Dry Bulk Summer 2021 issue

SUMMER 2021 - VOLUME 6 NUMBER 2

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With powerful cranes handling more than 1,000 tonnes per hour, 24/7, featuring low maintenance highdolor life cycles.

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CONTENTS 03

Comment

04

News

Dust Control

Regional Report 10

Neil Godfrey, Group Commercial Director - Shipping, GAC Group, considers recent activity in the shipping industry and how to implement lessons learned from 2020.

Change Is Happening

Dirk Janssens, VIGAN, Belgium, discusses changing trends around the world and what they could mean for the bulk industry moving forward.

Cover Story 18

27

35

Dust Busters

39

Check Out This Toolbox

Sanjeev Mathur, Bedeschi S.p.A., Italy, explains how the supply chain logistics of coal can be improved through offshore transhipment.

Austin Anderson, Vortex Global, USA, discusses ways to address safety concerns surrounding dust in the workplace.

Greg Bierie, Benetech, USA, discusses how cutting-edge conveyor technologies can improve safety, maintenance, and compliance for dry bulk material transport.

A New House For Dry Bulk

Jan de Wit, Managing Director, European Bulk Services B.V., the Netherlands, details the recent construction of a new covered storage facility in Rotterdam and its journey to operation.

Bagging, Packing & FIBCs

Inspect To Avoid The Unexpected

Dennis Blauser, Marietta Silos, USA, outlines how professional silo inspection and maintenance are fundamental for fiscally and socially responsible silo ownership.

Sounds Of Pure Cleanliness

David Fregez, Standard Industrie International, France, outlines how material losses and dust emissions can be reduced through the addition of conveyor belt accessories.

Storage & Stockyards 42

Bye Bye To Port Bottlenecks

Domes, Silos, Hoppers & Bunkers 23

Keep It On The Conveyor

Calm After The Storm

Shiploading, Unloading & Stevedoring 14

31

James Swindlehurst, Primasonics, UK, explains how acoustic cleaners can help maintain maximum continuous material flow in many industrial processes including silos and hoppers.

47

Access To The Once Unaccessible

50

The Trendiest Trends

53

Tackling The Plastic Problem

Ellie Langdon, Nectar Group Ltd, UK, describes how transport corridors can be opened through the use of quayside bagging.

Jörg Spiekermann, BEUMER Group, Germany, investigates what is on the minds of suppliers and how they react to the various issues in the sector, including digitalisation, recycled materials, and the increasing use of robots.

Sigrid Eder-Ince and Reinhard Lechner, Starlinger & Co. GmbH, Austria, explain why FIBCs made from PET can help boost the circular economy as countries introduce more stringent legislation on plastic.

ON THE COVER

SUMMER 2021 - VOLUME 6 NUMBER 2

In the grain sector, Bedeschi is a manufacturing and project engineering company with a global outlook. On the cover, the shiploader designed, engineered, and installed by Bedeschi for Cargill is a complete preprocessing mobile unit rather than a conventional shiploader, featuring a double track drive over hopper, grains sampling, weighing and scalping. The shiploader is able to load ships up to Panamax size at a capacity of 1000 tph of grain and oilseeds. www.bedeschi.com

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RETROFIT

BY THIELE Replacement of round steel chains with THIELE high-performance central bucket elevator chains www.thiele.de bulkmaterial@thiele.de

BEFORE

AFTER

COMMENT

LYDIA WOELLWARTH EDITOR

W MANAGING EDITOR James Little james.little@drybulkmagazine.com EDITOR Lydia Woellwarth lydia.woellwarth@drybulkmagazine.com EDITORIAL ASSISTANT Sarah Smith sarah.smith@drybulkmagazine.com SENIOR EDITOR Elizabeth Corner elizabeth.corner@drybulkmagazine.com SALES DIRECTOR Rod Hardy rod.hardy@drybulkmagazine.com SALES MANAGER Ryan Freeman ryan.freeman@drybulkmagazine.com PRODUCTION Kyla Waller kyla.waller@drybulkmagazine.com ADMINISTRATION MANAGER Laura White laura.white@drybulkmagazine.com WEBSITE MANAGER Tom Fullerton tom.fullerton@drybulkmagazine.com DIGITAL EVENTS CO-ORDINATOR Louise Cameron louise.cameron@drybulkmagazine.com DIGITAL EDITORIAL ASSISTANT Bella Weetch bella.weetch@drybulkmagazine.com

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hen reeling off aspects of the dry bulk industry, what springs to mind includes the skilled material handling for loading/unloading ships, the technology required at ports to co-ordinate with vessels, the variety of vessel sizes and designs for specific cargoes, the meticulous requirements for storage and silos, etc.

Personally, one of my last considerations would be the actual powering of a vessel and the not-so-sustainable fuels involved, and it seems I am not the only one failing to consider this vital aspect. According to research, the marine shipping sector emits approximately one billion tpy of greenhouse gas emissions. Since marine transport equates to 80% of global trade, decarbonisation of this sector is a must, and emissions can largely be eliminated by shifting away from heavy fuel oil and utilising zero carbon fuels such as hydrogen and ammonia, or low carbon fuels such as LNG. In November 2020, the International Maritime Organization (IMO) agreed to introduce a new technical measure for inservice vessels – called the Energy Efficiency Existing Ship Index (EEXI). Essentially, this measure will require all cargo vessels in operation to limit the amount of carbon dioxide emitted per unit of transport supply.

Assuming the technical measure is adopted this month at the Marine Environment Protection Committee (MEPC), EEXI’s requirements will come into force in 2023.

Not only are regulations such as the EEXI encouraging decarbonisation of the industry, there is also pressure from charterers and banks because of contracts and financing.

The organisation BIMCO has announced that its experts have begun preparing clauses to assist owners and charterers adhere to the upcoming carbon regulations. How the regulation is set to play out, it may see

shipowners having to lower their cargo intake as well as introduce slow speeding measures, all to ensure compliance with the carbon rules. BIMCO’s experts understand that charter party clauses are going to be essential going forwards because it may be the case that some shipowners risk breaching their obligations in performing their voyages under the standard charter party terms.

As mentioned earlier, utilising alternative fuels for marine fuel will be a significant step towards improving the sector’s sustainability.

According to IMO data, bulk carriers and container ships consumed 118 million t of heavy fuel oil-equivalent fuel in 2018 – which represents half of the marine shipping sector’s total fuel consumption. DNV has noted LNG, LPG, methanol, biofuel, and hydrogen as the most favourable alternative fuels for shipping, and this knowledge is prompting positive action throughout the sector. One such example is shipping and transportation company CMA CGM, which has invested deeply in a major programme to use LNG powered vessels. The company notes that LNG is an ideal transition fuel and will help reduce greenhouse gas emissions incrementally until zero carbon fuels get their time in the limelight.

In anticipation for the EEXI’s arrival, news of technologies and design developments to accommodate alternative fuels in dry bulk carriers should become more commonplace.

In fact, as I write this, Newport Shipping has announced it has developed an LNG fuel tank system for Capesize class vessels and received an Approval in Principle to facilitate retrofits on these vessels, which will assist in the universal aim to cut maritime emissions.

It appears that the next two years will be a time for much innovation for the bulk carriers responsible for such a large portion of global trade.

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WORLD NEWS CHINA MAN Energy Solutions to supply engines for EPS new-builds

N

ew Times Shipbuilding Co. Ltd, located in Jiangsu Province, China, has ordered three MAN B&W 6G70ME-GI engines in connection with the construction of three 210 000 DWT bulk carriers for Eastern Pacific (EPS), the Singapore-based shipping company. CSSC-MES Diesel (CMD) will build the engines in China, while Rio Tinto – the metals and mining multinational – will charter the vessels upon their entering service. The contract includes an option for three further vessels.

The new order comes shortly after MAN Energy Solutions received an order for five 6G70ME-GI Mk 10.5 dual-fuel engines in October 2020 in connection with the construction of five 210 000 DWT Newcastlemax bulk carriers, again for EPS,

which will subsequently be chartered to Australian mining giant, BHP, for a period of five years.

Thomas S. Hansen, Head of Promotion and Customer Support, MAN Energy Solutions, said: “The ME-GI engine is now the market standard for large, dual-fuel bulk carriers as the value chain in the segment has further increased its focus on decarbonisation. Here, this mature technology’s negligible methane slip and the inherent potential of alternative fuels, such as LNG, are significant advantages and demonstrate to the industry that viable options for lowering carbon footprints exist. These vessels will be among the cleanest and most efficient in their segment, as well as being IMO 2030-compliant well in advance of the legislation.”

THE NETHERLANDS OBA to further expand its activities through purchase of IGMA

O

BA has announced that it intends to enter into an agreement with Cargill regarding the purchase of the IGMA Bulk Terminal in Amsterdam by OBA. The purchase includes all assets relating to the IGMA terminal, including all loading and unloading equipment such as cranes, weighing towers, grabs, and transport systems. The employees of the IGMA terminal would join the OBA team as part of the transaction. The transaction would enable OBA to further optimise its capacity and become the leading, multifunctional dry bulk terminal operator in the Port of Amsterdam.

OBA and Cargill have already presented the proposed purchase to their respective Works Councils for consultation, and the purchase agreement is planned to be signed once such processes have been completed. Following signing, the transaction is expected to be concluded within a few months.

The purchase of IGMA will not lead to any forced redundancies at OBA and IGMA. Managing Director of OBA Jeroen van der Neut commented: “The purchase of IGMA would enable us to accelerate the transformation of OBA by focusing on agricultural products as an important flow for the future. I look forward to welcoming the workforce of IGMA with their extensive knowledge and expertise – following completion of the transaction – and am 4 . DRY BULK . SUMMER 2021

convinced we will be able to offer our customers an even better service level together.”

Philippa Purser, Group Leader for Cargill’s agricultural supply chain in EMEA, said: “The intended sale of our IGMA dry bulk transhipment terminal in the Port of Amsterdam reflects our efforts to align assets in our portfolio with our business strategy. It’s the right time for Cargill to offer this business and its people further growth opportunity with an organisation that is well equipped and dedicated to this specific industry.”

Koen Overtoom, CEO Port of Amsterdam, added: “This development ties in seamlessly with the strategy of the Port of Amsterdam, in improving the sustainability of the business activities and intensifying land use in the port, and further expanding non-fossil cargo flows.”

OBA has traditionally been focused on the storage and transhipment of coal and agricultural products, and several years ago took key steps towards expanding its diversification in dry bulk goods. By means of this purchase, OBA will further implement the transformation of its activities, by focusing on agricultural products as one of the main flows for the future.

The Cargill Agency and IGMA Parcelling Service (IPS) will continue to serve existing and new IGMA/OBA customers after completion of the deal.

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WORLD NEWS DIARY DATES

GEAPS Exchange 2021 06 - 09 August 2021 Ohio, USA www.geapsexchange.com TOC Europe 07 - 09 September 2021 Rotterdam, the Netherlands www.tocevents-europe.com MINExpo INTERNATIONAL 2021 13 - 15 September 2021 Las Vegas, USA www.minexpo.com Coaltrans Asia 2021 19 - 21 September 2021 Bali, Indonesia https://www.coaltrans.com/events BULKEX21 12 - 13 October 2021 Warwickshire, UK www.mhea.co.uk/event/bulkex21/ ADIPEC 2021 15 - 18 November 2021 Abu Dhabi, United Arab Emirates www.adipec.com/exhibition/ about-the-exhibition AntwerpXL 07 - 09 December 2021 Antwerp, Belgium www.antwerpxl.com SOLIDS & RECYCLING-TECHNIK Dortmund 16 - 17 February 2022 www.solids-dortmund.de Posidonia 2022 06 - 10 June 2022 Athens, Greece www.posidonia-events.com

6 . DRY BULK . SUMMER 2021

THE NETHERLANDS BulkHandlingMaterials.com provides a solution right off the shelf

F

or customers looking for heavy duty mobile equipment to move dry bulk products, BulkHandlingMaterials.com is a new arrival to the bulk handling market, and the company is able to offer proven, flexible machines to meet all needs.

There are many machines available to achieve stockpiling, reclaiming, blending, and shiploading on a limited budget. From mobile link conveyors, mobile radial stackers, and hopper-feeder systems to mobile hoppers and Eco hoppers, the emphasis lies in the use of strong, durable equipment which lasts. There are many configurations and options available, including different wheel and track options, luffing and slewing options, electrical power generation, and hopper in-feed systems.

The systems fit into standard 40 ft freight containers for transport and are fully mobile, either on their own power or using a front end loader or shovel to tow them. The company fully supports the equipment, and can even erect them on site if necessary.

RÉUNION Bedeschi to supply equipment for Albioma’s biomass transition

A

lbioma, an independent renewable energy producer engaged in the energy transition through biomass, photovoltaic, and geothermal energy, established in Metropolitan France, Overseas France, Mauritius, Brazil, and Turkey, has developed a unique partnership with the sugar industry for the use and combustion of bagasse, a fibrous residue from sugar cane, which significantly contributes to the energy autonomy of the French Overseas islands, by burning bagasse in their energy thermal plants during six months of the year (coal used for the other six months).

Albioma has now begun a new major project at its thermal Plant of Bois Rouge in La Réunion, which will have a significant impact on the environment by converting its existing boilers from bagasse and coal to fully green energy combustion. This plant, which produces more than 20% of the island’s electrical power, will fully give up the coal combustion to replace it by biomass combustion by the end of 2023, and will thereby contribute to increase the renewable energy rate of the total energy mix in La Réunion, from 35% to 51%.

Bedeschi is proud to contribute to such an important transition which marks a crucial milestone for environmental safeguarding and will respect the strictest environmental standards (dust emission, noise level, etc.). Bedeschi’s scope of supply involves Albioma installations at the Port of La Réunion, which will allow the unloading and storage of imported wood pellets from vessels. Bedeschi services are realised on a turnkey basis. They include two eco-hoppers, belt conveyors for transporting wood pellets to the domes of 45 000 m3 each, with a flow capacity of 1200 m3/hr. Moreover, Bedeschi will supply underground conveyor systems with a capacity of 1000 m3/hr to load the trucks. This project confirms not only Bedeschi’s long-term engagement in environmental safeguarding but also the high competence of its engineering team. Besides the turnkey systems and installation, Bedeschi will also guarantee continuous and prompt field assistance and maintenance to support Albioma in the realisation of the project.

WORLD NEWS NORWAY Belships ASA acquires Ultramax bulk carrier

B

elships ASA has agreed to acquire a new-building resale financed through a bareboat agreement for 10 years.

The 61 000 DWT Ultramax bulk carrier of Japanese design is expected to be delivered upon completion of construction at a Chinese yard during November 2021 and will be named BELFORCE. The estimated cash breakeven for the vessel upon delivery is approximately US$10 900/d including operational expenses. Belships will pay a sum of US$3.0 million upon signing contract, expected to occur during 2Q21, and which will be financed from available cash. The agreement comes with purchase options significantly below current market values and can be exercised after the third year until the end of the charter. There are no obligations to purchase the vessel. The agreement is conditional upon certain subjects being lifted by the parties involved.

Conclusion is expected within June 2021.

Belships is taking over an existing contract for a brand-new vessel soon ready for delivery whilst the orderbook approaches the lowest levels seen in 30 years. This vessel transaction signals the competitive advantage Belships has in sourcing ship finance. Belships’ fleet continues to increase and improve with only modest cash investments. Japanese-design

Ultramax bulk carriers entering the fleet represent some of the highest quality and lowest fuel consumption vessels available in the market today.

BELFOREST has been fixed for a time charter contract to a global agricultural corporation for approximately one year at a daily rate of US$21 250/d gross. The contract starts running within the end of May 2021.

“This is another step in expanding and developing Belships.

We expect this vessel acquisition to add to the company’s increasingly compelling earnings prospects. Together with the latest time charter contract we believe these agreements will generate outsized returns and contribute to generate distributable income,” said Belships CEO, Lars Christian Skarsgård.

The previously announced sale of BELORIENT has been completed and the vessel has been delivered to its new owners.

Belships has a uniform and modern fleet of bulk carriers well positioned to capitalise on a strong dry bulk market. Five new-buildings are expected to be delivered between August - November 2021, all of which have finance arranged.

MEXICO Bruks Siwertell commissions grain handling shipunloader

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ruks Siwertell has recently completed the commissioning of a Siwertell ST 640-M shipunloader for Puertos Especializados Transnacionales PETRA’s (a subsidiary of Grupo Gramosa) new agri-bulk terminal in Veracruz, Mexico. From the outset, the import facility will be able to offer unmatched grain handling and environmental protection capabilities as a result of proven Siwertell screw-type conveying technology.

Originally ordered in 2018 and delivered fully assembled in 2019, the terminal is now complete and, following operator training, its new shipunloader has been brought online.

Gramosa chose Siwertell technology because it out-performed all other competitor systems during a four-month selection process; particularly the two 600 tph pneumatic systems it was initially considering.

8 . DRY BULK . SUMMER 2021

The analysis showed that a single Siwertell ST 640-M shipunloader would be a more economical solution in the long run. The operating costs comparing two pneumatic unloaders, delivering an equal total capacity, was lower. Also, the Siwertell unloader offered cost savings from reduced berth occupancy as through-ship efficiency was greater.

Furthermore, the quality of grain shipments was also considered.

The new, rail-mounted Siwertell shipunloader is totally enclosed, ensuring a spillage and dust-free operation. It has a continuous rated capacity of 1200 tph and a peak one of 1320 tph, discharging vessels up to 80 000 DWT. The unloader’s seamless flexibility enables it to handle a number of different grains such as corn, soya meal, dried distillers grains (DDG), and canola seeds without any loss of efficiency.

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10 . DRY BULK . SUMMER 2021

after the storm T

Neil Godfrey, Group Commercial Director - Shipping, GAC Group, considers recent activity in the shipping industry and how to implement lessons learned from 2020.

he COVID-19 pandemic has had an immediate and lasting impact on us all. For the global shipping industry, it has been sharply felt with the dry cargo sector becoming caught up in the midst of disruption caused by restrictions against the virus and labour shortages. The impact looks set to echo through to the sector’s short and long-term future.

Disruption to global supply and demand

The pandemic is still negatively affecting global industrial production. Mining activities and raw materials supply chains have been disrupted, global energy demand has slumped leading to commodity trailing, and mining companies are looking to divest carbon-related assets.

This was exacerbated by other factors, such as China’s unofficial ban on imported Australian coal that left several bulk carriers waiting at anchor outside Chinese ports late last year.

As 2Q21 is entered, with the global rollout of vaccines and government initiatives aimed at increasing production coming into play, the outlook for shipping and the global economy is looking more positive. However, the hardlearned lessons that 2020 taught us should not be forgotten.

It was a year that presented the global shipping community with many challenges which demanded a rapid response. The result was a number of extremely valuable and innovative solutions the industry should take forward.

Turbulent start, promising future

No year in GAC’s more than five decades of handling dry bulk commodities and vessels can compare with 2020. Dry bulk is not just reeling from the shock of COVID-19, but also events such as the US-China trade war, tariffs, Asian swine fever, and the Vale dam collapse in Brazil that preceded it.

But it is not all bad news. China’s imposition of bans or restrictions on Australian coal imports signalled a trade shift, with opportunities opening up for cargoes from

alternative suppliers such as the US, South Africa, and Russia. Meanwhile, in India, demand remains strong for now with coal cargoes from South Africa to India continuing to be significant operations for GAC in both countries. Coal movements into India from Australia and China’s imports from South Africa and Indonesia have been driving rates higher. Vietnam is also pulling in thermal coal, and coking coal imports will rise because of increasing steel production.

Meanwhile, China needs iron ore to feed its ambition to remain one of the world’s top steel producers. It continues to import from countries like Australia and India, where China-bound iron ore exports rocketed 88% in 2020.

Records indicate that in 2019, 23.8 million t moved from India to China. In 2020, that figure was 44.8 million t – the most in nine years.

China’s demand for grains also remains buoyant, as evidenced by a recent record-breaking order for 5.8 million t of US corn. The US Department of Agriculture now forecasts that Chinese corn imports between October 2020 and September 2021 will set a new record of approximately 24 million t – up 16.4 million t from the previous 12 months.

GAC operations at both ends of the deal are standing ready to assist vessels in loading and discharging.

In light of renewed optimism and disruption to supply chains, container markets are skyrocketing and equipment is being prioritised for higher-paying cargoes. The surge in container rates will drive more general cargo to be shipped in bulk carriers.

2020 was a tough year for anyone in dry bulk. However, with burgeoning commodity demand looking unlikely to end soon, and after six months of dramatic losses and impairments, the future for bulkers is now looking promising as the markets rebound. Ship agents must be ready to support this growth.

Seafarers: key workers and unsung heroes of the pandemic

In a tough year for shipping, none have had it tougher than the world’s seafarers, whose plight during the pandemic

SUMMER 2021 . DRY BULK . 11

has been recognised as a humanitarian crisis. Thousands have been stranded at sea far beyond the end of their contracts as restrictions or outright bans on disembarkation came into force. Thousands more have been unable to sign on to ships for their tours of duty.

Through its network around the world, GAC has experienced this aspect of the pandemic first-hand and – where possible – has worked to enable crew changes to take place. Nearly 3000 Indian seafarers from Holland America Line, Princess Cruises, and Seabourn ships were reunited with their families after being successfully signed off from their vessels, guided through all COVID-19 procedures, and safely delivered to their hometowns by GAC India.

Elsewhere, GAC agents on the ground have used their local knowledge to assist with the introduction of crew change corridors. Such corridors provide a controlled environment through which crew are disembarked into a dedicated quarantine centre, then taken in COVID-compliant transportation to the airport to fly home.

The push for seafarers to have key worker status to facilitate easier crew changes – which at least 45 IMO member states have now designated to them – could not come soon enough.

GAC has signed the Neptune Declaration calling for urgent action to resolve the crew change crisis. The maritime community must learn from the experience to build a more resilient industry for all involved.

Unlocking the potential of digitalisation in shipping Digitalisation really came to the fore in 2020 as more and more professionals were forced to work remotely. Even the traditionally conservative shipping sector has had to embrace digital solutions, for example with Western Bulk’s state-of-the-art, cloud-based data infrastructure used to inform decision making and simplify work processes in chartering and operations.

Maritime business leaders are now looking to digitalisation to solve the pressing immediate challenges facing the sector and facilitate a safe return to pre-COVID practices.

Figure 1. Considering Asia-Pacific’s crucial strategic position for international trade, the future is looking bright for bulkers in this geography.

12 . DRY BULK . SUMMER 2021

There has been much talk about which digital solutions will offer the greatest practical value. Before getting carried away with grand plans, the shipping industry must focus on getting fundamentals right and create a strong digital culture through thorough training.

GAC is following a four-step process to digital transformation. The first three steps are: initially framing the digital challenge; identifying the solution and focusing investment; and mobilising training to ensure its staff know how to use the new technologies. The last step of the process requires a longer-term drive to sustain the digital transformation over time. Such a transformation can only succeed if it includes measuring and monitoring the use of technology, onboarding customers, and building and maintaining foundational skills. GAC will undertake that through its training arm, the GAC Corporate Academy.

Education about digitalisation must start with those who will use the technology. Only then can the uptake of new digital solutions be accelerated and enable businesses to take full advantage of what they have to offer. Experience has already taught the industry, for example, that greater data sharing between corporations worldwide would have mitigated some of the pandemic’s initial challenges and prevented incorrect and outdated information from wreaking havoc globally.

Cyber security is vital. As the uptake of news tools have grown, so too have opportunities for would-be hackers and digital imposters, as witnessed by several high-profile cyberattacks on large shipping organisations. The sharp increase in attacks and the resulting substantial risk to businesses should sound the alarm and highlight the need to treat the cyber threat as one of the main challenges it faces. Off the shelf security solutions – although simplistic and easy to understand and sell – cannot always solve the problem. More integrated, tailored solutions that go further may therefore be needed.

Calm after the storm

Looking back at the storms the maritime industry has weathered during 2020, the indispensable role of dry bulk shipping in modern life has been underlined. In the months to come, the sector will see a resurgence on the back of growing demand for commodities as consumption rises and raw materials are restocked.

As the world leaves behind the pandemic, the dry bulk sector must take the lessons learned on board to build resilience for the future. The human lesson of concern for seafarers’ wellbeing and status as key workers, in tandem with technological considerations related to the digital transformation of the industry and the vital role cyber security must play, must pave the way through 2021 and beyond.

The Asia-Pacific region is increasingly contributing to the world economy, and the dry bulk sector in the area can expect to achieve even greater traction in the coming months. Considering the Asia-Pacific’s crucial strategic position for international trade, the future is looking bright for bulkers in this geography amid a rebound in the markets.

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happening 14 . DRY BULK . SUMMER 2021

Dirk Janssens, VIGAN, Belgium, discusses changing trends around the world and what they could mean for the bulk industry moving forward.

T

he world is changing fast. Not only changes in climate but also many other things: food habits, the appearance of different ethnicities on continents around the world, the economic situation of many countries, and the economic and strategic leadership amongst countries and continents. As we speak, the world order is changing. COVID-19 seems to have further increased this speed of change by creating an awareness of the strengths and the weaknesses of our world of today. Therefore, countries strive more and more to reduce their dependencies on third parties, especially for their needs in terms of nourishment.

Looking back, there was a time when a lot of wheat was milled in Europe and the flour made there was transported to Africa and other parts of the world for consumption.

Nowadays the largest mills are to be found in Africa, Asia, and Latin America. The countries import wheat by Panamax ships for their own captive use as the milling industry has been concentrating over the last 15 years.

Although one might expect that many countries could opt for food crops that can be grown locally as well, food choices are not necessarily driven by those opportunities. The discovery of fossil fuels over the last 30+ years in many (sub) tropical countries around the

SUMMER 2021 . DRY BULK . 15

world has often motivated farmers to discontinue their activities, going for the fast track – selling their fertile lands for fuel exploitation purposes. As more and more households have both partners with jobs, the time spent on food preparation has reduced tremendously. The popularity of consuming snacks or other kinds of prepared meals is on the rise. This will also further stimulate the transport of the raw materials destined for their preparation.

Third world countries have increased their consumption of white meat, typically poultry meat. From importing fresh meat as the basis, trends now have moved on further to import finished compound feed and even more recently, feed mills have been built all around the world.

Figure 1. Isolation 1.

1. Roof insulation; 2. Inlet/outlet flexible insulation; 3. Complete machine room insulation with perforated plate; 4. Insulated turbines.

The expertise behind grain milling has spread worldwide through the willingness of expats to sell their experience wherever needed. The nutritional secrets in the making of quality feed have also travelled more recently and found their way to very distant parts of the world, whether it is pig or poultry farming. Also, feed produced for fish and shrimp farming has seen double digit growth figures lately. Countries like China, Thailand, Vietnam, and Bangladesh represent big markets for raw materials destined for this industry.

Transport via cargo is on the rise

All of these trends, together with increasing populations, means that the transport of cargo via bulk carriers has gone through the roof in the last decade. In addition, price pressure forces companies to group their purchasing power in order to get the best price deals on their raw materials. In flour milling, as in feed milling, the main cost of the final product is determined by more than 80% of the cost of the raw materials. The only way to stay in the market is to increase the scale of the business in such a way that purchase cost is minimally affected. Bulk transport costs are directly related to the cost of the main raw materials worldwide such as wheat, corn, and soy. In addition, fertilizers and other non-organic cargo are transported via large vessels.

As well as these trends, genetics, farming techniques, and acquired knowledge have generated new world players in terms of agro bulk production. In a short period, Russia went from a generally net wheat importer to the largest single country wheat exporter. Recently, Brazil became an exporter of soybean, soon leaving the US far behind.

One can expect that new genetics and farming techniques will further improve the potential of countries and vast spaces that were not even considered less than 15 years ago. The production capacities and types of crop will of course depend on climate and geographical location. The means that transport of bulk will definitely increase further in the coming years.

Ship design

Figure 2. Isolation 2.

1. Insulated elbows flexible with noise cover; 2. Insulated horizontal pipe; 3. Oversized exhaust silencers; 4. Insulated machine room; 5. Inlet and outlet air silencers; 6. Vertical pipe and suction nozzle, insulated from the inside.

16 . DRY BULK . SUMMER 2021

As ship sizes increase, so does the need for adapted loading and unloading systems. In order to minimise demurrage costs, required unloading and loading capacities are further increasing. Customers demand machines that are easy to use with a low cost-to-use.

Moreover, when raw materials that are destined for the food or feed industry are loaded or unloaded, contamination becomes an issue. The need for closed and dedicated systems is obvious. On top of that, the impact on the environment has to be minimal: noise, dust emissions, and spillage are under severe control in most ports.

When it comes to unloading by pneumatic means, one can easily assume it is by far the way of unloading that meets the requirements of today. VIGAN unloaders consume 0.7 - 0.8 kWh/t unloaded, they have a completely closed suction circuit, the spare part cost equals €0.04/t

discharged, the filters used have permeability that is in line with the most stringent rules. So, it is not about dust being in the air, it is more about dust particles being reduced to a minimum.

Depending on the location, noise emissions are minimised: the turbines are embedded in a noise insulating coating, the cabins are delivered with acoustic panels, and the air exhaust systems are specially built and oriented to have minimal noise impact. Several of VIGAN’s unloaders are operating within urban areas without complaints from the surroundings.

The company’s unloaders also try to keep operators happy by creating a silent environment with agreeable working conditions, PLC steered systems, and cameras that allow minimal efforts for maximum efficiency.

After building unloaders for the most demanding companies, VIGAN states that typically, the energy producing companies that increasingly opt for wood pellets as their firing substrate have given VIGAN a plus for the future. Reliability and safety are amongst the main priorities of those companies that deliver energy to the nation, whether it comes to operating 24/7, operating explosion proof, or being environmentally friendly. VIGAN ranks as a top choice for these clear requirements.

The company has therefore not neglected the implementation of these features into its standard equipment. It feels that customers all around the world have higher expectations when it comes to something

that is often considered a basic handling, however this is not the case.

Unloading a ship means it was loaded somewhere else. As much as requirements can be defined for unloading, the same is true for loading. With one huge difference: loading is facilitated by gravity, unloading is not.

Technology-wise, unloading requires many more different techniques than loading. But the same rules apply when it comes to the environment (dust and noise), efficiency, handling cost, and investment. In addition, specific systems exist to handle sensitive cargo with care, reduce falling speed to avoid dust emissions, and use filters to create pressure in the conveyor tunnels to avoid dust escaping. Also, the unloader needs to travel along the ship holds to reduce total loading time.

Conclusion

It has been thus determined that the complete handling of cargo requires many techniques, machines, and structures: silos, conveyors, elevators, drying systems, mills, vessels, and cleaning systems. Somewhere in between the farm and the fork, VIGAN intervenes, whether it is on a farm, a feed mill, next to a river, or in a port, the company keeps the cargo on the move to its final destination, thereby respecting the quality and shape, the purity, the environment, and the wallets of its customers.

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18 . DRY BULK . SUMMER 2021

TO PORT BOTTLENECKS Sanjeev Mathur, Bedeschi S.p.A., Italy, explains how the supply chain logistics of coal can be improved through offshore transhipment.

T

he coal industry has grown phenomenally over the last two decades. With the rapid industrialisation in China, Korea, Taiwan, India, and other developing countries, the demand for power has steadily increased, thus increasing the coal demand. Not many countries are blessed with deepwater ports but that has not deterred many from becoming the leading coal producing and exporting countries in the world. An example which comes to mind is Indonesia, which, despite not having large ports to support the demands of vast amounts of coal exports, has shown the world that it can still be the world’s largest exporter of coal, as a result of the various offshore transhipment facilities operating in the Indonesian waters today.

The world has recently witnessed a large growth in this niche area of offshore transhipment in recent years. Bedeschi has led from the front by way of innovativeness and has raised the bar of

SUMMER 2021 . DRY BULK . 19

creativity and performance. The array of work undertaken

by Bedeschi in this field is largely impressive, and that is precisely the reason why various discerning clients have selected Bedeschi over alternative players in the field.

The various factors which have contributed to the success of Bedeschi in the field of offshore transhipment include: Acknowledging that client’s requirements are most important.

Innovativeness is the key – how to remain ahead of the competition.

In-house design and production of key components.

Figure 1. Bedeschi floating transfer station (FTS) equipment, Princess Chloe.

Developing long-term relationships with clients.

The first and the foremost requirement is properly understanding the client and the project’s requirements, and then designing the solutions to suit them. The requirements of every project, however minor in nature, are unique for the project and thus the systems must be designed suitably.

Another aspect which helps Bedeschi stay current and innovative in its thinking is having the ability to translate its innovation into workable designs, and then having the capability to put the designs into production. Some of the examples of Bedeschi’s innovations include: curved and rotating delivery chutes on shiploaders to deliver cargo in all parts of the ocean-going vessel's holds; variable speed driven belt feeders for smooth material extraction from hoppers; double shiploaders on transhippers; hoppers with collapsible side walls to reduce crane grabs lifts; software integration between desired delivery flowrate and cargo extraction from hoppers; to name a few.

The aforementioned innovations are able to be implemented because Bedeschi has an in-house design team which works in close co-ordination with the project’s department to execute the ideas into workable designs and then interact with the in-house production facility. At the state-of-the-art production facility, the designs can be fabricated, assembled, and tested before being shipped for installation on board the transhippers.

Variety of transhippers

Over the years Bedeschi has developed several transhippers to handle coal – both for loading and for discharging operations. Depending on the requirements of the project they can be classified into two major types: Floating transfer station (FTS) – smaller devices with two cranes and a combination of cargo handling system.

Floating storage and transfer station (FSTS) – large vessel with four cranes combined with cargo handling system, with storage on board.

Figure 2. Bedeschi FTS for Emco 1, Russia.

Figure 3. Bedeschi floating storage and transfer station (FSTS) River King, Pakistan.

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Solutions in practice

Here, two recent coal transhipment solutions implemented

by Bedeschi are discussed, which essentially elaborate each of the types mentioned previously.

One example of the various solutions implemented by Bedeschi is the FTS Emco I, delivered to Russia as part of Shakshtersk Port to support their client – East Mining – in enhancing their cargo handling capacity to 8 million tpy (Figure 2). The FTS has been fully renovated and has been adapted to cater to the new operational needs by Bedeschi as well as its partners. Emphasis has been laid on the environmental protection, particularly dust emission, to render the system totally ‘green’. The FTS is equipped with two heavy duty Liebherr cranes, which deliver cargo into two hoppers fitted adjacent to the cranes. Each hopper has been fitted with a 1300 tph feeder belt which helps in uniform material extraction and transferring to the belt conveyors. An array of belt conveyors transfer the coal to

a 2500 tph capacity shiploader designed to load vessels up to Panamax size.

Another project commissioned by Bedeschi in 2019 was the FSTS River King (Figure 3). This project has been implemented to cater to the coal import requirements of Hub Power Company, the largest independent power producer of Pakistan. Owing to the draft restriction at Karachi Port, the FSTS has been deployed at the harbour where deep water is available to receive Capesize vessels. The FSTS transfers the coal from the OGVs into barges, which then transport the coal to the port for discharge.

The cargo handling system has been completely designed and produced by Bedeschi based on the requested requirements and functionality of the system for the transhipping of coal.

The cargo handling system comprises of two double receiving hoppers, which receive coal from four sidemounted Liebherr cranes. Each hopper is fitted with variable speed driven feeder belts. The feeder belts act as coal extractors from the hoppers and deliver the coal onto fixed longitudinal belt conveyors leading to a slewing and luffing type loader to deliver the coal into the receiving barges moored alongside at 2500 tph. The system has also been equipped with an automatic sampling device, online weighing scale, and metal detectors. This FSTS is the lifeline of the power plant and is successfully engaged in helping the power plant receive coal for its needs.

These two projects described have been implemented for handling coal – one for loading and the other for discharging. Both are being used to overcome the infrastructural bottlenecks of two different ports. With the implementation of these transhipment systems, both ports are now capable of handling large vessels, thereby eliminating their restrictions. These systems can operate in adverse weather conditions and are fully relocatable.

Furthermore, the systems were implemented under strict time schedules and adhere to stringent environmental norms.

In total, six transhipment solutions for coal have been implemented by Bedeschi for the Indonesian coal industry, and these have been operating successfully: FSTS Mara; FTS Princess Chloe; FTS Vittoria; FTS Zeus; FTS Apollo; and FTS Bulk Celebes.

Summary

Bedeschi remains committed to the development and betterment of the supply chain logistics of coal – whether it is for loading coal at exporting locations or for receiving coal at the destinations. In addition to development of offshore solutions for coal, Bedeschi has also developed several coal handling ports, which are in successful operation in Turkey, Philippines, US, Russia, Colombia, to name a few. For Bedeschi, innovativeness is not a destination but a process, which the company always strives to excel in.

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Dennis Blauser, Marietta Silos, USA, outlines how professional silo inspection and maintenance are fundamental for fiscally and socially responsible silo ownership.

I

n the past, silo engineers and construction experts recommended inspections at least every two to five years.

Yet, without Occupational Safety and Health Administration (OSHA), Health and Safety Executive (HSE), or other safety standard requirements, plant and facility managers would often opt for in-house inspections or skip the process altogether. After a rise in silo failures over recent years, many insurance companies now require silo inspections. Regular silo inspections can help reduce the liability issues that arise after a structural failure.

All silos, regardless of age, stored material, or construction type, must be inspected by a professional specialising in silo construction annually or semi-annually. Though it is important to keep an eye on silos by inspecting key elements regularly, there are too many limitations to in-house inspections to warrant skipping a professional assessment. A professional inspection by a qualified silo engineer or contractor is the only way to ensure a silo remains operational and safe.

A silo inspection includes a thorough examination of the structure to identify current and potential issues. After the inspection is complete, the customer receives a detailed report of findings that outlines all discoveries in order of importance. This allows customers to identify essential repairs easily. Full-service companies provide this findings report, recommended repairs list, and a proposal for the cost of repairs.

Maximising scheduled inspections

While the majority of silos should follow an annual or semiannual inspection programme, there are situations when a more frequent inspection schedule is necessary.

Concrete stave silos designed for industrial storage require frequent inspection. Heavier stored materials like aggregates increase the loads placed on internal components, including

SUMMER 2021 . DRY BULK . 23

walls and cones. This, coupled with pressure or vacuum loading and unloading, all increase the strain on a silo.

With these loads constantly cycling in the silo, it may be difficult for the silo to withstand the stresses; silo failure becomes only a matter of time.

Even silos that were purpose-built for industrial storage can pose serious threats to safety as they age. Many older silos were constructed with outdated design methods, like steel suspended cones, which carry a high failure rate.

When suspended cones collapse, they can cause complete silo failure. While it is true that material can sometimes be recovered and silos can occasionally be repaired after failure, companies often face additional costs from clean-up, possible environmental damage, and liabilities.

Even for newer silos, there are other factors that can result in a more frequent inspection schedule. As a result of extreme weather – including high winds, heavy rain or flooding, other natural disasters, or fires – silos should be inspected before normal operations resume. Though concrete silos are typically able to withstand high winds, steel silos are highly susceptible to failure from wind damage (Figure 2).

A silo that shows signs of new or worsening damage should be inspected as soon as possible. Regularly viewing the silo exterior can help facilities find new or worsening issues that might necessitate earlier or more frequent inspections.

Exterior damage

Cracks — while cracks can seem like a small problem, they are a sure sign of stress. They can also allow moisture into the silo or allow moisture to attack steel reinforcement. When storing clinker, raw or kiln feed, and finished product, moisture prevention is vital.

For silos storing cement, fly ash, and lime, moisture intrusion can lead to hydration of the stored material.

Not only does this degrade product quality, it also causes material build-up, blockages, and material flow issues.

Spalling — spalling of exterior walls can expose reinforcing steel and lead to corrosion of the reinforcement.

Corrosion — galvanised hoops used on stave silos for structural integrity are susceptible to corrosion.

Without proper maintenance and regular inspections, the hoops deteriorate and jeopardise silo wall integrity and risk failure.

Bowing walls — silo walls with visible bowing indicate a serious issue that can lead to wall collapse.

Repurposed agricultural silos commonly experience bowing walls due to the added stresses they face in an industrial application. Bowing walls can also be caused by asymmetric flow that places increased pressure along the wall. This bowing can quickly lead to wall failure and silo collapse.

Hidden issues

Figure 1. The image shows a failing wall on a stave silo.

Figure 2. Damaged hoops on this stave silo led to a structural failure.

24 . DRY BULK . SUMMER 2021

A professional silo engineer can check for issues that are not visible to the untrained eye. In addition to problems located out of sight high up on the silo exterior or rooftop, professionals are also trained to look for internal problems.

Silo roofs

Though silo roofs often house equipment used to operate the bulk storage system, they are easy to overlook when it comes to preventive maintenance. They must be constructed to withstand the equipment load, vibration from loading and unloading, environmental extremes, and light foot traffic. While cracking and peeling of rooftop coatings can be easy to spot, membrane coatings may allow water into the silo even when they appear unscathed. Because membrane coatings do not bond directly to the silo surface, a small pinhole leak can allow moisture between the barrier and across the entire silo roof causing unseen damage, including corrosion of metal silo components and stored material hydration. Stored cement and lime are particularly susceptible to hydration.

Beyond causing product degradation, hydration causes the stored product to expand, which increases pressure on silo walls. It also causes material build-up, leading to

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production. If this is not addressed early, it can increase pressure on silo walls and cause bowing and structural failure. It is important to understand the particulars of silo design to identify causes of material flow issues correctly. When material build-up is the suspected cause of material flow issues, it is essential to schedule a professional cleaning and inspection. Using inexperienced workers to attempt to address blockages or build-up is extremely dangerous and can lead to injury and death.

Crack migration

Without the proper experience and technology, it can be difficult to map the changes in cracks, spalling, and other signs of silo damage.

Figure 3. This image shows a silo with a wall failure that resulted from a failed suspended cone. material flow issues that further increase silo wall pressure and the chance of structural failure. Silo roofs that show signs of ponding or pooling water can indicate possible structural problems that should be addressed immediately.

Roof beams and pockets

The roof slab is supported by internal roof beams that rest inside beam pockets. These components must be regularly inspected and properly maintained to prevent roof collapse. Spalling concrete around the beam pocket indicates a weakening of the concrete. If this continues, the pocket will no longer be able to support the roof beam, leading to collapse.

Cones

Professional silo inspections include an examination of the silo cone as it impacts the performance and safety of the silo. Inspectors look for signs of rust, weld quality, check cone thickness, and ensure the design complies with current best practices. Inspections of silos that have suspended cone designs will include this as a finding.

When an experienced, full-service company conducts the inspection, the repair proposal will include the necessary remediation to bring the silo up to best practices and ensure safe operation.

Delamination of silo walls

Though concrete spalling can be a clear sign of silo damage, delamination of the concrete’s interior layers is not always visible. The delaminated, unbonded layers and loss of bond to reinforcement steel of the concrete walls reduce the structural integrity of the silo. Experienced silo engineers use a hammer to check for delamination through concrete sounding.

Material flow issues

Issues with the material flow can arise due to improper design for the stored materials or as a result of material build-up. A sure sign of material flow issues is decreased

26 . DRY BULK . SUMMER 2021

Conclusion

Regular, professional silo inspection and maintenance is a requirement of fiscally and socially responsible silo ownership. Unexpected silo failure has caused numerous operations to close their doors due to halted production and resulted in injury and loss of life. As more stories of silo failure, injuries, or fatalities are reported in the news, silo owners and the general public have become more aware of the possible dangers that ageing, unmaintained silos pose. Ageing silos, repurposed agricultural silos, and those designed with suspended cones need to be inspected more frequently to ensure structural integrity.

Regular, professional inspections by a firm specialising in silo construction or engineering are the most effective way to find potential problems early. Fixing problems quickly, before they become an emergency, helps save money and can reduce or eliminate safety issues. The long-term savings, reduced liability, and reduction of unplanned downtime that results from professional silo inspections should be seen as an investment. It is far cheaper to address issues early on than to address a silo failure. Between regularly scheduled professional inspections, facilities should observe the silo exterior for any obvious signs of damage. This will help determine if the schedule needs to be revised to include more frequent inspections.

While silo inspections help uncover issues, regular repairs and preventive maintenance are the only way to remediate and prevent problems like structural failure.

Facilities must follow through with recommended repairs to prevent failures due to inadequate maintenance.

Important silo maintenance includes airflow unit inspection and regular, professional silo cleaning to avoid material build-up issues. Though silos that are regularly emptied and refilled do not experience as many problems as silos that are kept topped off, it is still important to set a regular cleaning schedule. Sticking to a schedule also allows facilities to plan for silo cleaning during less busy times in the production schedule and avoid unplanned downtime. By scheduling a silo cleaning simultaneously with a silo inspection, facilities can save money and ensure they receive the most thorough examination of the silo interior.

James Swindlehurst, Primasonics, UK, explains how acoustic cleaners can help maintain maximum continuous material flow in many industrial processes including silos and hoppers.

A

coustic cleaners are widely employed wherever ash, dust, and powders are generated, processed, stored, or transported. Primasonics acoustic cleaning systems ranging from 60 - 420 Hz in fundamental frequency have been beneficial in both preventing material hang-ups and maintaining maximum continuous material flow in a range of industrial processes including silos and hoppers. Indeed, some of Primasonics’ most challenging but successful applications have been within silos which

contained dry materials such as cement, carbon black, and fly ash, to name a few common examples. It is important to understand several main advantages that acoustic cleaners have over the alternative cleaning and material handling methods which have been employed to try and aid material flow.

Primasonics’ acoustic cleaners operate at fundamental frequencies much higher than the natural frequency of the silo construction, thus

SUMMER 2021 . DRY BULK . 27

Figure 1. Twin PAS75 on a silo.

preventing resonance leading to vibrational/structural damage. Instead, sound at an extreme sound pressure level is focussed into the bulk material directly, which is used to break the adhesive and cohesive bonds between the bulk material particles and the walls of the application. This is quite unlike vibrators which by their very nature and method of installation cause vibration and stress weaknesses within the vessel or structure to which they are attached. The vibration resonances from the vibrators first have to pass through the vessel wall before reaching the material. With the acoustic cleaner the sound is not used to ‘drive’ the vessel, with 100% of the sound energy focussed into the material itself.

Air cannons/blasters seek to provide a very localised cure for a blockage problem which has already occurred. In many cases the air cannon simply ‘blows’ a localised hole through the blockage, necessitating the installation of many air cannons within the general problem area. This differs from acoustic cleaning as the problem is approached with an entirely different philosophy – by preventing the build-up from occurring in the first place.

Primasonics’ audiosonic acoustic cleaners aid material flow from hopper and silos in industries including, but not limited to, cement, gypsum, carbon black, MDF and other wood products, chemicals, food, pharmaceutical, and power generation plants. The cleaners are also employed in a range of ancillary plant such as baghouse filters, cyclones, ID fans, ductwork, as well as extreme temperature boiler applications for steam/power generation plants.

How does the cleaning process work in silos and hoppers?

Figure 2. Twin PAS75 on a 6000 t cement silo in Haiti.

Figure 3. PAS350 housed within mounting tube for bridging hopper.

28 . DRY BULK . SUMMER 2021

Primasonics’ audiosonic acoustic cleaners have been designed to be simple in their operation, requiring only normal plant compressed air for their initial energy source. Compressed air enters the wave generator and forces the only moving part, the ultra-high-grade titanium diaphragm, to reverberate very rapidly within its specially designed housing. These rapid reverberations set up the standing sound waves which are then amplified from the base tone to the selected key fundamental frequency set by the bell section itself. The current range of models produce set fundamental frequencies between 60 - 420 Hz. Irrespective as to whether the bulk storage facility is under 500 kg or over 10 000 t capacity, Primasonics’ audiosonic acoustic cleaners can be used to eliminate the three key problems that occur in silos.

The first of these is ‘bridging’, which is caused when the design of the conical section has insufficient angle of repose, side walls with excessive frictional properties, or an insufficiently sized outlet for the material being contained. Consequently, these problems can become severe if a silo is used for materials different to those it was designed for, either through process or plant layout changes over time.

To combat bridging, an acoustic cleaner is mounted close to the outlet just underneath where the bridge is known to typically form. When the unit sounds, single particles and clusters of particles move at different speeds, therefore causing the bridge to collapse and material flow restored. Once the acoustic cleaner has ceased to sound new bridges will begin to form.

To counter this, the sounding may be controlled in one of two ways, either simply on a timer device typically set for a few seconds every 5 - 10 min. during material discharge only, or alternatively it can be controlled automatically via a flow sensor downstream of the outlet or even from load cells.

The next problem associated with material build-up in silos is ‘ratholing’ or ‘funnel flow’ which, as the name suggests, is material adhering to the side walls causing reduced working capacity within the silo itself. This usually occurs with material that displays mechanical interlocking properties or very quickly bonds without compaction, for example by means of solvent evaporation. To defeat ratholing, acoustic cleaners with a long wavelength are placed on the top of the silo – usually through an available existing manhole or inspection hatch. If there is a large amount of hardened material that has built up over an extended period of time then the silo should be cleaned offline prior to the installation, using a cleaning method such as the GyroWhip system. This is because if an acoustic cleaner were to be sounded in a silo with these thick hardened

build-ups, and the adhesion forces between particles were greater than those between the side walls of the silo, there may be a chance that the material be dislodged in slabs and cause an obstruction to the outlet. This is due to the power of the low frequency acoustic cleaners which continue to sound their transmission through the bulk material until the reflective surface of the silo is reached.

If considering a full silo which is prone to ratholing being slowly discharged and emptied, the central core of the material can be imagined lowering a small amount, while an outer ring close to the side walls remain at the same height. Without acoustic cleaning this process would continue until eventually the central core was discharged and the outer ring was left adhering to the side walls. The control engineer must determine whether to remove the silo from active process lines while offline cleaning takes place, or to refill the silo and risk lower control over the quality of product as older adhered material mixes with new material entering.

When using acoustic cleaners, once the central core has lowered slightly, the cleaner will sound and the bonds holding the outer ring of material will collapse.

This will form a flat surface along the top of the material in the silo. This pattern is repeated as the silo empties, even if the silo refills before complete discharge has taken place. This now allows a first in, first out mass flow pattern. Again, the acoustic cleaner

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can be controlled by a simple solenoid valve and timer arrangement or via PLC of central DCS system.

The third area in silos and hoppers where acoustic cleaners can be employed is preventing material batch cross contamination. Considering the example of a weigh hopper, sometimes not all material is discharged before the next batch enters. This can lead to product contamination, which can in turn lead to quality control

problems. The reasons for material failing to discharge from hoppers are similar to those already mentioned, but in weigh hoppers or similar batch filled vessels, an additional problem occurs. Material can make contact with cold side walls and moisture precipitates from the bulk material onto the side wall. This moisture forms a meniscus between the side wall and the particles which holds the powder in place so that even after discharge, a thin layer of powder remains. In this instance, the acoustic cleaner is activated when the bin is being emptied, the alternate compressive and rarefactional forces break the surface tension of the moisture and allow this material to flow out, leaving the vessel to completely empty.

Case study

Figure 4. PAS420 mounted at hopper outlet to prevent bridging.

A company involved in the production of carbon black additives was finding it concerning that employees had to enter the inside of a tank to remove the carbon black on the bottom shell of the silo. One of the company’s sites in Hungary has already installed the Primasonics acoustic cleaner model PAS60, thus the plant in question in a different country was also interested in following suit.

The previous cleaning routine carried out by the company involved outside hammering and also manual entry of the silo for cleaning with a scraper.

By implementing one of Primasonics’ acoustic cleaners, the company is able to save on cleaning costs, equating to an annual saving of US$45 000.

Furthermore, employees are no longer required to enter the silo for manual cleaning, which is hugely beneficial to the company.

The system

Figure 5. Workers in Mumbai, India, at a cement plant.

30 . DRY BULK . SUMMER 2021

Acoustic cleaners are very easy and simple to install by either using Primasonics’ standard connecting flange, mounting tube assembly, or custom mounting arrangements designed specifically to suit the application. The fundamental frequency and therefore model required along with the quantity are determined on a case-by-case basis, dependent on a number of factors and parameters within the application itself. A dimensional drawing outlining each elevation of the application, along with a specific questionnaire, are requested prior to being able to quote. The possible mounting positions are also taken into account in being able to calculate the unit(s) required for effective coverage.

The acoustic cleaning systems are extremely low maintenance with the only consumable part being an aerospace specification titanium diaphragm, which should provide a minimum of two years of uninterrupted service before requiring replacement.

This is then a simple and short task taking approximately 10 min. to remove and replace, and can usually be undertaken while the system remains online with acoustic cleaner isolated.

Figure 1. Lafarge waste conveyor with LIFTUBE® to supply the kiln.

David Fregez, Standard Industrie International, France, outlines how material losses and dust emissions can be reduced through the addition of conveyor belt accessories.

O

ptimising production tools can enable a reduction of atmospheric emissions, improved visibility, staff safety, and reduced maintenance costs. Standard Industrie International has been a specialist in the design and manufacture of solutions aiming to facilitate the handling of bulk products by combining safety and respect for the environment, thus this article outlines several of the company’s solutions regarding dust control.

Reducing material losses and dust emissions

The LIFTUBE® is a solution from Standard Industrie that is designed to optimise the sealing of any conveyor belt – smooth or cleats, rubber or PVC, vulcanised hot or cold. It comes as a replacement to stations equipped with three rollers on the conventional conveyors. These are standard 1 m modules that are scalable and easy to install on all or part of a

SUMMER 2021 . DRY BULK . 31

new or existing conveyor, while keeping the belt, chassis, and motorisation of origin. It is installed between the point of loading and unloading. Available in widths from 500 - 1400 mm, and in high temperature, explosive, or self-extinguishing versions, the LIFTUBE is designed to avoid any contamination of the product transported with the outside environment. This seal-proof system enables simple tilting of the glide boards and the central roller for easy and minimal maintenance. As a result of its pinch point protection, the LIFTUBE aims to significantly improve the working conditions for the operators.

Installation 1: Cement plant in Mexico

Standard Industrie was contacted by a leading cement manufacturer in Mexico, where the plan was to improve one existing conveyor in the plant and to replace the 600 mm conveyor belt with an 800 mm belt – with the whole system upgraded with LIFTUB2-800 (Figure 1).

The cement manufacturer was looking for a solution that would also be combined with a drastic reduction in the plant’s fuel consumption. In order to reduce the average yearly energy costs, the target has been set to reduce the traditional fuel used, such as coal, to AFR – fluff fuel such as shredded plastics and cardboard.

Figure 2. Platinum plant without LIFTUBE – a conveyor of fine density materials causing volatile dust emissions, material spillage, and need for cleaning.

Opting for these new fuel types meant that the conveying system needed to be largely redesigned. AFR material – for instance, tiny plastic particles – needs to be conveyed in a totally sealed system because wind or any turbulent weather conditions have the potential to blow these particles away, thus impacting the immediate environment. The product density is very low at 0.3 - 0.5 t/m3, with moisture of 5 - 20% and high risks of toxicity and inflammability of the AFR. Last but not least, the belt needs to run around the clock, regardless of the slow velocity of the belt at 1 m/s.

LIFTUBE was found to be the solution most adaptable to the necessary requirements. Since its design offers complete sealing, AFR is thus entirely enclosed and contained in the conveyor. After a study was conducted on-site, several visits to the plant and a comprehensive adapted design solution of LIFTUBE was offered. Standard Industrie Mexico co-operated with the customer’s installation company and all details for energy consumption, design of tumblers and hooding, and 136 m of LIFTUBE were delivered. The installation was a success, and the cement manufacturer is already reaping the benefits.

Installation 2: Platinum factory in South Africa

Standard Industrie’s customer was facing a loss of 2 - 3 tpd of material on its mill feeding conveyor. This required putting in place significant resources in terms of cleaning: between four to six hours of cleaning per day was carried out by four to six workers. The extent of this cleaning meant that considerable time and money was wasted, as well as disruption to the production process.

To solve this problem, 30 m of LIFTUBE has been installed at the platinum factory, with a belt width of 900 mm to fit the dimensions of the conveyor. An inspection hatch has also been installed on one of the covers so that the customer can easily control the routing of the product to the mill.

The customer has regained its productivity and the routine daily cleaning cancelled, replaced instead by a routine maintenance check and a monthly planned quick cleaning campaign.

Installation 3: Limestone quarry in Switzerland

Figure 3. Platinum plant with LIFTUBE. Conveyor sealing: no overflow of material or dust emission, easy maintenance, and reduced cleaning costs.

32 . DRY BULK . SUMMER 2021

At a limestone quarry, the operator wanted to integrate the LIFTUBE solution and a dust collector in its new installation project – which included conveyors, an impactor, and crusher (Figure 4). The size of the conveyor equipped with LIFTUBE is 27 m, with a belt width of 800 mm, a hopper cover, and a dust collector. The conveyor is located just below the crusher, which creates a dusty air stream between the feed hopper and the chute.

The speed of the belt pulls this charged air into the conveyor and can create dust emissions at the outlet. To solve the problem, there are several solutions, including: installation of decompression boxes; fogging; vacuuming; and dust removal. This latter solution, dust removal, was chosen by the customer as being the most compact and economical.

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Fixed on only 2 m of the industrial solution, the dust collector is installed after the last chute, capturing the suspended particles due to the vacuum created by the fan.

The multi-pocket filter retains these particles, which then fall back by gravity onto the belt during the automatic cleaning cycles. Standard Industrie’s solution is also suitable for flammable and explosion-prone products, while also meeting various European and international standards.

Conveyor belt accessories

The patented LIFTUBE and the dust collector are accessories for conveyor belts. The dust collector has been developed to increase the containment effect of the material and to minimise dust emissions.

The LIFTUBE system enables the belt to run on a central horizontal tilting roller and to slide on the edges, which also tilt.

A removable hood can be adapted to the equipment to reduce belt conveyor dust emissions. Only the size of the hood and the central horizontal roller depends on the width of the conveyor. The conveyor belt and rollers can be easily accessed as a result of innovative tilting legs.

Belt width: From 500 - 1600 mm.

Belt speed: From 0.05 - 5 m/s.

Output: Up to 1500 tph.

Particle size: Up to 500 mm.

Density: Up to 4.

Product temperature: Up to 300˚C. Modules: Standard and evolutive.

Installation: Suitable for both new or existing conveyors.

Vacuum cleaning machines

Figure 4. LIFTUBE solution with a dust collector.

To meet its clients’ industrial cleaning requirements, Standard Industrie also offers a complete range of equipment and vehicles that combine safety and performance. All industrial vacuuming problems can be covered by the company’s vacuum vehicles to mobile vacuum units.

Example

Figure 5. The patented LIFTUBE system for the conveyor belt.

An integrated cement plant and all its surroundings (bagging, tunnels, conveyor belts, cement grinding, and coal workshop) require a huge demand on cleaning to make sure the whole facility is kept at an acceptable cleaning level. The plant was already equipped with Standard Industrie’s AIRCHOC® WIRELESS. This time, the cement producer turned to Standard Industrie International which supplied several vacuum machines and purchased a UMA3000DMX (Figure 6).

The UMA was determined to be the best solution to tackle the difficulties and constraints associated with a heavy vehicle. Powerful, mobile, and adaptable, the UMA is equipped with explosion vents. It can therefore vacuum coal and petcoke. The older equipment on site could not tackle this need. Standard Industrie International was also responsible for the installation of a fixed pipe network in the bagging area. The nine suction inlets of the network made it possible to optimise the cleaning of three existing buildings.

These innovative and reliable solutions proposed by the design office of Standard Industrie International have been adopted by many plants of bulk industry, worldwide.

Conclusion

Figure 6. The vacuum cleaner on the trailer enables cleaning operations to be carried out as well as heavy pumping – offering a large scope of cleaning possibilities.

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Dust collection is an important issue for factories. Especially in certain sectors of activity where health and safety standards are developing, as has recently been seen with the risks linked to the propagation of crystalline silica dust.

Standard Industrie International assists its bulk customers in finding the best solutions for the safe storage, transport, and collection of materials.

M

Austin Anderson, Vortex Global, USA, discusses ways to address safety concerns surrounding dust in the workplace.

aterial dusting and equipment leakage plague factories across the globe. The hazards generated by dust increase the risk of explosion, material waste, and loss of profit. The rogue dust also imposes potential health and safety concerns for employees and environmental consequences for nearby communities and ecosystems.

Employees of manufacturing plants and factories face potential exposure to these hazards on a daily basis. In recent years, these facilities have faced tighter regulations and restrictions by federal and local agencies to protect their employees and prevent environmental pollution.

Common issues faced by employees in dust-ridden environments include irritated skin due to allergic reaction, irritation of the lungs due to inhalation of potentially toxic materials, and slips, trips, and falls due to dust accumulation on surfaces. Fugitive dusts can also

accumulate to form a dust cloud that can ignite, burn, and in some instances, explode.

Employee and plant safety are key components in dust control. In many applications, dust-tight valves can help mitigate some of these concerns by drastically reducing the percentage of fugitive dusts.

Dust-tight valves can help facilities mitigate potentially detrimental effects simply by the way they are designed.

Dust migrates through the path of least resistance. This can be a challenge when using soft polymers and packing as seals. Many dust-tight valves designed today feature hard polymers as a sealing surface, because they tend to offer better wear characteristics for most applications.

When replacing a regular valve with a dust-tight valve, it is important to verify that the connections between the valve and what sits above and below are tight. For example, transition flanges need to be true and flat, with

SUMMER 2021 . DRY BULK . 35

no bow, and gaskets need to be inspected and replaced if necessary. Keeping a good seal on every connection, minimising the escape of dust from process equipment, and inspecting and cleaning dust residues at regular intervals are all part of a robust dust control safety plan.

Dust control

Vortex designs slide gates, diverter valves, and loading spouts specifically to address material leakage and dusting concerns. Facilities have an ethical obligation to protect against the hazards of manufacturing. Vortex closely studies trends in air quality, environmental dust emissions, workplace safety, and evolving regulations, and develops its components to comply and address these concerns.

The patented sealing technology in Vortex products has evolved over four decades and is utilised in manufacturing processes across the world. Vortex utilises hard polymer seals in its products with a strategically placed compressed rubber backing to decompress as the polymer wears, making the seals compensate for wear.

This applies constant force against the blade, creating a positive seal of fine dust and powders and keeping factories clean with minimal maintenance over time.

The fundamental difference between Vortex’s designs from typical slide or knife gates is that Vortex valves are designed specifically for handling dry materials. Many valves used in dry bulk processing utilise soft elastomers to create the seal between the internal process and the factory atmosphere. When handling dry materials, these valves suffer from major sealing problems as material wears through the seals on every actuation.

Over the past 40 years, Vortex has provided dust-free solutions to customers in a variety of industries where dusting and material leakage is a concern, including the cement, chemical, food and beverage, milling, and mining and minerals industries. While each industry has its unique challenges when it comes to dust, the principles used to develop Vortex products can be applied in a variety of applications.

Case study 1: fine metal dust

A manufacturer of welded steel pipe contacted Vortex to solve a problem with material leakage onto their factory floor, which was creating safety concerns within the workplace. The challenge was to source a lightweight valve that could maintain a positive seal under full vacuum.

Application

In this application, seven Vortex Orifice Gates were sourced to incorporate into the manufacturer’s dust collection system to solve the problem of fine metal dust leakage onto the factory floor.

Features and results

Figure 1. Vortex Orifice Gate incorporated into a manufacturer’s dust collection system.

When the plant manager was instructed to improve the air quality within the facility, he knew the first areas that needed to be addressed were the seven individual stations where the manufactured pipes were cut to length. The fine metal dust created by the cut-off saws became suspended in the air and migrated into every corner of the plant.

A Vortex sales representative suggested that a Vortex Orifice Gate could be installed on each station to isolate them. The slide gates were capable of sealing the differential pressure involved and could be equipped with

Figure 2. Vortex Titan Slide Gates sourced by steel producer to dispense material into containers.

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Application

Five Vortex Titan Slide Gates were sourced to solve this producer’s access problems when dispensing material into containers for future recycling.

Features and results

This producer utilises electric arc furnaces to melt scrap steel. The melt is then poured to form carbon steel bar, which is marketed to industries across the globe. The original gates located at the bottom of the collection bins were pneumatically operated and did not seal material well. This allowed the material to escape to the atmosphere. Air lines would freeze up in the winter time and eventually the gates quit working altogether.

Due to the success they experienced with other Vortex gates and diverters, the producer ordered five special Titan Slide Gates manufactured to match the size of the bin openings. The gates were ordered with 460 V, three-phase electric actuators to eliminate any future issues with winter weather.

In a follow-up visit to the facility, the production and maintenance managers commented that “We should have replaced those gates a long time ago. The Vortex gates work well, contain the material, and have already provided big savings with our labour costs.”

Case study 3: Handling corn

A hybrid seed producer required a solution for the loading of materials at their new hybrid corn railcar loadout station. When developing the new loadout station, the client’s primary concerns were loading efficiency and dust management, in order to address workplace and environmental health and safety best practices.

Application

A Vortex Loading Spout was sourced as part of a dustless loading system to handle corn in this client’s process.

Figure 3. Vortex Loading Spout utilised by hybrid seed producer for the loading of corn. a solenoid valve to open and close the gate in conjunction with the use of the cut-off saw. When the cut-off saw was not being used, the valve was closed and the demand on the industrial vacuum was greatly relieved.

At the representative's suggestion, hoods were fabricated to collect the fine metal dust around the cut-off area, the industrial vacuum and hoses were placed, and the Vortex valves were installed. The result of the project was a significant improvement in the plant environment.

Case study 2: furnace dust

A steel producer required new slide gates to replace existing slide gates in their process to handle electric arc furnace dust and slag. The existing slide gates were very difficult to access and actuate and did not seal material well, leading to material leakage within the facility and into the atmosphere.

38 . DRY BULK . SUMMER 2021

Features and results

In addition to the Vortex Loading Spout, the client also sourced Vortex Aggregate Gates, Vortex Maintenance Gates, and Vortex Roller Gates as part of this system.

Since beginning operations, the client has enjoyed low maintenance and spare parts costs, and the loading system has exceeded their expectations for loadout speed.

Features of the Loading Spout include a material level-sensing device with auto-raise system, to avoid overfilling. Together, these systems eliminate the need for visual monitoring throughout the loading process. Other features included stacking cones constructed from abrasion-resistant steel and a handheld remote-control pendant.

The spout also includes three-piece, CNC-machined pulleys with rounded edges and precision cable grooves, to significantly reduce cable wear and backlashing. For these reasons, Vortex lifting cables carry a 10-year warranty for wear, tear, and workmanship.

C

Greg Bierie, Benetech, USA, discusses how cutting-edge conveyor technologies can improve safety, maintenance, and compliance for dry bulk material transport.

argo includes a variety of dry bulk products or materials in need of transportation, storage, and transfer involving the use of belt conveyor systems. Although cargo could be anything from forest products to mining materials, the issues are similar. The systems and components are similar but vary in design and performance characteristics depending on the transported material. This article will discuss some of

the problems and solutions that have benefitted from the Benetech design philosophy of total dust management.

Stringent environmental and occupational health and safety regulations require attention to spillage and dust that is generated from handling dry bulk cargoes. The Benetech approach uses an entire box of tools it has developed to attain total dust and spillage management

SUMMER 2021 . DRY BULK . 39

goals. Because these tools have been created specifically by plant professionals for use in the field to address various concerns, particular attention has been devoted to easing maintenance and safety in service.

Lifecycle costing is a paramount consideration in achieving robust products and efficient systems to combine safety by design with improved performance characteristics and regulatory compliance. This article will look at specific applications making a difference to: Reduce dust – lower risk, increase safety.

Prevent spillage – reduce clean-up and transfer cost.

Improve material flow – enhance productivity and earnings.

Ensure compliance – regulatory agencies, NGOs, and community.

Transfer and bulk storage

To avoid demurrage and facilitate the loading process, it is often required to have a readily available supply of dry bulk cargo that can safely and efficiently move from the stockpile to the ship while meeting all environmental and regulatory requirements. Dust and spillage are concerns that are inherent with the movement of materials to and from storage. With most ports, there is also the added pressure from neighbours, NGOs, and environmental agencies.

Biomass and renewables

There is currently a shift in energy resource materials that is seeing more and more need for biomass, pellets, and alternative sources than fossil fuels such as coal. These products bring their own set of problems with storage, loading, and transfer. Storage is accomplished in both outside and covered storage.

Combustible dust is an additional factor that must be addressed in many cases.

Several applications are illustrated in the figures, defining both the problems and solutions for uninterrupted operations and production carried out safely within environmental guidelines.

Dust suppression Figure 1. Biomass stack out and storage. Left: before; right: after.

The installation in Figure 1 was under intense pressure from California (US) state environmental agencies for air quality management concerns and scrutiny from neighbours. There were also combustible dust concerns for dust accumulation on adjacent structures with wood dust, causing a fire or explosion risk.

Engineered transfer points and modular load zones

Figure 2. Covered storage and transfer of wood pellets. Left: before; right: after.

Figure 3. GreenTarp™ – pile sealant for taconite pellets.

40 . DRY BULK . SUMMER 2021

Combustible dust was a significant concern in Figure 2.

This client decided that its best opportunity to reduce combustible dust issues in an enclosed area was to cure the problem at the source instead of putting band aids on the problem. A fully engineered chute and load zone design was chosen for that task.

As can be seen in Figure 2, a significant difference was achieved. No additional dust control measures were necessary to eliminate the problem in this enclosed conveyor system. By controlling

material flow and minimising entrained air along with soft loading and centre loading of wood pellets onto the receiving belt, the dust and risks of fire or explosions are reduced well below the acceptable level.

Course and fine ore storage and transfer

These materials are abrasive and aggressive for material handling equipment and can generate significant dusting in both handling and storage applications.

These materials require robust components and systems to handle rigorous wear and heavy-duty loading requirements.

Bulk storage is also a concern for local NGOs, neighbours, and regulatory pressures.

One of Benetech’s larger clients, a Brazilian producer in the iron ore industry, has adopted many of Benetech’s systems and technologies to improve its operations at mine and port facilities. Benetech has also developed the GreenTarp™ pile sealant, which has solved the dusting issues as well as provides major PR benefits within the local communities.

Figure 4. Pile colour changed to show support for various causes.

Problems and solutions

The pile in Figure 3 is now sealed and eliminates leaching and material run-off during storage. The coating also prevents wind erosion that can carry dust from storage piles to neighbouring structures or sensitive coastal environments.

In addition, the colour of the GreenTarp protective seal can be varied to reflect the needs of the end user. In the case of this client, storage pile colour will vary as they use this as a Figure 5. Stainless steel engineered chute and MaxZone® modular means to show support for local causes. For load zone. instance, the pile colour was changed to pink during breast cancer awareness month, blue for prostate cancer awareness month, and yellow for suicide Eliminate spillage with MaxZone® load zone and XN prevention awareness, all to show support for the causes Liners (internal liners/external adjustment). and heighten public awareness, as shown in Figure 4.

Service and replacement now possible by one person.

The heaviest section is 37 lb.

Engineered chutes and modular load Reduce dust and spillage with improved load zone and sealing. zones Baffles in load zone to control air velocity and dust settling.

Problems Spillage and plugging issues.

BXS5 belt cleaners to eliminate carryback (spillage).

Extremely sensitive environmental conditions.

Easy to service by one person. No hot work is required after installation. All bolted connections and external Throughput, capacity, and demurrage issues. serviceability are made possible in tight spaces.

Difficult for maintenance.

Regulatory pressure from agencies, NGOs, and local Demurrage charges are reduced, and ships can be community. loaded without interruption and at desired capacity.

Solutions provided

Fully engineered chute.

Increased capacity and smooth flow capability.

Improve belt loading and eliminate plugging (soft load and centre load belt).

In conclusion, the Benetech toolbox offers many products and services to help with total dust management and easy maintenance to keep port facilities cleaner, more profitable, and meet stringent environmental pressures.

SUMMER 2021 . DRY BULK . 41

Figure 1. Aerial image of the new warehouse for EBS. Image courtesy of Paul Martens Fotografie.

42 . DRY BULK . SUMMER 2021

Jan de Wit, Managing Director, European Bulk Services B.V., the Netherlands, details the recent construction of a new covered storage facility in Rotterdam and its journey to operation.

E

uropean Bulk Services (EBS) B.V., a 100% subsidiary of HES International B.V., has taken its new covered storage facility into operation. With this new multipurpose facility, the existing storage capacity of 650 000 m3 has increased to 700 000 m3, supporting EBS’ position as a leading provider of covered storage for dry bulk products in the Port of Rotterdam, the Netherlands.

The Port of Rotterdam is Europe’s largest sea port, and it owes its leading position to its high accessibility for sea-going vessels. In addition, the Port of Rotterdam creates direct and indirect employment for some 385 000 people in businesses throughout the Netherlands.

The responsibility of logistics

EBS is a logistics partner for customers in the food and feed industry, the construction and manufacturing industries, and the energy sector. The company is an important link in the supply of essential raw materials for products that everyone uses

SUMMER 2021 . DRY BULK . 43

in their daily lives. For everything from the bread, pasta, and couscous you eat to the beer you drink, chances are that the raw materials needed for these products were transported by EBS, and the same also goes for concrete and plaster used in the construction industry.

Storage

Figure 2. Construction of a conveyer belt.

Storage demand for agribulk has risen in recent years. In the beginning of the 1970s, the Port of Rotterdam was a transhipment port – grain was imported from all over the world and was transhipped into smaller vessels for onward transportation to the end users in Europe. As a result, storage demand was relatively limited. In the early 1990s, more storage was required as grain was exported in large volumes. Over time this export storage has slowly turned into storage for import. These storage sheds at the destination are used as strategic storage locations to supply directly to end users via just-in-time deliveries.

Located strategically

Figure 3. Construction of the store's roof.

Figure 4. Carrying out the first concrete pour.

EBS is a multipurpose dry bulk terminal operator and operates two strategically located terminals in the Port of Rotterdam area: Botlek and Europoort. The terminals have beneficial access to deepwater seaways and to the hinterland by means of inland waterways, rail links, and motorways.

Both terminals are equipped with the latest technology in the area of loading, unloading, and storage facilities. EBS not only has onshore mechanical equipment at its disposal, but also self-supporting floating cranes and weighing towers, in addition to land and berth capacity available for further expansion.

To grow the company's available services in agricultural products, minerals, building materials, and biomass, highquality covered storage is required. Due to the high demand for closed storage, EBS has invested in expanding its covered storage capacity to meet customers’ requirements.

The new facility is situated at the EBS Europoort location and has a capacity of 50 000 m3. It is suitable for the storage of agricultural products and consists of seven separate sections. The design is carried out with a strong focus on flexibility for customers and stringent safety and environmental standards. Products can be loaded onto barge, rail, and truck to continue their route to their final destination.

Construction

Figure 5. The completed shed for storage of dry bulk products in the Port of Rotterdam.

44 . DRY BULK . SUMMER 2021

EBS contracted three main contractors (civil, mechanical, and electrical) and multiple subcontractors to build this high-tech warehouse.

The main civil construction was executed by Züblin Nederland, part of the European Strabag construction group.

The mechanical installations were supplied by the company N.M. Heilig BV from Heerhugowaard, the Netherlands. Heilig is a well-known supplier in design, development, and delivery of bulk handling material for both single units and complete turnkey installations. The company was tasked to create a conveyor belt system that includes a load and unloading system.

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The electrical components and instrumentation have been delivered by TES Industrial Systems Oosterhout. TES develops and produces sustainable solutions for industrial drive systems and industrial automation. The company uses its concepts and solutions around the world in container cranes, industrial cranes, conveyor belt systems, maritime installations, amusement parks, and other industrial applications. For this project, TES developed, among other things, a system which loads the warehouse automatically.

Design

Following the contract assignments, the engineering commenced in the winter of 2020. The design was executed by the contractors based on the optimal function of transhipment and transport. The civil, mechanical, and electrical designs were perfectly connected together through many multidisciplinary engineering sessions.

Challenging project

Realisation of this challenging project started in spring 2020 with the demolition of the old superstructure, prior to the floor being poured and approximately 20 m high walls being built. The sheer quantity of concrete mixer trucks and other traffic through the gate was a logistical challenge and was managed by intensive construction meetings between EBS and the contractors.

Before the last walls were poured, N.M. Heilig and TES began to build the transport installation simultaneously, whereby the operational process of EBS experienced minimal inconvenience.

Despite all technical and timeline challenges, and in respect to all COVID-19 regulations, all contractors collaborated admirably within agreed budgets and timelines. As a result, this made it possible for the warehouse to be fully constructed within 10 months, thus the warehouse has been operational since February 2021.

N.M. Heilig Project Lead Frank Laan stated: “Our co-operation with the secondary contractors and client went smoothly and we are happy with the final result. We wish EBS every success with their new warehouse.”

Marching onwards

EBS’s covered storage capacity now totals a remarkable 700 000 m3 and is on track in executing a multi-year masterplan to extend the covered storage capacity with 350 000 m3 – of which 236 000 m3 has now been realised.

The company's masterplan is outlined below: 2017: 60 000 m3 Botlek terminal.

2019: 126 000 m3 Botlek terminal.

2020: 50 000 m3 Europoort terminal.

2021: 66 000 m3 Botlek (permit received).

2022: 50 000 m3 Europoort terminal (planned).

A permit for yet another new warehouse at the EBS Botlek location has already been obtained and a tender process for construction companies is underway. The expansions are in line with the strategy to move away from coal and focus on closed storage facilities.

Whilst there is demand for agribulk storage, EBS plans to develop its services and meet its customers requirements.

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Ellie Langdon, Nectar Group Ltd, UK, describes how transport corridors can be opened through the use of quayside bagging.

I

n the early 1980s, UK company Nectar Group Ltd changed the bulk commodities handling industry in developing ports around the world with the invention of the world’s first mobile bagging system known as the MOPACK™; now superseded by the COMPAC range. The mobile bagging concept was completely new and designed specifically to work alongside the vessel on the quayside. This innovative and radical approach offered improved flexibility of discharge

SUMMER 2021 . DRY BULK . 47

and distribution of bulk cargoes in ports where facilities were not available, and therefore dramatically reduced the overall cost of the end-to-end logistics chain.

Although the concept of quayside bagging is not new, mobile bagging equipment continues to transform how cargoes are handled in developing countries. The design – which incorporates receiving, weighing, stitching, and conveying systems – is housed in two 20 ft ISO containers, allowing for the system to be completely self-contained and easily transported between locations using approved container handling equipment. Today, this continues to prove vital in assisting major organisations such as aid agencies and commodity traders to deliver food-grains and fertilizers into ports globally that lack the existing infrastructure to handle bulk cargoes. In many cases, due in part to its mobility and affordability, mobile bagging equipment is now the preferred solution over fixed bagging infrastructure.

The use of mobile equipment has continued to remain popular, with operations taking place around the globe for a wide range of free-flowing commodities including, but not limited to, grains, pulses, fertilizer, sugar, soda ash,

and sulfur. Today, annual volumes equate to many millions of tonnes per year.

Almost 50 years on from Nectar’s inception, quayside bagging still brings a huge range of benefits to ports worldwide. These include: Faster loading speeds: Cargo can be sourced from bulk export terminals allowing for extremely fast vessel loading, making it an increasingly popular choice over pre bagged/pre slung cargo, especially with increasing freight rates.

Faster discharging speeds: Cargo is discharged in bulk using grabs into the bagging units, which are capable of handling more than 1500 tpd per machine. Speeds in excess of 5000 t per weather working day are achievable for well managed operations.

Reduced risk of cargo loss and damage: As the product remains in bulk throughout loading/discharge there is no damage to the bags when stowing/ unloading, reducing cargo losses, and ensuring correct bag weights.

Marketing of cargo: Bags are clean and new on dispatch from the port. This also means that cargo can be sold on the water and bagged into the clients' specific bags upon arrival, reducing double handling and costs for re-bagging.

Service provider guarantees: Some service providers are able to provide guarantees on operational aspects such as discharge speeds (in line with Charter Party terms), cargo loss, and bag weight accuracy. This helps the shipper/receivers manage and mitigate their risk.

Diversifying the bagging

Figure 1. Commissioning and testing of Nectar COMPAC XL120.

Figure 2. Training of personnel.

48 . DRY BULK . SUMMER 2021

As the availability of handling equipment across supply chains in developing nations has increased, so has the possibility of diversifying from the standard 50 kg output in most quayside bagging operations. Demand for larger bag weights is now becoming more popular, with receivers utilising more widely available handling equipment to support their operational requirements.

Flexible intermediate bulk containers (FIBCs) or 1 t bulk bags, a staple across Europe, are now seeing far more widespread use across developing markets, especially where commodities must travel a long distance by road into remote areas away from the coast and/or major rivers.

One such location that has used quayside FIBC bagging to great effect is the port of Walvis Bay, Namibia. Walvis Bay has long been used as a transport corridor for commodities into Botswana/Zambia, most commonly for the transport of products to/from the mining regions.

However, its increased distance from the usual hubs of Beira, Maputo, and Durban placed it at a significant disadvantage. One of the major disadvantages is the availability of return journeys for trucks and trailers that are used on the transport corridor, with empty return runs driving costs higher than viable for most receivers. In 2020, a local logistics operator in Namibia, in co-operation with its clients at both the shipping and receiving end of

the supply chain, purchased COMPAC XL120 bagging machines for operation on the quayside. This significantly reduced the double handling of cargoes and removed the requirement for warehouse operations to manually bag the cargo for onward transport. The first operation took place in January 2021 and was a resounding success, achieving speeds of approximately 3000 t PWWD and completing a shipment of 20 000 t, bagged and dispatched, within one week.

Previously, the type of truck/trailer available at the time of transport dictated what could and could not flow out of the region. By introducing FIBC quayside bagging, the bags can now be loaded onto bulk, curtain side, or flatbed trucks – tripling the options for transport and mitigating one of the major historical bottlenecks on the transport corridor. The same logistics operator is also effectively reducing the transport of empty bags within the region, a smart cost saving method that is completely unique to the market. The now streamlined process starts by bagging sulfur on the quayside for transport to the mining region, where they subsequently discharge, clean, and reuse the bags for return transport of copper concentrate. A simple solution, leading to major cost savings for the operator and its receivers.

Namibia’s principal port is strategically located and supported by a network of well-maintained roads that extend across Namibia into Angola, Botswana, South Africa, Zambia, Zimbabwe, and the DRC. In addition to accessibility and efficiency, Walvis Bay is closer to the Americas and Europe than any of the East Coast ports, with Botswana, Zambia, and Zimbabwe having developed dry port facilities in Walvis Bay. The capacity of the port is expected to continue to grow as a result of ongoing investment projects with greater attention required in managing logistics sustainability. By 2025, Namibia is expected to become a logistics hub for the Southern African Development Community, with emphasis on developing dry port facilities and subsequent growth of quayside FIBC bagging.

Another recent bagging assignment undertaken by Nectar Group Ltd involved the discharge and bagging of 12 000 t of rice in West Africa. In this instance, the Group was responsible for handling the bulk discharge of the cargo, bagging into 50 kg and 25 kg, and loading on the client’s trucks. Nectar co-ordinated with the supplier of the cargo, the ships agent, and provided on-site monitoring and daily reporting on the vessel’s discharging operations and post-operation follow up with all parties. A new concept to the client in question, the Group’s involvement produced an impressive reduction in damages and losses saving the client over US$150 000 in costs. The Group’s expertise ensured that the whole process ran smoothly from beginning to end and paved the way for the client to reduce operating and insurance costs substantially on future shipments.

Conclusion

With faster loading and discharge speeds, reduced risk of cargo loss and damage, and several providers now

Figure 3. First grab discharge into Nectar bagging machine.

Figure 4. First 1 t bag from Nectar bagging machine. including service guarantees, it is no surprise that quayside bagging has continued to remain popular.

40 years from its invention, quayside bagging is still opening transport corridors and providing significant cost benefits to its users. The concept continues to develop alongside global supply chains, with receivers widely utilising the availability of handling equipment to support their operational requirements and subsequently providing opportunities to diversify from the standard 50 kg output to larger bag weights. The result is cheaper bag rates for the end user with savings achieved within a number of aspects of the supply chain.

The versatility of bagging equipment has ensured that many bulk shipments can be discharged and bagged successfully despite challenging markets and port conditions in many locations. The key for successful operations in many cases is down to a wealth of knowledge, experience, and high levels of communication between providers and receivers. With better communication comes a greater understanding of bottlenecks and operational requirements/challenges to mitigate risk and provide end-to-end benefits through smarter and streamlined operations, however big or small the project may be.

SUMMER 2021 . DRY BULK . 49

Jörg Spiekermann, BEUMER Group, Germany, investigates what is on the minds of suppliers and how they react to the various issues in the sector, including digitalisation, recycled materials, and the increasing use of robots.

T

he changes in the packaging sector can be clearly felt.

BEUMER Group’s customers require solutions permitting them to further relieve their staff, make their processes more flexible, and increase their production and resource efficiency. On request, the system provider delivers the packaging sector with complete packaging lines: from filling up to the palletised stack, and also from one

50 . DRY BULK . SUMMER 2021

single source. This means that interfaces can be omitted or minimised and the customer only needs one point of contact.

With BEUMER Group’s system solutions, full pallets or individual bags can be forwarded to a connected warehouse or directly to the loading space of a truck. The system components are mainly transport technologies such as conveyors or vehicle-based systems. Various solutions for

handling and manipulators such as robots, and buffer and storage modules are available as well. As BEUMER Group always uses components from a modular system, the solutions can be expanded at any time and can grow with the customer’s needs.

Co-ordinated processes

Software solutions are becoming more and more important.

For the best results and to ensure full material and data tracking, the filling, palletising, and packaging components as well as other system components must be perfectly matched. It is more and more important to network logistic processes and to control them in an automated way.

For this, BEUMER Group has developed a modular software suite as a superior data processing system; it can be adapted individually to the particular tasks. Since the company wants to consider and optimise the process as a whole, its experts are able to easily integrate products from third-party suppliers. A cross-program user interface shows process data and reports. All available data can be accessed without having to switch between different applications.

With the BEUMER Group warehouse control system, the software suite can be easily connected to the warehouse management system or the customer’s ERP solution. This way, BEUMER Group ensures the communication between the different control levels for the user. BEUMER Group can create an intelligent connection between the individual systems, and integrate them into the existing processes and inventory control systems of the customer.

Smarter with the support of start-ups The trend goes towards digital solutions that increase automation potentials and further optimise supply chains

and processes. But for many mechanical engineering companies in Germany this is a huge challenge. They simply miss the necessary know-how. And how is it at BEUMER Group? Digitalisation means co-operation, interaction, and data interchange. This also changes the role of the packaging system suppliers and co-operation with the customer. There are many young companies with a lot of know-how ready to surprise the market, but BEUMER GROUP does not want to wait for them to take the company off the hook with their fresh ideas. BEUMER would prefer to take the helm itself, thus it looks for and supports promising start-ups to carry digital projects into the company. Consider this example that is only remotely related to the packaging sector: with its digital marketplace, the start-up Sparrow Networks ensures that the participants are supplied with the appropriate spare part as quickly as possible in the event a component in their systems fails. Sparrow connects the stock of the system operators with each other. Due to the network, a suitable supplier can always be found quickly.

This prevents long downtimes and expensive storage costs.

The start-up receives extensive support from the Berlin, Germany-based, autonomous company builder Beam, a spin-off of BEUMER Group. Unique problems in logistics are solved together with start-up teams. It is important to find entrepreneurs with promising business ideas. The system provider is planning on founding three start-ups per year and transferring them (while being consolidated under Beam) into a separate company. This includes Sparrow Networks.

Robots have become more and more important

A further trend is to be expected in the increasing use of robots, and the (petro) chemical industry can be considered

SUMMER 2021 . DRY BULK . 51

stacked accurately on pallets can then be transported successfully to the downstream packaging system – for example, the BEUMER stretch hood. The BEUMER stretch hood packaging system is designed to be highly energy efficient. An intuitive human-machine interface simplifies operation and makes quick work of film roll changes, meanwhile operating parameters can be changed as well.

Sustainable all along the line

Figure 1. The intuitive and reliable operation of the new BEUMER stretch hood A is especially appealing to customers.

Figure 2. The BEUMER robotpac is designed to palletise barrels in an efficient way. as an example. In this industry, the products are filled in special bags, barrels, canisters, cartons, or buckets. To palletise them, BEUMER Group offers its space-saving articulated robot, the BEUMER robotpac. Depending on the packaged items, BEUMER Group equips the robot with the appropriate gripping system which can be easily and automatically changed if the packaged items change. The fork gripper was, for example, designed for palletising bagged goods and cardboard boxes. The finger gripper is particularly suitable for the efficient handling of bagged goods. For maximum performance, BEUMER Group offers a double gripper for both types. The company also offers parallel grippers for dimensionally stable packed items, suction grippers for items with a smooth surface, and many other special grippers and combination tools. The modular structure permits adaptation of this series to special market-specific and customer-specific requirements. Bags

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BEUMER Group not only committed itself to evaluate this packaging system comprehensively on the levels of economy, ecology, and social responsibility, but for all products made by BEUMER. This demonstrates BEUMER Group’s commitment to the total value of ownership (TVO).

Systems are considered in their entirety, not only from its cost side. For example, BEUMER continuously looks to reduce energy and resource consumption in the production cycle and during operation, as well as keeping emissions to a minimum.

Not only are the machines sustainable but also the packaging – at least a strong trend goes in that direction, since the plastic products have been criticised for some time now. After using them, they often end up as waste on landfills or – and this particularly applies with regards to consumer goods – in nature, considerably polluting the environment. Since the beginning of 2019, the new packaging law has therefore also been in force. Its aim is to avoid packaging waste and to strengthen recycling.

Therefore many films will include recycled material in future, which might considerably change their characteristics and handling. Many packaging system owners who fix and package goods ready for dispatch by using stretch film for transhipment on pallets, are of course unsettled. Customers often enquire whether they can further use BEUMER’s packaging system, and the answer is yes. The BEUMER stretch hood A processes these films as usual in a very reliable way. At this regard, the experts in co-operation with the film manufacturers have performed tests and analysis with various films in the in-house R&D centre in Beckum, Germany.

With the BEUMER stretch hood A packaging system, the system supplier supports the customers along the line, and with regard to safety. The high restoring forces in the stretch film make sure that the film fits tightly to the entire stack, like a second skin, and thus ensures the necessary stability. The products are protected from the environment. The palletised goods are clearly visible due to the smooth surface of the transparent, highly flexible film. In addition, underlaying barcode labelling is quickly and consistently recognisable.

Logos and text can also be printed on the film to be used as an advertising medium. Tamper protection is also important: unauthorised persons cannot take goods from the pallet without damaging the film. The packaging also protects against dangerous substances; the content for example shall not come in contact with the surface of the container. This is the case for lubricants and adhesives, antifreezes, resins, brake cleaners, as well as for bulk material such as pellets.

The packaging system can also be used to line the inside of the container with a film hood.

Sigrid Eder-Ince and Reinhard Lechner, Starlinger & Co. GmbH, Austria, explain why FIBCs made from PET can help boost the circular economy as countries introduce more stringent legislation on plastic.

T

he UK’s proposed Plastic Packaging Tax could set an example for governments worldwide to follow in order to meet sustainability goals and promote recycled content in plastic packaging. In the area of heavy-duty bulk packaging, flexible intermediate bulk containers (FIBCs) made of PET tape fabric provide an economically viable solution to comply with such legislation.

Parallel to the EU’s Single-Use Plastics Directive and the EU Plastic Packaging Levy, the UK plans to tackle plastic waste and promote the recycling of it by taxing plastic packaging that contains less than 30% recycled content.1 The HM Revenue & Customs – the UK’s tax, payments, and customs authority – has drafted a legislation defining chargeable types of plastic packaging, thresholds of recycled content, tax rates, and

liability, which will take effect from 1 April 2022. The aim of the tax is to provide a clear economic incentive for businesses to use recycled material in plastic packaging, which will create greater demand for this material and in turn stimulate increased levels of recycling and collection of plastic waste, diverting it away from landfill or incineration.

Once in force, this tax will also affect FIBC producers who export their bags to the UK. Importers will have to pay a tax of £200/t in addition to the customs duty if the FIBCs do not contain the defined amount of recycled content, which will make them uncompetitive.2 If other countries follow, exports to these countries will also be affected.

FIBCs are generally made of polypropylene (PP), and although PP can be recycled, it degrades in the process. Low

SUMMER 2021 . DRY BULK . 53

quality recycled PP cannot be used in tape production for heavy-duty FIBC fabrics. As a result, in order to achieve a certain amount of recycled content in PP FIBCs the recycled material has to be of high quality. This strongly depends on the quality of the recycling process and the amount of foreign substances and polymers – additives such as CaCO3, or polymers like polyamide used for seams – in the input material for recycling.

In addition, there are no existing legal requirements and definitions for using recycled PP in FIBCs for food and pharmaceutical grade applications yet, although the industry is working on solutions.

Up to 100% recycled material

An alternative for FIBC producers is FIBC fabric made of PET tapes. Besides its high strength and form stability, which makes PET fabric ideal for heavy-duty applications, PET can be recycled and refined so that its properties are restored to those of virgin material. For FIBC producers, this means that with PET they can kill two birds with one stone: produce high-quality FIBCs, and meet sustainability criteria which are likely to become a must in the near future. With PET, the recycled content of an FIBC can even be up to 100% – with PP, this high rate can never be reached.

Advantages of PET Figure 1. A PET FIBC produced at a Starlinger customer in Asia.

Making new products out of PET waste is not a new approach. For many years, PET flakes have been recycled into new PET bottles or sheet for food trays, and the unique properties of PET recommend it for other applications as well. Austrian manufacturer Starlinger & Co. GmbH, which has been exporting machinery for the production of woven polypropylene fabric since the 1970s, has developed the technology to turn flakes from used PET bottles into fabric for sacks, bags, and FIBCs. PET offers a whole range of advantages that can benefit the logistics industry, and with millions of FIBCs being produced worldwide every year, the potential to save resources through the use of recycled material is enormous.

The production of packaging from waste (i.e. PET flakes) allows for a closed loop production. PET has an edge over other plastics because of its advanced recyclability. With a method known as solid-state polycondensation, the molecular weight of recycled PET can be restored to its original level, thereby yielding material that is as good as new, even after being recycled many times. Furthermore, due to its high decontamination performance, this process opens up multiple possibilities for food-grade packaging and broadens the customer base of FIBC manufacturers.

Applied to heavy-duty fabrics

Figure 2. Starlinger circular looms produce PET fabric for FIBCs.

54 . DRY BULK . SUMMER 2021

High form stability and a high melting point are the main reasons why PET strives to achieve a better performance and can withstand higher working temperatures than other polymers used for fabric production. A field where these advantages are particularly useful is bulk material logistics, as the properties of PET benefit heavy-duty fabrics in a number of ways, as outlined next.

Positive characteristics of PET FIBCs include:

Form stability: PET FIBCs are an ideal combination of strength and flexibility. They are flexible compared to cardboard octabins, but due to the high creep resistance of PET, they maintain their form over long periods of time. This stiffness of PET prevents bulging and therefore allows big bags to be stacked on top of each other without the risk of toppling over. As a result, PET FIBCs are highly suitable for multiple stacking and long-term storage of goods with little inter-particle friction, such as polystyrene beads or polymer chips with slip additives.

Moreover, the strength of PET makes FIBCs resistant to abrasion – an advantage during rough handling.

High melting point: PET maintains its modulus and strength at temperatures up to 80˚C. PET FIBCs can therefore be used in an environment with extremely high or low ambient temperatures, and because of the high melting point of PET, PET FIBCs are ideal for hot-fill applications.

Price and availability: PET bottle flakes are available at a reasonable price as compared to other raw materials (Figure 3). In many countries, public and/or private collection systems have been set up that satisfy the growing demand for washed and sorted flakes. Some companies even operate their own sorting and washing equipment.

Sustainability: Post-consumer bottle flakes are turned into FIBCs that are in turn recyclable. Starlinger calls this concept ‘bottle to bag’, as PET bottles are used to make new bags or big bags. If collected and reprocessed with the right equipment, PET FIBCs can be recycled indefinitely due to the recyclability of PET. Truly eco-conscious producers can now transport their recycled goods in recycled FIBCs as well.

Waste reduction: PET FIBCs are highly suitable for multiple use, which saves valuable resources.

Food safety: Equipment for PET decontamination makes bottle flakes and consequently, the recycled fabric, safe for food contact, so that FIBCs can be used to transport food products such as seeds.

Since Starlinger circular looms do not have sliding parts, no oil/grease is needed in the weaving process that could potentially contaminate the fabric.

Visual appeal: First impressions count – packaging is the business card of the finished product and conveys an impression of superior quality. PET has a shiny surface and good printing properties; this visual appeal gives PET an edge over other materials, as it permits sophisticated packaging designs.

Investing in technology

Starlinger has been working since 2010 on developing the process and equipment for converting PET into woven fabric – initially from virgin material, then recycled pellets, and ultimately, from PET flakes. This was something that no technology provider had managed to achieve up until this point, as the conversion of PET to plastic tapes is not a

Figure 3. Raw material prices in Western Europe, January 2018 - February 2021. Image courtesy of KI Kunststoff Information Verlagsgesellschaft mbH. straightforward process and entails many challenges that need to be addressed. In doing so, Starlinger was able to draw on its knowledge and experience in the area of PET recycling, as the company has been developing recycling technology for more than 30 years. Building on this foundation, Starlinger spent considerable time and resources on research and development, perfecting the technology for PET tape fabric until finally presenting the first PET FIBC at K show 2016 in Düsseldorf, Germany.

The investment cost for PET FIBC fabric manufacturing equipment can vary greatly and depends on the type of FIBC

(size, food safety, coating, printing) as well as the required production capacity. Because the manufacturing process of PET FIBCs is more complex, the investment is higher as compared to PP fabric, but this difference is more than compensated for by cost savings in input material (i.e. flakes instead of PP granules). Figure 3 compares the price development of five types of raw materials, namely PP homopolymer suitable for film production, virgin PET for packaging applications, as well as recycled PET granules and clear and coloured PET bottle flakes, between January 2018 and February 2021 on the Western European market (prices are given in €/t). The graph clearly shows that the purchase price of PP is consistently well above the price of PET flakes; especially coloured PET flakes which cannot be used in PET bottle production provide input material at a very favourable cost. The applicable price difference at the time of purchase determines the manufacturing cost of the end product.

An important consideration in this respect is that PET flakes as a secondary resource are less dependent on the development of the oil price. This cost advantage in combination with the favorable properties of PET causes an increasing number of FIBC producers to look into a bag project for PET fabric. Such a project is an especially attractive investment opportunity for companies that already sort and wash flakes, and would like to expand their business into related areas of activity.

Conclusion

The proposed Plastic Packaging Tax the UK is planning to implement by 1 April 2022 might be an example other countries are deciding to follow. According to the tax, plastic packaging that does not contain a minimum of recycled content will be charged with an additional tax when sold. This also affects FIBC producers and importers of FIBCs. Starlinger has developed the technology for a very competitive alternative: FIBCs made of PET. This polymer achieves the same properties as virgin material after recycling and thus can be used to produce heavy duty fabrics for FIBCs containing up to 100% recycled content.

FIBC producers thus will not only be able to comply with government regulations such as the UK’s, they will also benefit from the unique characteristics of PET that makes it an ideal material for heavy duty applications. As sustainability goals are on the agenda of many governments worldwide, it is to be expected that similar regulations will be put into place in the upcoming years. The use of PET for FIBC production provides producers with an ecologically and economically viable solution for this future challenge.

References 1.

HM Revenue & Customs, Introduction of Plastic Packaging Tax from April 2022, 3 March 2021.

2.

Ibid.

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