintenance team ensures perfect installation and after-sales service over the whole world through a dealer network. In conclusion, Spraystream atomizing systems are an effective tool for reducing dust and fire risk in grain handling facilities. By emitting a fine mist of water droplets, they can capture dust particles and prevent them from becoming airborne, creating a safer and healthier environment for workers. They can also reduce the risk of fires and explosions by preventing dust from accumulating on surfaces and equipment. When a dust problem can not be solved by a standard fog cannon, Spraystream can provide customized systems.
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Plain Water Dust Suppression – large droplets size in the mist range (>30 - 100 microns) and lower droplet density.
THE CHALLENGES AT THE ROTASIDE WAGON TIPPLER AREA
FP Series air driven acoustic oscillator nozzle. Tippling with no containment and no dust control – dust laden displaced air gushing out through the grizzly, resulting in dust escape into the work area and surrounding area. generates dust-laden high-velocity displaced air plumes in the emission zone (Grizzly Area). v Displaced air gushing out from the emission zone (over the Grizzly Area) into the work zone (beyond the Grizzly Area) is a primary cause of dust nuisance. v Containment of the emission zone (over the Grizzly Area) was essential to prevent dust dispersion. v Avoiding crosswinds entering the emission zone was crucial to make fog and dust agglomeration effective. v Frontal containment wasn’t possible as payloaders needed access to the Grizzly Area. Eventually, a minimum possible containment strategy was worked out and settled upon which primarily relied on the existing sides of the grizzly shed, with some partial frontal containment, and just enough coverage of the grizzly to minimize the escape of displaced air.
ADS™ - THE DRY FOG SYSTEM BY F. HARLEY AT THE ROTASIDE WAGON TIPPLER The ADS™ dry fog dust suppression system, employs dual fluid sonic nozzles, generically known as air driven acoustic oscillator nozzle which is the heart of the dry fog dust suppression system. These nozzles generate dense dry fog which is
defined as 0–30 micron droplets, similar to natural fog, which is created by atomizing water through injection of compressed air in a ratio at sonic velocity. Advancement to these air driven acoustic oscillator nozzles or the 'sonic type' nozzles under the FP Series by The Raring Corporation, USA are unique to the ADS™ System, thus making it more maintenance friendly and durable. Integral to the ADS™ dust control strategy is the containment of the dust which is the first step to the success in dust control, which helps in retarding the high velocity dust laden displaced air to help the fog to mix with the airborne dust viz. agglomeration of fine water droplets with like sized dust particles to gain mass and settle through gravity. Effectively, the ADS™ Dry Fog dust suppression system dampens the dust generated and not the material unlike plain water dust suppression systems (PWDS) whose working principle is based on wetting the material up to 1.5% of the material handled, whereas the effective moisture addition for the ADS™ Dry Fog system is only 0.1% approximately. Considering the effectiveness in dust control in the US coal industry, in October 2009, the USEPA designated both passive enclosure systems and fogging systems (dry fog systems) as best demonstrated technologies for coal handling. Essentially, the containment is termed as passive dust control, and the fogging is termed as active dust control, which is like the Chinese
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v Rotaside wagon tipplers have restricted underground hopper depths, leading to material being dropped almost at ground level, resulting in a significant dust nuisance. v Constructing a shed in the tippling area was not feasible due to the plant’s operational constraints. v The tippling area being open/semiopen tippling one was far from an ideally controlled one. v The surge load, high volume operation of the Rotaside WT
ADS™ Dry Fog System (by F. Harley) – fine droplet size in the fog range (0 – 30 microns) and high droplet density.
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National Thermal Power Corporation (NTPC), India’s largest power company scored a successful debut with F. Harley’s installation of the ADS™ Dry Fog based dust suppression system (in technical collaboration with TRC (USA) world renowned dust control specialists in bulk material handling) at the NTPC Unchahar thermal power plant for its Rotaside wagon tippler application, replacing the plain water dust suppression system, writes Nirav Shah, Dy. Managing Director, F. Harley & Co. Pvt. Ltd. The order was placed in end of 2019 and was slated for commissioning in March 2020. Due to the Covid-19 pandemic the installation was done in phases and the system was ultimately commissioned in end January 2022. Subsequent to the commissioning, NTPC put the system to test for full 30 days, and the results were an astounding 80% plus average reduction in the TSPM, with practically no visible dust emissions escaping from the emission zone (the grizzly area) into the work zone (outside the grizzly area and shed), despite the challenges of the application being a largely open one. NTPC observed that along with the fogging, the containment recommendations from F. Harley were found very useful in achieving the results.
After
ENGINEERING & EQUIPMENT
F. Harley caps Rotaside wagon tippler ‘high volume surge dust’ with ADS™ Dry Fog System at NTPC, India’s largest thermal power generating company
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Fogging Without Dust Containment impact of displaced air velocity cuts through the fog and reduces agglomeration resulting in escape of visible dust into the Work Zone.
Fogging With Dust Containment – dramatically retards the impact of displaced air velocity enabling a high quantum of agglomeration resulting in no visible emissions into the Work Zone.
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The ‘Dense & Spineful’ ADS™ Fog Power in action.
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philosophical principle of ‘Yin (passive) and Yang (active)’ — of inseparable and contradictory opposites existing in harmony.
DUST CONTAINMENT: THE FIRST STEP TO DUST CONTROL IS — DON’T LET IT OUT
containment, respectively, over the Grizzly, and both with fogging, given above are a few pictures which show the difference in the escape of visible dust into the work zone from the emission zone — which can be totally avoided with strategically applied dust containment. To be precise, dust containment is an integral part of dust control, which would otherwise make a great ultra fine, dense fog useless in controlling dust.
ADVANTAGES AND SUCCESS FACTORS OF THE ADS™ DRY FOG BASED DUST SUPPRESSION OVER PLAIN WATER DUST SUPPRESSION SYSTEMS
v Dust containment – containment around and within the emission zone is Quite often the importance of dust critical to prevent crosswinds from containment is undermined and not entering and to stop dust-laden air appreciated. To have an idea of dust from escaping. This allows for effective generation without and with dust agglomeration of fog and dust, making particles heavy enough to fall back to the source. v No visible dust escape from the emission zone to the work zone – unlike traditional systems, the dust containment and Agglomeration Explained. dense fog
v
v
v
v
generation of the ADS™ Dry Fog system (higher than the rate of dust generation) ensures no visible dust escape from the emission zone to the work zone. Fine water droplets and their density – the ADS™ system produces ultra-fine water droplets (0–30 microns), creating a dense fog that effectively captures respirable dust, surpassing traditional systems with larger droplets. Spineful dense fog – the ADS™ system’s FP Nozzles generate a dense, spineful fog that counters rising dust plume velocity, promoting maximum agglomeration and dust emission control above the Grizzly. Agglomeration – the ADS™ Dry Fog system achieves higher agglomeration of fine water droplets with dust particles, making airborne dust heavier and facilitating gravity-based settling. Drastic reduction of water consumption and elimination of water flooding – the ADS™ system significantly reduces water consumption by up to 300% compared to traditional systems, eliminating the need for water flooding in the underground area below the hopper.
CONCLUSION NTPC Unchahar thermal power plant expressed its satisfaction with the effectiveness of the ADS™ Dry Fog System installed by F. Harley, upon putting the system to a full 30 days test, resulting in increased interest to change over from the conventional plain water dust suppression systems in other NTPC plants. Effectively, with this installation and all it’s challenges, and with the convincing test results, it is yet another breakthrough and a highly successful one for the ADS™ Dry Fog based dust suppression system by F. Harley after the highly appreciated and successful installation of the ADS™ Dry Fog system for the track hopper installation at Paradip Port Trust in 2018. Alongside, many other companies are satisfied users of the ADS™ Dry Fog systems for the Rotaside Wagon Tipplers in the thermal power industry by the sheer elimination of visible dust emissions during the tippling operation for this highly challenging dust generating and common application in the Indian industry, while the ADS™ Dry Fog system remains the ‘war horse’ for dust control for bulk material handling applications across the thermal power, steel, mining, ports and cement segments. DCi
enclosed storage and handling
ENGINEERING & EQUIPMENT
Seeking shelter
Jay Venter
Points to consider when designing storage structures unloaded, it can create cavities and asymmetric loads inside the storage structure. Depending on the silo, those uneven forces can create structural integrity issues, weakening it over time. In addition to these problems, even more setbacks can arise with extra-large diameter storage, like material hardpack along the silo wall. The customization of the unloading equipment to the structure it operates in is key to a successful operation. Laidig recently designed a set of eight custom X-Traktor™ reclaimers for an export terminal in Brazil. The massive machines measure 24 metres and are used to reclaim transloaded soybean meal, whole soybeans, and shelled corn in eight different 24m diameter x 34m H concrete silos. The reclaimers deliver the material through a dual discharge auger at a rate of 400–500tph (metric tonnes per hour) before it goes to a conveyor for vessel loadout. Laidig has completed similarly sized projects for other port and terminal facilities in South America, as well as in North America, Europe, and Asia.
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is built to perform with all of the controls external to the silo or dome. The systems are also designed so that maintenance points and service areas can be accessed safely. Storage structures found at ports and terminals are typically very large, which can present unique unloading challenges based on how the material behaves at a given volume. This is another aspect that must be considered when designing an efficient unloading system. With some finer materials that are made up of smaller particles, like meals and powders, this phenomenon can seriously impede material delivery by causing bridging, channel flow, or plugging. For this reason, it’s important to have an aggressive agitation system like a reclaimer that works to prevent the problems from forming in the first place. When flow problems are not prevented, they almost always require manual silo cleanout, which creates process downtime and unwanted expenses. The reclaim system should also be designed for the exact silo in which it will be installed. When material is loaded and
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Laidig Systems, Inc., an automated storage and reclaim system designer and manufacturer based in Mishawaka, Indiana, USA, has seen a marked rise in port facilities interested in upgrading their storage structures and unloading systems. Investing in upgrades not only protects dry bulk material from quality degradation issues, but reduces silo loadout time for ships and barges. The company specifically deals with businesses storing particularly hard-tohandle bulk materials, such as soybean meal and similar products. Decades ago, large quantities of those kinds of materials required manual labour to manage. More recently, Laidig has seen a trend of businesses wishing to completely automate what was once a time-consuming, painstaking, and often dangerous process. Worker and operator safety cannot be ignored when configuring a storage and unloading system. Entering an enclosed storage space is extremely dangerous and should never be considered unless absolutely necessary. All of Laidig’s reclaim systems are designed based on a ‘zeroentry’ philosophy, meaning the technology
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Cambelt advises on important safety tips for entering grain silos Entering a grain silo can be extremely dangerous and even deadly. Every year, countless incidents in the agriculture industry cause serious and fatal injuries to workers. Anyone who plans on entering a grain silo must be aware of the risks involved and take all necessary safety precautions. Here, Cambelt International LLCl provides three important safety tips for entering grain silos to avoid accidents and injuries:
WEAR PERSONAL PROTECTIVE EQUIPMENT When entering a grain silo, it’s crucial to prioritize safety by wearing personal protective equipment (PPE). This gear will protect you from hazards in the silo. Falling into the grain and getting trapped underneath is a serious concern, so wearing a rope and safety harness is essential to avoid such incidents. Wear a respirator approved for toxic dust to prevent any respiratory issues. This is especially important if you encounter moldy silage. Adequate safety gear can ensure you safely navigate the challenges of working inside a grain silo and avoid any accidents or injuries.
LOCKOUT THE CONTROL CIRCUIT One of the most crucial steps in ensuring your safety when entering a grain silo is to lockout the control circuit. Doing so can prevent any grain from entering the silo
while you are inside. Grain can easily shift or flow, and it can threaten your safety if it does so while you are in the silo. Suffocation is a major risk if you become trapped under shifting grain. Taking the time to lockout the control circuit is imperative and can potentially save your life. It’s always better to err on the side of caution.
the silo for potential hazards, such as bridged or hung-up grain. They also inspect the silo’s atmosphere and perform the control circuit lockout. The attendant stays in contact with the entrant and monitors the space for any changing conditions that could pose risks. The entrant performs the work inside the grain silo, follows safety precautions, and communicates with the attendant.
ALWAYS WORK WITH A TEAM Entering a grain silo can be extremely dangerous, so you should never do it alone. Always work with a team to keep everyone safe and address any risks. The team should consist of an entry supervisor, an attendant, and an entrant. The entry supervisor leads the entire entry from beginning to end and inspects
ABOUT CAMBELT INTERNATIONAL LLC With over 60 years of experience in designing quality conveyors, Cambelt provides solutions for its customers’ material handling needs; its high-quality selection of high angle conveying equipment makes it easy to complete operations safely and efficiently.
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Dome Technology completes DomeSilo for Continental Cement
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Continental Cement Co., a Summit Materials company, has built another DomeSilo with Dome Technology, this time at its Davenport, Iowa, USA facility. The DomeSilo can store 125,000 short tons of cement powder, and according to Dome Technology’s records, the structure is among the largest-capacity cement storage facilities in the world, said sales manager Lane Roberts.
CONTINENTAL CEMENT CO., DAVENPORT, IOWA , USA The dome size is a response to demand that’s been building for the past decade. CCC Davenport ran short on storage for many years, resulting in cement being loaded on barges and stored on the river. Over the past decade, CCC has stored significant amounts of cement each year, resulting in substantial demurrage costs. With demand for cement and barge
demurrage costs increasing each year, Summit Materials and Continental Cement were confident that now was the time to invest in larger, more permanent storage. “CCC will reduce its demurrage costs for cement storage on the river and
eliminate the need to curtail production or shut down the plant. This helps to ensure we have sufficient cement to ship coming out of the winter months into the busy spring and summer seasons,” Continental Cement Co. plant manager Shawn Mages said.
Standard Industrie International is an international group specializing in the engineering and manufacture of industrial equipment for the handling, storage and transportation of bulk materials. Its innovative solutions help to improve production performance and efficiency, reduce maintenance costs and risks, and ensure a safer working environment.
Photo 1. Accumulation of material (bran) inside the silo.
Photo 2. AIRCHOC placed to act directly on the stored material.
THE PREVENTIVE SOLUTION : AIRCHOC AIR CANNON
For example, Standard Industrie’s longstanding AIRCHOC® air cannon solution has been helping numerous plants for over 40 years to prevent clogging of the material stored in their silos, and consequently to avoid production stoppages. With a wide range of products (tank capacities from four litres to 400 litres), this preventative system can be adapted to a wide variety of bulk applications. Following a technical audit, AIRCHOC® can be placed in various locations on raw material storage units (sand, flour, wood shavings, peat, straw, mulch, etc.). AIRCHOC® acts preventively on the material, with regular programmed shots. It’s an economical solution that uses only air, and only when the shots are activated. This cleaning solution eliminates material deposits in storage units and material conveyors.
CLEANING SYSTEM
As a curative solution, Standard Industrie
International also offers a complete storage unit cleaning service, which enables the storage capacity of clogged or congested silos or hoppers to be recovered. This service is carried out using the POWERNET and GIRONET (photo 4), guaranteeing safe intervention from the top of the silo. The articulated arm of the GIRONET, which rotates at 360°, eliminates the
ratholing problems. This solution meets stringent safety standards: it avoids the need for any human presence inside silos. The GIRONET intervention will make it possible to increase the capacity of collection in order to avoid supply disruptions. The GIRONET is effective on any type of blockage, product or storage unit. It can be used without stopping
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THE CURATIVE SOLUTION: GIRONET
Photo 3. Cylindrical unit for bran storage, equipped with 4 AIRCHOC air cannons.
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CUSTOMER CASE, FOR EXAMPLE: This animal feed plant has a cylindrical bran storage unit equipped with a rectangular multi-screw unloader (photo 1). In the transition section from round to rectangular above the unloader, bran accumulates regularly until extraction, and therefore production, comes to a complete standstill. (photo 2) Standard Industrie proposed the installation of four AIRCHOC® air cannons on the storage unit (photo 3) and guaranteed that no clogging problems would occur as long as the AIRCHOC® were in service, in accordance with the predetermined location and firing sequence. Since February 2021, AIRCHOC®-- has been working on the silo with good results. The customer is satisfied and has placed an order for a further 12 air cannons for a fourcompartment soy silo.
ENGINEERING & EQUIPMENT
Maintain flow of stored material
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Photo 4. Gironet.
production. Also, declogging with the POWERNET will solve bridging problems through safe breaking down of the clogged material to help it flow more freely. The POWERNET is used before the GIRONET when the storage unit is completely blocked. Idea of the POWERNET is to create a chimney through which the GIRONET will be use to sag down the build-ups. CUSTOMER CASE, FOR EXAMPLE: The customer, a leader in the food industry, had bran stored in two of its silos that had both bridged and did not have flow of material from these silos. The
Photo 5. Before silo cleaning started. Completely bridged.
Photo 6. Bran silo that has been cleaned with the ATEX Gironet application.
customer wanted to clean the silos by removing all the material hanging inside of the silo and regain full silo capacity on both bran silos. The customer had been using cardox with mixed results in terms of performance and safety. The customer heard of the Gironet solution from another plant of the group where Standard Industrie did a similar Powernet/ATEX Gironet intervention, also on a bran silo, and asked if Standard Industrie would be able to clean its bran silos. Standard Industrie conducted a site inspection and agreed that it could help. First, the Powernet was used to penetrate
the bridged material and then the ATEX Gironet was applied to clean the material inside of the silo with brass chains. This was applied to both bran silos, and the customer regained full capacity at the end of the intervention. Both silos were cleaned in seven working days. The customer obtained the results that he expected (Photos 5 & 6). Regardless of the cleaning solution chosen by its customers, Standard Industrie meets the dual challenge of maintaining a high level of maintenance to guarantee production flow, while keeping costs to a minimum.
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Enclosed Eurosilo storage of petcoke at the INA Refinery
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At the INA refinery in Rijeka, Croatia, the construction of a fully enclosed Eurosilo for the storage of petcoke is well under way. EPC Contractor KT, highly specialized in the refining industry, chose the Eurosilo system as a state-of-the-art solution to store the petcoke produced by the new coker unit that is being built at the refinery. Saving space was decisive for KT to choose the Eurosilo, but as always in the petrochemical industry, the high safety standards are unconditional.
VERTICAL STORAGE FITS LIMITED SPACE One of the biggest challenges was to work with the limited space at the fully built-up plant site. By using the vertical storage concept of the Eurosilo, KT was able to position the storage facility on premises, near the new coker unit. The small footprint not only saves KT and end-user INA the huge costs of land reclamation and a logistic infrastructure, but also includes the extra measures to guarantee environmental safety. Compared to storage in storage halls, the Eurosilo system reduces the required ground space
to only 25% for the same amount of petcoke.
BUILD-IN SAFETY SYSTEMS The safety standards in the petrochemical
industry are traditionally high. But the location at the seaside adds a list of further requirements, to meet environmental issues. A number of safety systems ensure compliance with the requirements. The
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system. Contrary to conventional shed storage, the Eurosilo provides automatic blending. As a fuel for the aluminium, steel or cement producing industries, a balanced blend of petcoke ensures constant and controlled combustion.
TRACK RECORD IN PETROCHEMICAL
The infeed of petcoke via the telescopic chute is evenly distributed in layers on top of the stored mass by the rotating screw conveyors.
As a partner for different industries with a great variety of requirements, ESI is accustomed to handling the extensive administration and mandatory paper work for complex projects. This also applies to the petrochemical industry, with the delivery of two petcoke silos in Sohar, Oman for Orpic. Following Orpic’s strong commitment to safety and sustainability, EPC Contractor Larsen & Toubro chose the Eurosilo system. Two Eurosilos of 42,000m3 each, now streamline the logistic flow between the production and the periodic loading of the transport ships at the nearby port. The project received the Best EPC PROJECT AWARD 2017.
BUILDING FUTURE-PROOF STORAGE
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SOLUTIONS
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infeed of the petcoke is fully contained and drops via a telescopic loading chute to the top surface. In this way the dust formation within the facility is minimized. CO and CH4 detection sensors, mounted close to the bulk solids surface, and the related gas monitoring system detect potential risks at an early stage. To ensure a flawless output at the required rate, the silo system is equipped with a double outfeed hopper system that works with vibrating feeders and slide valves to prevent an oxygen flow into the petcoke stored. This way a fully redundant, safe and reliable reclaim rate
can be guaranteed.
NO SEGREGATION Due to the working principle of the Eurosilo, the infeed of petcoke via the telescopic chute is evenly distributed in layers on top of the stored mass by the rotating screw conveyors. This eliminates the problem of segregation into unbalanced layers with either fine grit or larger chunks of petcoke. In reverse, the rotating screw conveyors move the petcoke towards the centre into the core flow that is induced by the outfeed hopper
ESI received the order to provide the state-of-the-art petcoke silo for the INA Refinery from KT in 2021. ESI is now finalizing the civil construction and all mechanical and electronical parts have been designed, produced, tested and delivered. With a worldwide growing demand for aluminium, steel and cement, the need for petcoke for the producing industries is predicted to steadily grow in the coming years. The Eurosilo system and the experienced project management of ESI are ready to meet that growth. Richard Spaargaren, ESI sales director stresses the key value for petcoke producers: “Of course we can draw on our experience with this great project for KT in Croatia and the awarded twin petcoke silos in Oman. But the decisive factor — saving invaluable space at cramped plant sites — applies to all refineries that need to step up to the growing demand for petcoke.” Twin Petcoke silo in Oman.
ENGINEERING & EQUIPMENT www.drycargomag.com SEPTEMBER 2023
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New shipping facility for agricultural products for Port Milwaukee A new shipping facility for agricultural products — expected to generate $63 million in statewide economic impact each year — officially opened in Port Milwaukee, WI. The $40 million Agricultural Maritime Export Facility is one of the first facilities in the Great Lakes-St. Lawrence Seaway to move bulk agricultural exports, including dried distillers grains — a byproduct from beer and ethanol production that is used in livestock feed — through intermodal transportation. Instead of sending products down the Mississippi River, Wisconsin farmers and businesses can now send their products by truck or rail directly to the facility where they will be loaded onto international shipping vessels. DeLong chose Legacy Building Solutions along with Hanson Silo Precast 16' walls for its 120'x580' indoor bunker. A centre reclaim tunnel along with a shiploader is installed on the project. DeLong bought an optional 16'T concrete divider made by Hanson Silo, that is portable pending on the needs of two different bulk grains. The building will hold around 1.5 million bushels of corn and DeLong plans on several turns per year. As shown in the photos Hanson Silo's patented Easy Rake® Silage Facer is used for DDG that bridges up in the covered bunker. Easy Rake is a common safety tool in many bulk storage applications. The DeLong Co. helped develop the new facility, which began construction in 2021 on Jones Island. The public–private partnership is the largest one-time investment in Port Milwaukee since the 1950s. The project was funded by a federal grant from the U.S. Department of Transportation, private funds from The DeLong Company, grants from the Wisconsin Department of Transportation and funds from Port Milwaukee. The AMEF will be used to export an ethanol byproduct, dry distillers grain with solubles (DDGS), to Europe and northern Africa, as well as other agricultural products. It’s the first port on the Great Lakes capable of handling DDGS, which is moisture-laden and poorly suited for shipping containers. DDGS is used as a nutrient-rich feed to supplement animal diets. Hanson is a 104-year old company, in its fourth generation of family ownership and operation. Hanson Silo Company operates five independent business units that provide diverse solutions for end-users and suppliers of grain, feed ingredients, and food ingredients around the globe.
CLIENT NEED Neptune Bulk Terminals (Canada) Ltd.
CHALLENGES CWA was presented with scattered historical maintenance records for the existing storage shed system, representing both quantitative and qualitative data for goods and services executed by the terminal’s in-house labour personnel, as well as outside vendors and contractors. The records, as provided, followed no common structure that could be used as a defined basis for trending future maintenance costs to the level of confidence that NBTL sought.
SOLUTIONS Based on CWA’s expertise and experience, defined categories were established to sort and forecast the historical maintenance events and costs. This included grouping the works by asset and discipline type, and distinguishing between preventative work versus reactive work, and capital work versus non-capital work. Once the data was classified, an analysis was undertaken to identify category-specific trends for maintenance events and activities, and the magnitude of their costs when they occurred. This provided the forecasting basis for annual costs over a ten-year timeline, which also accounted for escalation and inflation.
PROJECT HIGHLIGHTS v Forecast a maintenance programme for an existing 108,000-tonne potash storage-shed system. v Applied CWA’s maintenance engineering expertise to evaluate and classify historical maintenance records to determine meaningful trends and cycles of when maintenance events and costs may be expected to occur.
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Neptune Terminals is a bulk shipping terminal located on the north shore of Burrard Inlet in the Port of Vancouver. The terminal handles potash from Saskatchewan and steelmaking coal from British Columbia and Alberta. Neptune has the capacity to handle over 23.5mt (million tonnes) of bulk products a year. With the completion of terminal and rail improvement projects currently under way, capacity at the terminal will increase to 30mt.
(NBTL) engaged CWA Engineers Inc. (CWA) to forecast the maintenance programme for the existing potash Shed 1 storage system infrastructure (108,000 tonnes), established to a ten-year time horizon. The desired outcomes of the maintenance-programme study were to forecast annual costs along with schedule intervals for the works necessary to facilitate continued safe operations, and to mitigate risks of operational interruptions. These results were then used by NBTL as part of the terminal’s master planning development.
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Forecasting a ten-year maintenance program and cash flow schedule to facilitate asset management decisions for an existing 130,000-tonne potash storage shed system. v Client: Neptune Bulk Terminals (Canada) Ltd. v Services: strategic planning; optimization & reliability v Services: ports & terminals, asset reliability v Location: North Vancouver, British Columbia, Canada
ENGINEERING & EQUIPMENT
CWA Engineers Inc. The Potash Shed 1 System — Predictive Maintenance Program
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v Set up a ten-year maintenance schedule and cash flow schedule. v Provided materials necessary for commercial business case comparisons between keeping the existing storage system or replacing and upgrading the storage system. CWA provides a comprehensive suite of services for every phase of the project life
cycle, from concept development through to commissioning and operations support. The company’s core expertise lies in the planning, optimization, detailed design, and implementation of dry-bulk materials handling systems for port and terminal operations — specifically, the design of conveyors, transfers, bins and hoppers, shiploading and unloading systems, storage and reclaim systems, truck and rail load-out
facilities, as well as truck and rail receiving and unloading facilities. CWA has extensive experience with potash handling and has also worked with most other industrial dry-bulk commodities, providing the firm with a large library of designs, details, models, state-of-the art design tools, and in-house methodologies for the design and optimization of materials DCi handling systems.
Thank you To find out how you can benefit from advertising in the world’s only monthly dry bulk publication contact: Andrew Hucker-Brown on Tel: +27 31 583 4360 Email: info@dc-int.com
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international
ENGINEERING & EQUIPMENT
Transport and storage of grain
improving efficiency with high-tech systems Louise Dodds-Ely
Grain handling in ports and terminals: enhancing efficiency and sustainability with SAMSON Materials Handling
Three primary factors stand out as pivotal in ensuring effective grain storage:
MASTERING THE ELEMENTS — IMPORT/ EXPORT
Grain holds a pivotal place in global commerce due to its inherent ability to withstand storage and transportation with minimal degradation. This trade has historical roots predating modern agricultural practices, and it continues to evolve through technological innovations. The advent of various technologies has revolutionized grain handling, enhancing efficiency and sustainability.
STOCKPILING GRAIN The SAMSON mobile STORMAJOR® presents a groundbreaking solution for stockpiling, barge loading, and railcar loading. Offering a radial outloading boom on a single chassis, it combines versatility with high performance. The unique advantage lies in its mobility, eliminating the need for permanent infrastructure while enabling a wide range
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ESSENTIALS FOR STORAGE
v Temperature: maintaining the right temperature is crucial for preserving grain quality and preventing damage. Different grains require specific temperature standards, which must be meticulously regulated to prevent spoilage. v Moisture: excessive moisture in stored grains can lead to mould growth and pest infestations. Managing moisture levels is imperative to preserve grain integrity and avoid contamination. v Inspections: regular assessments play a vital role in optimizing grain handling quality. Comprehensive inspections encompass the evaluation of both grain stocks and mechanical systems. Identifying and addressing equipment malfunctions, such as fans, is vital to ensure accurate grain handling and storage.
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The global trade in grains is a pivotal component of the world’s food supply chain, with import, export, and storage practices influenced by a multitude of factors, writes Petar Karaivanov, SAMSON Materials Handling. Moisture content, bulk density, combustion risk levels, compositional value, and more play a significant role in determining the best approach to handling grains in ports and terminals. As the demand for grains surges worldwide, the industry is witnessing a proliferation of applications and investments aimed at optimizing these processes. With operational usage often limited throughout the year, innovative solutions such as fast-track mobile equipment are gaining popularity due to their flexibility and potential for higher financial returns.
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ENGINEERING & EQUIPMENT www.drycargomag.com SEPTEMBER 2023
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of material reception methods. This equipment provides the performance of a fixed installation without the associated infrastructure requirements.
shovels. Its above-ground installation eliminates the need for deep pits and costly civil engineering work, providing a flexible alternative to traditional hoppers.
FROM FIELD TO SHIP
DUST IN GRAIN
In regions where grain fields are in proximity to water bodies, mobile shiploaders combined with material feeders streamline the truck-to-ship conveying process. The SAMSON Mobile Shiploader boasts full mobility within ports, accommodating vessels of various sizes. With loading capacities of up to 2,500 tonnes per hour, this solution is tailored to handle diverse materials. Additionally, the Samson® Material Feeder enhances the process, receiving bulk materials from trucks and loading
Handling dusty materials like grain carries inherent risks, including spontaneous combustion. Addressing this challenge, advanced hoppers offer dust extraction and explosion-proof measures. The Eco Hopper is an ecologically responsible solution designed to suit the characteristics of different bulk materials. By incorporating one or more hoppers, terminal throughput can be augmented, aligning with increased capacity in downstream handling systems.
CONCLUSION In the modern landscape of international commodities markets, grain trade assumes a critical role in the dynamics of food systems and pricing. As climate change impacts agricultural policies, grain prices are poised to fluctuate, necessitating enduring and environmentally compliant equipment. The convergence of stringent regulations, technological advancements, and evolving trade demands underpins the evolution of grain handling practices. The emphasis on efficient storage, temperature and moisture control, and cutting-edge equipment innovations are set to shape the future of grain handling in ports and terminals. As industry players respond to these challenges, they contribute to the resilience and sustainability of global food systems.
Professional companies in more than 110 countries worldwide work with Verstegen grabs, because our grabs offer them the highest reliability and best productivity. Combining our extensive knowledge and experience with the feedback from our loyal customers results in optimized grabs for all bulk materials and unloading situations. We call this ‘Grab Intelligence’. Looking for increased reliability and productivity, lower maintenance costs and an extended lifespan? Let us know, because together we can move mountains.
LET’S MOVE MOUNTAINS WWW.VERSTEGEN.NET
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Barge-mounted grain handling with help from Rulmeca
Dos Santos International’s end-user Return sets for sustaining the empty belt in operated its barge mounted the return section. conveyor system for carbon fuel products and wanted to convert the system for handling grain. The client’s end-user operated its barge mounted conveyor system for carbon fuel products and wanted to convert the system for handling grain. Due to the limited geometry of the existing barge, the owner had a choice between a Impact rollers with rubber rings: these consist of bucket elevator or a Dos Santos the basic steel PSV rollers design, on which are Sandwich Belt conveyor. It chose the fitted rings, designed to 84-inch-wide Dos Santos Sandwich Belt resist and system because of its ability to elevate absorb the 2,500stph (short tons per hour) the material over a short distance, and pressure because of the gentleness of conveying, given by the to limit damage to the grain. Because impact of materials onto the belt. the system is in a marine environment and handling food product, the client its idlers for this project. wanted a superior sealing system for the conveyor’s idlers for long lasting reliable SOLUTION service. It therefore contacted Rulmeca for With the ultimate objective that the belt
gently sandwich and convey the material within the geometry restrictions of the conversion, the client chose Rulmeca idlers sets and custom rollers to suit their unique carrying and hold-down frame requirements. Timing of the project dictated supply chain challenges that needed to be overcome, as the initially requested CEMA E7 rolls were not readily available to meet the project schedule. Rulmeca partnered with Dos Santos to design and supply foot spacers to compensate and match the client’s desired belt line, and we were able to substitute CEMA E 6-inch diameter rolls to effectively match the performance needs of the system within the project schedule.
BENEFIT Rulmeca’s PSV sealing system provides superior, long-lasting and reliable sealing of the idler bearings in harsh environments including saltwater port application.
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Upper carrying troughing set: troughing sets used for sustaining the belt on the loaded section and the section where it is loaded with material.
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In the heart of Nivelles, Belgium, a company with over 55 years of experience has been revolutionizing the way bulk products are handled in ports across the globe. VIGAN Engineering S.A., a true pioneer in its field, has risen to become one of the world leaders in designing, manufacturing, and assembling on-site handling equipment for dry bulk products, with a primary focus on agricultural commodities, particularly cereals. Driven by a commitment to excellence and innovation, VIGAN has been instrumental in shaping the landscape of port equipment handling. With a robust history spanning more than half a century, VIGAN has solidified its reputation as a reliable partner for grain handling system or turnkey projects, delivering cutting-edge solutions to create efficient and effective port terminals. With a staggering 99% of its business exported worldwide, VIGAN’s footprint extends across continents and oceans. Boasting a vast installation base of more than 1,500 machines globally, the company’s equipment can be found in ports scattered across every corner of the world. From Europe to Asia, the Americas to Africa, VIGAN’s impact on the bulk handling industry is both extensive and profound. VIGAN’s commitment to excellence is reflected in its diverse range of offerings tailored to meet the unique demands of bulk loading and unloading in ports. The company’s portfolio includes:
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2. Pneumatic and mechanical shipunloaders: a hallmark of VIGAN’s equipment range, unloaders are a common sight in port environments. Available in both fixed and mobile variants, these gantries exhibit a remarkable degree of autonomy, powered by diesel generators or cable reels. Capacities can soar to a staggering 800tph, with mechanical unloaders pushing the boundaries even further, achieving throughputs of up to 1,500tph.
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1. Grain pumps: VIGAN’s compact and mobile grain pumps are designed for swift deployment across different sites. Evolving over the years, these machines have grown increasingly efficient, achieving peak outputs of up to an impressive 250tph (tonnes per hour). These pumps provide an ingenious solution that enables rapid implementation without the need for heavy mechanical investments.
ENGINEERING & EQUIPMENT
VIGAN offers wide portfolio for handling of agricultural products
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ENGINEERING & EQUIPMENT www.drycargomag.com SEPTEMBER 2023
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3. Loaders: VIGAN loaders offer a versatile solution for almost any kind of bulk products. Whether dealing with large or small barges, as well as vessels, VIGAN’s loaders are tailored to fit. The loading is mechanical: cargo can be for instance transported into the loading boom by integrated belt or chain conveyor and discharged by gravity into the ship hold thanks to a telescopic loading chute. VIGAN designs loaders for high volumes. Its primary objective is to minimize the need for equipment and part replacements due to wear. The company’s shiploaders boast capacities of up to 2,000tph for various products. Many layouts are possible, such as fixed/on tyres/on rails gantries, with varying height and width, customized boom length, loading spout type, dust control system, control cabin, static or rotating thrower, and so forth. 4. Terminals: VIGAN capabilities include also complete turnkey projects for port terminal including ship unloading and loading, storage facilities and bagging operations. Throughout the project’s lifecycle, VIGAN upholds a strict, multidisciplinary approach, ensuring seamless coordination and control of all activities to achieve the highest level of customer satisfaction. VIGAN’s unwavering dedication to customer contentment is reflected in its continuous pursuit of addressing evolving requirements. As customer expectations evolve, encompassing enhanced performance, energy efficiency, noise reduction, and simplified maintenance, VIGAN remains steadfast in embracing these challenges and delivering optimal solutions.
STRENGTHS THAT SET VIGAN APART VIGAN’s tremendous success is built on a foundation of strengths that truly set the company apart: v Vertical integration: unlike competitors reliant on a web of subcontractors, VIGAN takes pride in its vertical integration. The company handles everything from complete machine design to manufacturing, assembly, and installation. This level of control ensures impeccable quality and adherence to strict timelines. The same specialized team that assembles and commissions machines overseas also meticulously pre-assembles and tests them in the factory.
Handle bulk with efficiency and reliability Pneumatic and mechanical ship (un)loaders Up to 2500 tph for loaders and up to 1200 tph for unloaders.
Low noise & no dust emission
Turnkey solutions for cereals, soy flour, fertilizer, pellets and more...
ENGINEERING & EQUIPMENT www.drycargomag.com SEPTEMBER 2023
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v Robust technology: VIGAN’s commitment to reliability shines through in its use of robust and proven technology. By selecting standardized components, high-quality materials, and wear-resistant materials, the company ensures longevity and consistent performance, even in the harshest conditions. v Engineering and development: at the forefront of innovation, VIGAN continuously develops cutting-edge solutions that push the boundaries of bulk handling. From multi-stage turbines to turbulence-free round bends, the company’s technological leadership is evident. The incorporation of variable speed drive technology for suction units highlights VIGAN’s dedication to energy efficiency. v Customer services: VIGAN’s commitment to customer satisfaction extends beyond equipment delivery. The company’s after-sales service, seamlessly integrated with spare parts sales, provides flexible solutions. Longlasting components, preventative maintenance programmes, and strategic spare part stocks ensure clients can harness their equipment’s full potential. v Recent innovations: in an era of heightened environmental awareness, VIGAN’s expertise in noise protection is particularly noteworthy. With advanced calculations, studies, and onsite measurements, the company has
pioneered noise protection solutions for turbo sets, machine rooms, and suction pipes. This commitment to minimizing noise pollution further solidifies VIGAN’s reputation as an industry leader in sustainable bulk handling. While energy efficiency and high
performance are integral factors, VIGAN also recognized the need to reduce dust emissions. In an era where industrial estates neighbour residential areas, the company’s adoption of pneumatic suction technology has been a game-changer. The innovative closedcircuit system, featuring overpressure filters, minimizes dust emissions, ensuring a cleaner environment. With emissions often as low as 3mg/m3, VIGAN’s solutions are both effective and environmentally responsible.
CONCLUSION VIGAN Engineering S.A. stands as a beacon of innovation, quality, and reliability in the bulk handling industry. From humble beginnings to a global force, the company’s journey has been characterized by its unwavering commitment to excellence. Through cutting-edge technology, meticulous engineering, and a dedication to meeting customer demands, VIGAN continues to reshape the landscape of port handling. As the world moves toward more sustainable and efficient practices, VIGAN’s role as a pioneer in noise reduction solutions further cements its position as a partner for a greener future in the bulk goods industry.
ENGINEERING & EQUIPMENT
AGI expands portable grain handling manufacturing capabilities to meet growing customer demand throughout the Asia Pacific market
Portable grain handling for APAC: farmers in Australia and New Zealand rely on augers that can withstand tough weather and harvest field conditions. AGI augers are well-known for their high quality, efficiency and, most of all, reliability and durability.
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With demand for portable grain handling Zealand dating back many decades to when also maintains ISO certifications 9001:2008 equipment in Australia and New Zealand the Westfield brand was first introduced to for quality management systems, and ISO growing, Ag Growth International Inc. (AGI) the market,” commented Rustom Mistry, 14001:2004 for environmental manageis expanding its manufacturing capacity at Senior Vice President of the Asia Pacific ment systems. its India-based AGI Bengaluru facilities to region. “For our dealers and growers, More information on AGI’s expansive accommodate production of its flagship enabling more localized supply within the catalogue of farm and commercial storage, AGI Westfield and AGI brands. APAC region means better service and handling, conditioning, and processing “This initiative will increase our shorter lead times. We anticipate these solutions for grain, fertilizer, seed, feed, and manufacturing capabilities in the Asia-Pacific changes to prompt further demand for AGI food industries, is available on the (APAC) region and helps to lay the portable grain handling products company’s website. foundation for ongoing growth,” said Paul throughout the region in 2024 and Householder, AGI President and CEO. beyond.” ABOUT AGI “The successful completion of both the AGI Bengaluru is dedicating a 4,180m2 AGI is a provider of solutions for global product transfer from our Canadian (45,000ft2) production space for portable food infrastructure including seed, fertilizer, facilities and the production ramp-up at our grain handling equipment and features the grain, feed, and food processing systems. AGI Bengaluru facilities ensures that no latest manufacturing technologies including AGI has manufacturing facilities in Canada, matter where in the world your AGI laser cutters, robotic welding, benders, the United States, Brazil, India, France, and equipment is made, you receive the same formers, and advanced painting systems. It Italy and distributes its product globally. excellence in quality, reliability and durability.” AGI is highly respected in the portable grain handling market, with swing-hopper augers and belt conveyors among its top-sellers. The AGI Westfield STX2 and the AGI XTA truck augers will be the first to roll off the lines at AGI Bengaluru. Engineered to withstand tough field conditions, the STX2 and XTA are designed for longevity, fast grain delivery, large capacity, and manoeuvrability. AGI is expanding its manufacturing capacity at its state-of-the-art India-based AGI Bengaluru facilities “Our augers have a longto accommodate production of its flagship AGI Westfield and AGI brands. The goal is to better serve the standing tradition with grain portable grain handling needs of farmers in the APAC region. farmers in Australia and New
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ENGINEERING & EQUIPMENT www.drycargomag.com SEPTEMBER 2023
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Streamlining grain terminals with TBA Group’s CommTrac system Waterside grain terminals are complex facilities handling many product varieties through intricate conveying systems. There are a number of factors that are paramount in operating a successful grain terminal: v Cross contamination: systems need to be put in place to ensure that the risk of contaminating one product with another is reliably mitigated. v Food standards: compliance with international food standards, such as TASCC and AIB. v Traffic management: minimizing turnaround times and scheduling delivery/shipping times as effectively as possible. v Accurate billing: ensuring that customers are accurately invoiced and minimizing lost revenue. CommTrac from TBA Group addresses each of these factors, along with many others, to provide a scalable, robust and feature-rich terminal operating system (TOS). CommTrac is a highly respected and multi-award-winning product, designed to manage all aspects of bulk cargo operations. Developed over the past 20 years, CommTrac is in use in over 40 operations around the world and operates in sectors including coal, breakbulk and fertilizers; however, TBA’s CommTrac team have specific and long-standing experience in grain handling. Traditionally, grain terminals will have an ERP system in place that takes care of commercial inventory, finance and maybe some order processing. They will also have weighing and control systems, but these will be completely separate and lack a centralized system to tie everything together. All too often, this gap will be filled with spreadsheets and manual processes, providing the links between the various systems, but prone to failure and inefficiencies. Without a central hub, we end up with several isolated stakeholders (such as operations, management, finance and the customer) with multiple points of data collection and different IT systems. This inevitably leads to difficulty in obtaining real-time operational data, but it’s also hard to scale and maintain. This is where a terminal operating system (TOS) such as CommTrac comes into its own. By integrating with all of these previously isolated and separate systems, we not only end up with a more efficient and well-managed operation, we also have a ‘single version of the truth’ — a hub of all
the terminal’s information, which enables us to gain better insights, spot problems early and plan for the future. Here are a few specific examples of CommTrac’s functionality and how it can make a real difference in the scenario of a grain terminal: v CommTrac’s inventory management mitigates the risk of cross contamination and maintains product quality and traceability through a robust material handling process. It interfaces into automation systems to control conveying routes through the terminal to give clear visibility of cargo movement and prevent cross contamination. v The Quality Specification Monitor enables the tracking of grain quality specifications by averaging accumulative specifications across a silo to improve blending decisions and create maximum value for the terminal. v The Weighbridge Management module fully integrates with a terminal’s truck and rail weighing systems, improving turnaround times and reducing administration. v Web-based customer access terminal allows customers to log in and view the status of their account and specific shipments, reducing the administration involved in handling these enquiries manually and providing greater accuracy and customer satisfaction. v Real-Time Service and Rental Accrual automatically accrues revenues based on service and storage activities, ensuring more accurate and fully documented invoicing. Alternatives to CommTrac are often developed locally, either in-house or in partnership with local software suppliers. There has long been the perception that the large variation in operational processes necessitated bespoke development, specifically designed to meet the needs of
individual sites. However, software such as CommTrac is highly configurable and can be customized to meet the needs of any type of operation. Furthermore, by selecting an established and mature solution such as CommTrac, terminals also get the benefit of the millions of pounds invested into the product’s development. Such an investment would naturally be difficult to justify for individual ports — TBA has the resources needed to continually invest in the software’s security, functionality and stability, plus the industry expertise to satisfy the hugely variable needs of its customers. One example of how this investment has resulted in real-world benefits is in use of mobile devices. ‘On the ground’ workers cannot work effectively with desktop computers as they need to be in their working environment close to the activity they are performing. Traditionally they might have to resort to paper-based means of documenting events and information, which then need entering digitally later. Similarly, they may have to refer to printed documentation, which may be out of date and difficult to manage. However, if they can receive timely information and record their activities directly into the system, this can greatly enhance their efficiency and that of the whole operation. Software designed for this environment needs to be simple, easy to use with minimal inputs and able to run on a mobile device, such as a smartphone. CommTrac Mobile can be used for a range of use cases, including: v event/delay logging during vessel activities; v tallying of cargo; v work instructions for payloader and forklift drivers; and v scanning of cargo barcodes. To ensure that operations are uninterrupted, CommTrac Mobile
ENGINEERING & EQUIPMENT
seamlessly operates over WiFi, 5G and offline modes, switching between the modes as required. If the app needs to operate in offline mode, it automatically synchronizes with the main system when going back online. In summary, implanting a system such as CommTrac can dramatically improve the effectiveness of a grain terminal. All aspects of operation can be positively impacted, providing a central hub of information, integrating with all stakeholders and maximizing revenue, profitability, compliance and growth potential while reducing risk.
CASE STUDY: SOUTH AFRICAN BULK TERMINALS, PORT OF DURBAN
SEPTEMBER 2023
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SABT owns and operates two world class bulk terminals (DBS and RBT) in the Port of Durban. The RBT terminal at Maydon Wharf 5 (MW5) has a combined silo/flat bin storage capacity of 150,000 tonnes and the DBS terminal located at Island View 3 (IV3) has a silo storage capacity of 70,000 tonnes. As South Africa’s largest bulk grain handler, SABT plays an integral role within the South African economy allowing both import and export cargoes to flow through the Port of Durban efficiently and effectively. SABT, who are also about to embark on a site wide automation upgrade, selected CommTrac based on its industry leading functionality as well as its ability to
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fully integrate into the terminals automation layer. TBA’s engineering experience alongside CommTrac’s functionality provides SABT the ability to eliminate the potential risk of cross contamination by handling all the critical routing decisions within the terminal as well as recording all plant stoppages and events automatically. “We are really looking forward to take our company to the next level with the CommTrac Terminal Management Software,” said Mr Jackie Goodwin, Managing Director of SABT.
Glynn Thomas, Head of CommTrac Sales at TBA Group: “We are delighted and excited to be working with SABT on this project. The enterprise software solution being delivered will allow for the standardization of operational procedures across both locations as well as simplifying their master data from a product, customer and finance perspective. The enterprise solution also enables senior management to quickly report on activities at either a terminal or company level, allowing key decisions to be made in an efficient and timely manner.”
aggrowth.com | +1.605.332.3200
ENGINEERING & EQUIPMENT
Complex system from Schenck Process showcases adaptability in a highly challenging environment
Flat storage is widely used for storing bulk materials, including grain.
LONGEVITY OF MATERIAL STORAGE SOLUTION FROM SCHENCK PROCESS PROVEN IN DEMANDING CIRCUMSTANCES
Storing and safely handling bulk materials such as grain in harbours is a challenging prospect and an area where Schenck Process engineers and supplies a unique solution in the form of its MaxiStore®.
SOLVING STORAGE CHALLENGES IN DEMANDING ENVIRONMENT
A customer, part of the dry bulk commodities industry, wanted a long-term bulk material storage solution within their limited available space at a harbour. They contacted Schenck Process for a solution
that led to the MaxiStore demonstrating its longevity and starting a relationship lasting over 15 years. With restricted space within the port, the customer needed to maximize what was available. A traditional loading system uses a high-level conveyor with a tripper supported from the apex of the building roof. Potentially, it could have made for a costly build and resulted in inefficient material loading. Also, controlling the material positioning across the length of the store could have proved difficult for that system. After establishing that the traditional system wouldn’t solve the customer’s challenges and a more innovative approach
was required, the team at Schenck Process proposed the unique MaxiStore system. Based on the combined advantages of proven Redler en-masse conveyor technology, and an industry-leading approach to the process of store loading, the MaxiStore system used a cranked en-masse chain conveyor within a steel structure to span the building laterally. The machine could move along the length of the store with material fed through the chain conveyor to drop to the floor. It allowed the material to easily be fed to any required storage bay while having the capacity to fill up to the ceiling and along the entire length of the building, optimizing storage volumes www.drycargomag.com SEPTEMBER 2023
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ENGINEERING & EQUIPMENT for any given space. MaxiStore manages the area safely by minimizing dust that can lead to explosions.
MAXISTORE: DURABLE AND FULLY ADAPTABLE SOLUTION TO CUSTOMER NEEDS
SEPTEMBER 2023
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Each MaxiStore system can be specifically designed to meet the customer’s exact needs, no matter how complex. By working with the customer to understand their particular requirements, Schenck Process developed a robust system that optimized the storage volume for their limited store size and maximized profit. The result empowered them to work within their conditions and have a storage system that could operate continuously.
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The MaxiStore system is made to handle large quantities of animal feed, minerals, and other bulk materials at rates up to 1,000 tonnes per hour. It enables the user to maximize their space while providing better and safer material distribution. The MaxiStore was proven to provide the most efficient and flexible filling of dry bulk solid materials throughout a storage building. Schenck Process offers installation and after-sales support — across the entire lifecycle of its process solutions — assuring the longevity of the systems it designs, manufactures and engineers. With over 100 years of experience in mechanical conveying and storage solutions, the
customer benefited from access to a wealth of Schenck Process’s expertise. Maintaining the infrastructure within the harsh marine environment of the port has been crucial to extending the service life of their acquisition, giving them confidence that they had purchased a best-in-industry storage solution. Having a long-term satisfied customer is a testament to the performance of Schenck Process’s solutions and demonstrates the company’s commitment to developing innovative and efficient automated bulk storage solutions. The system was installed 15 years ago is still working 24 hours a day and remains a fundamental part of the customer’s port operation. DCi
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INDEX OF ADVERTISERS Company
Page
Company
Page
AGI
152
JSC “Convir”
61
Agudio / Leitner S.p.A.
47
Kiepe Electric GmbH
66
Alex Stewart International Corporation Ltd
7
Liebherr-MCCtec Rostock GmbH
BEUMER Group GmbH & Co KG
17
Lion Bulk Handling b.v.
101
BossTek
121
Martin Engineering
49
Bulk Storage Inc
133
Materials Handling Engineers Association
96
Cimbria A/S
10
Negrini Srl
149
Cleveland Cascades Ltd
117
Neuero Industrietechnik GmbH
Conductix-Wampfler GmbH
95
ORTS GmbH Maschinenfabrik
CRS – Container Rotation Systems Pty Ltd
3
RULMECA HOLDING S.P.A.
50
DCL, Incorporated
115
ScrapeTec Trading GmbH
69
Den Bakker Dustcrusting Technology b.v.
113
SENNEBOGEN Maschinenfabrik GmbH
Doppelmayr Transport Technology GmbH
39
SIBRE — Siegerland Bremsen GmbH
11
Dunlop Conveyor Belting
59
Starlinger & Co. Gesellschaft m.b.H.
12
EasyFairs Netherlands BV
98
STATEC BINDER GmbH
155
E-Crane Worldwide
9
TAKRAF GmbH
63
ELME Spreader AB
105
TBK Group bv
51
ESI Eurosilo BV
135
Telestack Limited
57
Hägglunds
64
TMPB (Terminal de Multiusos do Poço do Bispo)
37
INTEROCEAN Engenharia & Shipmanagement Ltda.
5
TMSA Tecnologia em Movimentação S/A
55
Inside Front Cover
Back Cover Inside Back Cover
Front Cover
103
Van Beek
67
J & B Grijpers b.v.
151
Verstegen Grijpers BV
141
Jotun A/S
23
Vigan
145
DCi
Italgru S.r.l.
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SHIP LOADER SPECIALIST NEUERO produces the most reliable and high-quality bulk ship loaders worldwide. Environmentally friendly with less dust, less noise and more efficiency | neuero.de/en