BULK HANDLING
NEWS BRUKS SIWERTELL CUSTOMER MAGAZINE  #2/2020
14
Augmented reality supports customers with rapid, remote expert assistance
CONTENTS
10
14
24
28
CONTENTS
17
4 News in brief 7
Innovative loading technology delivers operational excellence
10
Think outside the box for efficiency and environmental gains
14 Remote expert assistance enabled with augmented reality platforms
2  BULK HANDLING NEWS
Extraordinary times require rapid, innovative responses
22 Difficult waste wood handling demands met with ease 24 Black gold: making sustainable steps 28 Customized truck unloader delivers dust control with a difference 31
Our People: Mats Lindberg
EDITORIAL
ABOUT BRUKS SIWERTELL GROUP Bruks Siwertell is a market-leading supplier of dry bulk handling and wood processing systems. With thousands of installations worldwide, our machines handle raw materials from forests, fields, quarries and mines, maintaining critical supply lines for manufacturers, mills, power plants and ports. We design, produce and deliver systems for loading, unloading, conveying, storing, and stacking and reclaiming dry bulk materials, alongside equipment for chipping, screening, milling and processing wood for the biofuel, board, sawmill, pulp and paper industries. An extensive global service team offers support to Bruks Siwertell customers whenever and wherever it is needed. bruks-siwertell.com
Follow us on social media
Bulk Handling News is a customer magazine for the dry bulk handling industry. The opinions expressed by the authors or individuals interviewed do not necessarily represent the views of Bruks Siwertell. Publisher: Siwertell AB, P.O. Box 566 Gunnarstorp SE-26725 Bjuv, Sweden Editors: Emily BrĂŚkhus Cueva (emily.cueva@bruks-siwertell.com) Malin Pekberg (malin.pekberg@bruks-siwertell.com) Lindsay Gilliland (lindsay.gilliland@bruks-siwertell.com) Editorial assistant: Anette Andersson (anette.andersson@bruks-siwertell.com) Layout and production: Metamorf Design Group AB Cover: Shutterstock Printed by: Exakta
This magazine is printed on responsibly sourced paper and conforms with Svanen eco-label and FSC-certification standards.
Strong demand for sustainable solutions Dear reader, Firstly, I would like to extend my sincerest thanks to all our customers and personnel; the last few months have presented unimaginable challenges, but the combined dedication, professionalism and patience of everyone has allowed us to continue to manufacture, deliver, and serve global industries. Furthermore, testament to the essential role and standing that our equipment has in dry bulk handling and wood processing, orders have continued apace and across different sectors. Amongst them are a trio of new Siwertell ship unloaders in Singapore, a milestone ship unloader contract in the US, as well as two major US woodyard projects; one for the wood pellet industry and the other for pulp and paper manufacturing. Our wood-processing technology also continues to be in strong demand. The magazine features major orders and the fruition of exceptional projects. Colleagues highlight vivid examples of our capacity to pull together and make the best of these new operating conditions. But we have not stopped there, demonstrating an ability to go a step further and accelerate advances so that we can better serve our customers going forward. We are transforming our operations and services, quickly adapting where needed. We are able to leverage our service expertise with the advantages of augmented reality technology, assisting customers remotely if we cannot be there face-to-face. At the forefront of all our solutions is a commitment to maximizing the efficiency and minimizing the environmental impact of handling and processing dry bulk materials. Our equipment is part of a collective responsibility to drive change, and help make the industries that we serve sustainable now, and in the future.
Peter Jonsson, Group CEO BULK HANDLING NEWS  3
NEWS IN BRIEF New Siwertell ship unloaders extend dust-free cement handling in Singapore A prestigious new order will see Bruks Siwertell deliver three new Siwertell ship unloaders to Jurong Port in Singapore. The trio will join existing Siwertell technology, delivered in the late 1990s, and together they will ensure the environment-friendly handling of Singapore’s cement imports. Singapore upholds strict environmental standards in cement handling and Jurong Port works closely with local government authorities on establishing requirements and measures to minimize fugitive dust from any industrial operations, and maintaining operational safety standards. As the world’s largest common-user cement terminal for over twenty years, Jurong Port’s Cement Terminal started off with three high-capacity Siwertell ship unloaders that collectively met the cement handling needs of multiple smaller import terminals.
“It is now time to retire two of those hard-working unloaders,” continues Jeppsson. “They have served the terminal well for over two decades, and their proven performance was a deciding factor in the port once again opting for Siwertell technology. The new units will continue their legacy of impressive through-ship efficiencies and will work along-side one of the older units, which will remain in service. Together they will handle Singapore’s cement import volumes.” Like their predecessors, the three new ST 490-M screwtype rail-traveling unloaders will each discharge cement, fly ash and cement slag from vessels up to 50,000 dwt at a continuous rated capacity of 800t/h. Two of the new unloaders are scheduled for delivery in May 2022 and the third by the end of 2022. All will be fully assembled prior to delivery and transported by heavy-lift ship. Final commissioning and performance tests will be carried out in Jurong Port.
“With the evolution of technology and equipment, Jurong Port is delighted to work with Bruks Siwertell to take our terminal’s capabilities and standards further in our vision of becoming a next-generation multi-purpose port,” says Tan Wee Meng, Chief Technical Officer, Jurong Port. “This is a very positive endorsement of our Siwertell ship unloading technology, ” says Ola Jeppsson, Bruks Siwertell Sales Manager, APAC. “The new units, like all Siwertell unloaders are totally enclosed, and will secure the continuation of extremely efficient, high-capacity cement handling for the port, without dust emissions or spillage, so no cement is wasted and the environment is protected.
4 BULK HANDLING NEWS
A trio of new ship unloaders will join existing Siwertell technology, delivered to Jurong Port in the late 1990s
NEWS IN BRIEF
Bruks Siwertell. “The unloader will be installed near a historic, very sensitive, downtown location; any industrial activities in the area must comply with strict environmental protection regulations. “The Siwertell unloader offered this capability, along with impressive through-ship efficiencies, making it the ideal machine,” continues Upchurch. “Also, by working closely with Colonial and its engineering team, we were able to develop a customized solution that will work within the operator’s existing infrastructure.
Colonial’s new Siwertell unloader will deliver dust-free cement handling at a rated capacity of 800t/h
“Furthermore, the combined capabilities now offered by the merged Bruks Siwertell Group, provide Colonial with local support that is unmatched by others,” he adds.
Colonial increases Savannah Terminal unloading capacity
The Siwertell 490 F-type ship unloader offers a rated cement handling capacity of 800t/h and can discharge vessels up to Panamax size. They have proven capabilities in dry bulk handling installations worldwide and have been specially engineered to be lighter than other systems in their capacity class, offering significant cost savings in jetty reinforcements.
The USA-based Colonial Group has ordered a new highcapacity Siwertell ship unloader. The fully enclosed system will deliver dust-free cement handling for the company’s Savannah, Georgia, terminal, and supports Colonial’s cement import growth.
“This is Colonial’s first Siwertell ship unloader,” Upchurch notes. “The company was impressed by the technology and the machine’s flexibility, enabling it to handle various designs and capacities of geared vessels.”
“Environmental credentials were a strong factor in securing the contract,” says Ken Upchurch, VP Sales and Marketing,
Machine components will be delivered to Savannah for assembly in May 2021 and the unloader is planned for commissioning by August 1, 2021.
Port-mobile unloader expands material range The latest market-changing Siwertell ship unloader, the port-mobile unloader, can now offer totally enclosed, highefficiency dry bulk material handling to the alumina, cement and soya meal sectors, as well as grain. “The port-mobile unloader was initially launched to challenge the limitations of pneumatic discharge systems used in grain handling,” says Jörgen Ojeda, Director, Mobile Unloaders, Bruks Siwertell. “However, we realized that, as well as ensuring high-capacities, no spillage and close-to-zero dust emissions, it delivers many distinct benefits when handling all these materials.
The Siwertell port-mobile ship unloader can handle alumina, cement, soybean meal and grain
BULK HANDLING NEWS 5
NEWS IN BRIEF “One of the greatest advantages of unloading dry bulk, especially more delicate cargoes, with screw-conveyor technology is the low material degradation rates, minimizing the production of powdery fines,” explains Ojeda. “Like all Siwertell unloaders, port-mobile units offer a steady conveying velocity, with no particle collisions or crushing forces, which is in contrast to the cargo degradation concerns that traditionally accompany pneumatic unloaders.”
dramatically increased by their presence, and for grains and soya beans, the quality of whole shipments can be downgraded; significantly impacting profits.
Fines, produced when materials degrade, are problematic for many dry bulks, but for alumina, the cost of smelting is
The port-mobile unloader is available in two sizes, a 400t/h and 600t/h model; both can discharge vessels up to 60,000 dwt.
Service tower added to ship unloader range
costs and improves the overall safety of the operation. Also, because the tower is specifically designed for the task, the whole process is faster; various screw lengths and sizes can be accommodated using adaptors.”
A new service product, which will substantially simplify and lower the cost of fitting replacement screws on marketleading Siwertell ship unloaders, has been launched.
Replacement screws are placed and fitted into the tower’s lowered screw-holding cradle, specifically matched to the dimensions of the screw. A winch raises the cradle and screw into an upright position. When in place, the new screw is locked into position and the outer diameter bearing wings are assembled. The same procedure is repeated with the next screw section. Removal and disassembly of the screws are achieved using the same equipment, but in reverse.
“All our equipment, including service strategies, benefits from decades of continuous research, development and improvement, and the latest product is a service tower for replacing screw sections on our Siwertell ship unloaders,” says Björn Ohlsson, Manager, Bulk Terminals Design and Engineering, Bruks Siwertell. “It offers a number of key advantages,” he explains. “Principally, the service tower eliminates the need for cranes, which are traditionally used to lift the screws. This reduces
“For operators looking for a flexible, port-based system, and needing to discharge large vessels at a high capacity, then our new port-mobile unloaders are a fantastic, extremely cost-effective option,” adds Ojeda.
“Although specifically designed for screw replacements, it can also be built with additional levels to service and inspect other areas of the vertical conveyor,” notes Ohlsson. “For any new or existing unloader, this is an extremely cost and time effective addition to any operator’s service portfolio.”
The new service tower eliminates the need for cranes, with replacement screws winched into place
6 BULK HANDLING NEWS
INNOVATIVE LOADING TECHNOLOGY DELIVERS OPERATIONAL EXCELLENCE Boliden is working hard to automate its mining facilities and drive advances in environmental protection, safety and production; as part of this, its Ireland facility now features Bruks Siwertell’s first fully automatic loader and conveyor coupling technology TEXT
Bengt Svensson and Peter Göransson PHOTOS Bruks Siwertell
AT EUROPE’S LARGEST ZINC MINE ,
Boliden Tara Mines, near Navan, in County Meath, Ireland, around 2.6 million metric tons of ore is mined annually for the production of zinc and lead concentrates.
The 1,000m-deep facility has been in production since 1977 and was acquired by Swedish company, Boliden AB, in 2004. Over this time, more than 85 million metric tons of ore has been extracted. The mine is also one of the BULK HANDLING NEWS 7
CASE STUDY
The new system was built and commissioned at Dublin Port in 2019 in partnership with local Irish sub-contractors
most automated. Boliden says that it has increasingly digitalized its mining facilities to make them among the safest in the world and also to keep production running non-stop, round-the-clock.
An environmental agenda In 2018, Boliden Tara Mines processed 2,200 kilotons of ore into metal concentrates containing zinc, lead and silver. In the same year, the company turned to Bruks Siwertell for its expertise in developing a unique material handling system to serve the company’s new terminal located in Dublin’s Alexandra Basin. As the equipment is only 150m away from a popular docklands area, closeto-zero dust emissions were stipulated in the contract. “The system needed to be installed in the downtown area in the port of Dublin, just beside a new concert hall, office buildings and an exclusive hotel,” notes Bengt Svensson, Contract Manager, Bruks Siwertell. “The cruise ship port was also a close neighbor. We therefore had to meet low noise requirements and very high environmental standards. Also, to comply with planning regulations, architectural restrictions, relating to the color and shape of machinery, had to be met.” 8 BULK HANDLING NEWS
Echoing the need for strict environmental requirements in the machinery, Peter Göransson, Sales Manager and Senior Advisor, Bruks Siwertell, explains: “Zinc and lead are extremely hazardous, not only to the environment, but also to humans, so we needed to find a way to limit any atmospheric pollution from the loading and conveying process, but also any physical contact that operators had with the materials. “A high loading capacity, combined with easy system operation and low service and maintenance costs, were also significant factors for the company, along with our technology’s ability to comply with best available technology (BAT) and reference document (BREF) regulations,” adds Göransson.
Collaborative design Working together with the operator, Bruks Siwertell developed a totally new system. It comprises a triple-enclosed belt-type ship loader, with luffing and slewing capabilities, a reversible shuttle-belt conveyor, with double-embedded covers, and dual remotely-operated connection points, as well as a triple-enclosed jetty and overland conveyor. The conveyor and its walkways are also embedded.
“Great effort has been made to comply with the zero emissions strategy set up for the project,” he notes. “For the dust extraction system, which was tailor-made for the application, it meant a new approach; a two-stage filtration process. This is achieved by collecting initially filtered, clean air from the dust collector, and passing it through a second filtration unit with special high-efficiency particulate air (HEPA) filters, forming the final stage of the process. Only at this point is the air released into the atmosphere.
“
CASE STUDY
It really is the best available technology on the market BENGT SVENSSON, CONTR ACT MANAGER, BRUKS SIWERTELL
“The HEPA filters in the second filtration process reduce the amount of airborne particles in the clean air from traditional milligram levels to non-measurable emissions. “Not only hazardous, lead and zinc are also very sticky materials and require specialist machinery to handle them,” Göransson continues. “To stop material clogging up the loader we designed it to have different angles and rounded corners, which prevent any ore build-up. Other measures include a stainless-steel base plate, with built-in vibrators and heating elements; all designed to keep the material flowing.”
“Boliden required a completely new concept, but one that was also capable of flexibility, handling its variety of cargoes and a wide range of vessel sizes,” says Göransson. “Our lengthy experience and expertise in bulk material loading was a significant factor in Boliden opting to work with us on developing this technology.”
The zinc and lead concentrates are transferred from the mine in rail wagons to a receiving storage warehouse. From here, a conveyor belt leads to a new quayside facility in Alexandra Basin. Siwertell units are well-suited for these sticky and hard-to-handle materials and the new system is capable of loading ships of up to 10,000 dwt at a continuous rated capacity of 600t/h.
The system was built and commissioned at Dublin Port in partnership with local Irish sub-contractors in 2019. “Construction supervision was part of the delivery scope, ensuring that the designs were closely followed and any queries quickly dealt with. The system required a number of carefully selected components from Swedish and other European sub-contractors,” continues Svensson.
Best on the market
“The timescale was very tight, but we had good cooperation with local support; we combined expertise, working together to build a very special installation,” Göransson notes. “The system has now been in successful operation for almost a year and delivers the highest safety standards and environmental protection, ” adds Svensson. “It really is the best available technology on the market, with fully automatic coupling between loader and conveyor. This maintains very high loading capacities, vital to the mine, but also minimizes all human contact with lead and zinc, which is vital for health and safety.”
Boliden’s new loader is capable of handling a variety of cargoes and a wide range of vessel sizes
For peace of mind, Boliden also has a spare parts package and a two-year planned service agreement in place, which schedules eight service visits, four a year, to the operator over the course of the contract. BULK HANDLING NEWS 9
THINK OUTSIDE THE BOX FOR EFFICIENCY AND ENVIRONMENTAL GAINS TEXT
Daniel Pace PHOTOS Bruks Siwertell and Shutterstock
A recent order from Packaging Corporation of America will see Bruks Siwertell deliver a fully automated woodyard to its Wallula mill, promising dramatically reduced dust emissions and operating costs
AS ONE OF THE LARGEST manufacturers of containerboard and corrugated packaging in the United States, Packaging Corporation of America (PCA), knows a lot about operating efficiency. In 2019, its network of six containerboard mills and 93 converting operations produced about 4.2 million metric tons of containerboard and shipped about 5,520 million square meters (59.4 billion square feet) of corrugated products.
10 BULK HANDLING NEWS
Over a number of years, PCA has repeatedly turned to Bruks Siwertell for its wood-processing and handling expertise. Last year, Bruks Siwertell’s new air-cushioned conveyor technology, The Belt ConveyorTM, made its debut at PCA’s highest-volume mill, Counce, in Tennessee, and this year, the company also required something special for its Wallula mill, in Washington.
“
WOOD HANDLING
By automating the woodyard, the Wallula mill will reduce its operating costs drastically DANIEL PACE, SALES MANAGER, BRUKS SIWERTELL
The Wallula mill has two containerboard machines producing semi-chemical corrugating medium and kraft linerboard. To improve operating efficiencies and reduce environmental impact material degradation, PCA approached Bruks Siwertell looking to automate its woodyard.
Reduced operating costs “The mill currently operates with manual equipment such as dozers,” explains Daniel Pace, Sales Manager, Bruks Siwertell. “This is very costly and degrades the material during handling. By automating the wood-
yard, the Wallula mill will reduce its operating costs drastically.” Bruks Siwertell’s fully automated woodyard will comprise: two Bruks back-on truck dumpers, with covered receiving hoppers, which can each process up to six bulk trucks an hour; two circular blending bed stacker reclaimers (CBBSRs), one for handling wood chips, with a storage capacity of 35,000 tons and the other for sawdust, with a storage capacity of 20,000 tons; a sawdust metering tower; and a complete conveyor system featuring Bruks air-cushion conveying technology, The Belt Conveyor. BULK HANDLING NEWS 11 11
WOOD HANDLING
The Belt Conveyor uses a pressurized air-enclosure system, eliminating the need for idlers and ensuring smooth, efficient material handling
“By choosing our blending bed stacker reclaimer, Wallula will have a true first-in-first-out management of its wood chip and sawdust storage which optimizes the blend of chip sizing across the pile cross-section,” notes Pace.
Innovative collaboration “We also had to overcome some significant engineering considerations before finalizing the equipment solution,” he continues. “These predominantly stemmed from the location of the mill, right on the Columbia River. This proximity meant that the water table, relative to the ground level where the stacker reclaimers needed to be positioned, was a challenge. PCA’s preference of the blending bed stacker reclaimer systems and their 360degree operation requires below-ground tunnels for the reclaim conveyor and emergency access. “Typical foundation designs would have been too costly. However, through innovative collaboration between Bruks Siwertell’s mechanical and civil engineers, a solution was 12 BULK HANDLING NEWS
devised that met the customer’s operational requirements as well as the project budget,” Pace says.
Preventing dust emissions “PCA not only wants the highest operating efficiencies for its mills, it also is heavily focused on the environment,” adds Pace. “All its mills are certified under the US Sustainable Forestry Initiative, and it looks to reduce its environmental impact at every stage in its production processes.” Raw materials for the mill, wood chips and sawdust, are inherently dusty, so enclosing receiving and handling systems, where possible, reduces any fugitive dust emissions. The first dust-reduction strategy is with the truck-unloading systems. As the bulk trucks are raised, the low-profile, end-pivot design of the Bruks truck dumper ensures that the truck unloads its cargo at a low elevation, approximately 2.5m above the ground, and directly into the back
“
WOOD HANDLING
PCA looks to reduce its environmental impact at every stage in its production processes DANIEL PACE, SALES MANAGER, BRUKS SIWERTELL
end of the hopper. This keeps the impact of the free-flowing material very low and results in minimal dust emissions. This is further managed with the covered receiving hoppers, which are also fitted with dust collectors, which capture fugitive dust during the initial emptying of the trucks. The Belt Conveyor technology reduces any dust or spillage even further. The conveying system is totally contained within a pressurized air-enclosure system underneath the belt. This eliminates the need for idlers and ensures a very smooth material conveying profile, which prevents any material degradation and further dust creation.
Expert, turn-key deliveries As the new woodyard will be constructed in the middle of the mill’s current one, with operations continuing, the project will be completed in two phases. The first phase
will involve the installation of the wood chip handling system, and is planned for completion by the end of 2021. The second phase, installing the sawdust handling system, is scheduled to be complete towards the end of 2022. Bruks Siwertell will be responsible for the mechanical installation, as well as the foundation design and installation of all its delivered equipment. “PCA knows what it can expect from our equipment and project involvement. Our proven track record for turn-key deliveries and our leading supplier status for stacker reclaimers in North America, builds on this confidence. PCA also knows that we have the ability to support the project from our Americas office in Alpharetta, Georgia, providing the company with a 24/7 support network throughout the project and for many years to come,” concludes Pace.
All PCA mills are certified under the US Sustainable Forestry Initiative
BULK HANDLING NEWS 13
REMOTE EXPERT ASSISTANCE ENABLED WITH AUGMENTED REALITY PLATFORMS
Significant developments in digital technology are driving fundamental industry advances, including the use of augmented reality to help support customers remotely with expert assistance from original equipment manufacturers TEXT
Daniel Frostberg and Örjan Westerberg PHOTOS Bruks Siwertell
RECENT HISTORY HAS NEVER KNOWN A TIME that customers needed to have reliable, expert service support more than this one. The dry bulk handling and processing industry feeds, powers and builds the world. The wheels of our society that have to keep turning; service is critical.
“Although the current situation forces a change in approach in some circumstances, we have always considered our customer service role as essential,” says Daniel Frostberg, Service Director, Bruks Siwertell. We know that our machines are expected to work hard day-in, day-out, with the same levels of performance for years. 14 BULK HANDLING NEWS
“Good service is therefore absolutely essential to our role as an original equipment manufacturer and supplier in the industry, but so is our ability to offer an expert-eye as quickly as possible when it is needed,” continues Frostberg.
Change on the horizon “Even before the Covid-19 crisis, our service role has been moving towards new technologies,” he notes. “The rapid advances in digitalization, connected machinery, software development and augmented reality platforms have brought about an extraordinary change in capabilities.
AUGMENTED REALITY
“We are able to leverage our service expertise with the advantages of these new platforms. This helps bridge service support to our customer’s right now, while travel is restricted, but also, as part of our commitment to continuous service development, then adopt them as a widely-available service capability, which we can continue to use in future customer communications. “The direction we are moving is a positive shift,” Frostberg says. “It is likely that there will always be a need for on-the-ground service, surveyor visits and expert inspections, but historically, call-outs have happened because the interface between the surveyor and the operator has not been good enough or accessible enough to accurately assess a situation remotely. It is these cases that can now potentially be avoided, reducing the environmental load from flight travel, and substantially reducing the cost of service visits for the operator.
Digital service portfolio Bruks Siwertell’s digital service portfolio is expanding. It builds on advanced simulation software used as a ship unloader training tool within the company and built-in connectivity with the Dell Edge Gateway, an Internet of things (IoT) device, for next-generation Siwertell road-mobile unloaders. The first models to feature the Dell Edge Gateway are 15 000 S next-generation Siwertell road-mobile unloaders; the 5 000 S and 10 000 S models will follow shortly. The system enables more extensive monitoring, follow-up, support and trouble-shooting through remote access.
“
In the future, it will also be possible to analyze the data collected from a ship unloader, through a web portal, customizing remote monitoring capabilities and advancing predictive support. “Adding to these capabilities, we now use two remote assistance platforms, Microsoft Dynamics 365 Remote Assist and TeamViewer Pilot. These provide a number of ways for an expert Siwertell product surveyor to use augmented reality to trouble-shoot and help from a distance,” explains Örjan Westerberg, Service Contract Engineer, Bruks Siwertell. “Our surveyors can see and experience what operators can via mobile digital devices such as smartphones and tablets, or even using mixed reality goggles such as Microsoft HoloLens. These visual assistance guides enable us to address a technical issue with live instructions and the ability to write notes and annotate, on a screen, highlighting the parts that need attention. It is also possible for Siwertell surveyors to communicate with customers by sending video tutorials as an explanation for a particular task.”
Connecting at every level “An additional benefit is that these new systems overcome any language barriers. Not only do they deliver clear visual guides, which improves comprehension, but also text and other elements can be translated through the platforms. Furthermore, video calls can be recorded and stored as a back-up or used at another time for training, or to refresh an operator as to the correct approach if a similar issue occurs,” Westerberg highlights.
The rapid advances in digitalization have brought about an extraordinary change in capabilities DANIEL FROSTBERG, SERVICE DIRECTOR, BRUKS SIWERTELL
BULK HANDLING NEWS 15
AUGMENTED REALITY
“We connect with customers in whatever way is most convenient to them. Sometimes a phone call is perfect, and for others we communicate across a range of different internet-based systems. The important thing is that we adapt to whatever support is needed, and these big drivers for change mean that we can access the technology to match service needs. “New times are approaching, and new types of services are developing. While we will continue to travel as before, whenever possible, these innovative communication opportunities offer real benefits and are here to stay,” concludes Frostberg.
Technical issues can be addressed with live instructions and the ability to annotate a screen, highlighting parts that need attention
NEW STEPS FORWARD INTO DIGITAL ERA Bruks Siwertell is embracing all the advantages that advanced technology can deliver, strengthening its systems so that these can pass on commercial benefits to customers. Recent new additions include a semi-automatic unloading system and an operational and maintenance management tool. The new semi-automatic unloading system helps to deliver maximum efficiency during the freedigging phase by making the unloading operation less dependent on the skills of the operator, which increases safety and reduces the likelihood of damage to the unloader. It also enhances overall through-ship performance.
customers rapidly identify any potential bottlenecks and therefore enhance efficiency. The tool covers performance elements during an operation, such as tons of material unloaded – highlighting the unloader’s average capacity – tons of material remaining in the vessel’s holds, and the time taken since commencing the unloading operation. Other parameters that can be analyzed include off-hire time, historical performance of the ship unloader, and component data collection as well.
Further expanding the digital portfolio is the operational and maintenance management tool, which can optimize a customer’s entire unloading process and ongoing service strategy.
For digitally enhanced maintenance analysis, the tool will be able to provide detailed information about service intervals. This can include data down to component-level, keeping track of which parts need service attention and when. It can also include online support.
In terms of operational management, the new tool collects critical data for advanced analysis. It has been specifically designed to provide an accurate overview of unloading operations, helping
The new operational and maintenance management tool is suitable for all large-scale Siwertell ship unloaders, including port-mobile units; road-mobile unloaders can also benefit from a tailored version.
16 BULK HANDLING NEWS
EXTRAORDINARY TIMES REQUIRE RAPID, INNOVATIVE RESPONSES
The Covid-19 pandemic has brought about some of the most significant societal changes and restrictions that modern populations have even seen, but within this, the wheels of economies are still turning, requiring business to respond and adapt TEXT
Axel Dahl, Per Hansson, Stephanie Dong, and Daniel Nilsson PHOTOS Bruks Siwertell and Shutterstock
with the majority of people directly and indirectly impacted by the Covid-19 pandemic. The universality of this shared experience means that everyone understands the restrictions that are in place, but businesses still need to continue operating and customers still need support. IN THE LAST FEW MONTHS, THE WORLD HAS CHANGED,
The very nature of the dry bulk handling and processing markets mean that these sectors are critical; transporting the materials for life’s essentials. So, for port terminal equipment, how has Bruks Siwertell ensured that these continue and that customers get the help they need? Furthermore, has the crisis raised any opportunities for positive change?
Importance of a hand-shake “We operate in a business where practically all contact and discussions have historically been carried out faceto-face, during physical meetings,” says Axel Dahl, Sales Manager, Bruks Siwertell. “As most of our machines are custom-made, a great deal of time and energy is spent in technical discussions with customers to ensure that a final solution is the most effective for an individual operator’s needs. “The pandemic changed this almost overnight,” continues Dahl. “Today, they are instead held remotely via internet link, with people joining from either their home or their workplace. BULK HANDLING NEWS 17
C O V I D -1 9
“For customers where we have an established relationship this works fine, even though it is not optimal. However, with new customers, it is a bit more of a challenge as we have not had a chance to establish a relationship and understand the nuances of their operations,” he says. Bruks Siwertell’s dry bulk handling operations are coordinated from its offices in Bjuv, Sweden, which stands out as a country with a different approach to the pandemic to many. Although restrictions are in place, it has not seen the national lockdowns familiar in others and extremely tight travel restrictions. “We are aware that we are operating a bit differently as a country,” Dahl points out. “Each country has its own travel restrictions, which can make it complicated, but from our point-of-view, we just have to adapt to the situation. “I think the main challenges to our way-of-business-life is habit: we are used to having physical meetings; we are used to being able to travel at ease. We are in an industry where meetings held through video conferencing is a new concept, where other industries have operated like this for many years. Change can be difficult, but we are transforming. “In fact, this change was actually easier than we first thought, particularly because what is happening is a common experience; customers and suppliers are of the same opinion, let us make the best of the current situation,” he says.
Restrictions bring rewards “There are also benefits; schedules are more open, as you can have meetings with different customers from different countries in the same day. Many customers are focusing more on the environment and their return on investment; these are some of our key strengths as a company. Restrictions on flight travel are having a positive environmental impact, and once these have been lifted,
“
some customer meetings can definitely continue to be held via internet links, and some things might never return to the way they were. “Except for the environmental impact of traveling, however, face-to-face physical meetings offer something that online ones do not. We are social creatures after all, we respond to each other’s presence and build relationships more quickly. A handshake has always been a gesture of trust. I cannot see it losing this importance, but at the moment, it is not worth the risk. “The pandemic has of course affected and impacted the entire world, and our market is not an exception. Some projects have been affected, whilst others have carried on with little interruption. The way we interact with customers has been completely reshaped. “Even though we cannot rely on visits and conferences to make new contacts and get our messages out to the industry, I think that this is a good opportunity to take a step back and focus on the core strengths of our business; maximizing the efficiency and minimizing the environmental impact of handling dry bulk. It is our responsibility to help customers find the best solution for their terminals. In times like these, this is more important than ever,” concludes Dahl.
Projects managed remotely Connecting with operators and finalizing equipment and terminal designs presents a specific set of challenges during these times, but surveying, building and delivering equipment reveals a whole new array of considerations. When asked: what has been the biggest change in how you are able to deliver and commission an unloader installation during the pandemic? Per Hansson, Project Manager, Bruks Siwertell, replied: “Everything.
We have witnessed our strengths and have discovered new ways of working and communicating PER HANSSON, PROJECT MANAGER, BRUKS SIWERTELL
18 BULK HANDLING NEWS
C O V I D -1 9
Staying on track
Change can be difficult, but also transforming
“As most borders were closed, and some still are, travel is restricted so sending out supervisors and commissioning engineers is difficult. The current situation means that our ordinary work takes longer and new site visits, to evaluate and study them, have been difficult to achieve. We solved much of this by relying on our local representatives and colleagues, establishing group ‘chats’, and internet-based communication platforms. We also had to dictate more subject-specific documentation and additional information to help guide people on how to carry out work,” continues Hansson. But, like Dahl, Hansson notes some positives to this change. “We have witnessed our strengths as a team and company, and have discovered new ways of working and communicating. We have been forced to look at our operations from another perspective, driving a resolve to consider better alternatives. This is a good thing, and has a positive environmental impact. “A face-to-face discussion can never be replaced by a computer and a monitor, and for much of our work, we are needed ‘on the ground’, but for sure some project meetings and different follow-up functions, can absolutely be done remotely and was something that we had already started to implement,” he says.
Working, at times, from what he calls his ‘command-centre’ at home, Hansson explains that some projects naturally found themselves mid-way through and needing input. “This has been a challenge, but like us, customers are open and understanding, focusing on solving issues. They rightly want us during ongoing commissioning work. Because of an exemption for specialist assistance for essential business, we have been allowed to travel to some sites without having to quarantine upon arrival. However, for others, in fact most, we have to quarantine for 14 days, before work can commence. It is also difficult to keep track of all the changing restrictions around the world; but we do what we can to stay on our toes. “To highlight one ship unloader assembly project in China, a primary task that we had to undertake was a risk assessment; evaluating the situation that Covid-19 put us in and assessing all elements that needed to happen to keep a delivery on track. This included local and technical, commercial considerations as well as the project’s execution. “All of this was discussed with the customer and together we presented a solution for the four different scenarios, resulting from the impact of Covid-19; all of which we now had a solution to. With this as a basis, we carried them out accordingly, and in the knowledge that we had a bounty of back-ups if the situation shifted,” he notes. “We also established specific chatgroups for assembly personnel, so that for us in Sweden, we could respond quickly when a question from the site arose. To further strengthen back-office support, we had weekly project meetings, both internally as well as with the owner, monitoring not only the project but also the evolution of Covid19,” says Hansson. “We are used to having our own people on site, so for this assembly case, we really did have to step out of our comfort zone. Information and communication are BULK HANDLING NEWS 19
C O V I D -1 9
everything. Our Chinese co-workers not only needed enough information, but good information to ensure the quality and outcome of the work. It is a fine line, as too much detail is confusing and has the opposite effect to clarifying something. “Our communication network, with all relevant experts, was reviewed regularly. Thanks to our colleagues in China, who know our equipment well, this was a very successful approach. As a collective they are very strong and I had no concerns about their ability to undertake the work. “The ship unloader has now been successfully assembled and is currently on a vessel bound for its final destination. Once ready at the site, our physical presence will be required for commissioning,” Hansson notes.
We do it together A key player in the successful assembly of the ship unloader came from support from Bruks Siwertell’s offices in Shanghai, headed by Stephanie Dong, General Manager, China. Commenting on the project, Dong notes that it was a “vivid example of our capabilities to ‘do it together’. Through working remotely, but closely with colleagues from Sweden, we assembled the machine and completed its shipping as a team.”
Like her colleagues, Dong says that the biggest shift in recent times is moving face-to-face meetings to internet-based platforms. “Currently, we have had to rely on our own local personnel for China-based installations, which is fine, but it is always good to have all the relevant experts on-the-ground for projects. “For us, the main challenges of the pandemic are that potential customer visits have been postponed due to travel restrictions, and it takes a little longer to send service personnel to help with any technical issues. Also, delivery schedules are having to be extended and spare parts need to be ordered with a bit more lead time,” Dong says.
A digitalization boost “On a positive note, I think this pandemic has pressed the ‘fast-forward’ button on the digitalization keyboard. We are adopting advanced technologies faster and are embracing this change, which will definitely bring competitive opportunities in the future,” she notes. “Remote offices and online business styles are more and more widely used. We have realized the efficiency and convenience of these online collaborations, which is vital in turning a ‘passive’ position into an ‘active’ ongoing positive choice for the company. The communication tools that we now have at our finger-tips, if used
Not being able to visit customers has brought about some unique challenges for operator training
20 BULK HANDLING NEWS
“
C O V I D -1 9
I think this pandemic has pressed the ‘fast-forward’ button on the digitalization keyboard STEPHANIE DONG, GENER AL MANAGER, CHINA
correctly, can prove extremely helpful and also reduce the number of some costly, both financially and environmentally, travel. “Besides, through the continuing integration of Bruks Siwertell’s resources and a well-built contingency plan to reflect the best advantages in the change of operational procedures, we have been able to gather the efforts of the whole China team. We have learned that, with the support of the wider organization, some essential work can be performed by local staff, which benefits customers and the whole company,” highlights Dong.
Keeping it interesting Another area of change is in operator training, needed not only once a ship unloader has been delivered, but throughout its lifetime to ensure peak operating performance years down the line. Not being able to visit customers has brought about some unique challenges for training experts like Daniel Nilsson, Project Leader Electrical Systems, Bruks Siwertell. “Remote training has to be more detailed, but even more interesting. Engagement is key in an online setting, where you lose some of the dynamism that is naturally present in face-to-face sessions,” he says. Bruks Siwertell is already moving forwards with its digitalization portfolio, capitalizing on the benefits that augmented reality can deliver to its customers (page 14). The use of these platforms and other practical and theoretical training methods is helping to bridge this current gap in travel. “Once we understood that this was the direction that we needed to go in, we were quickly able to move to online training portals. But we know from our extensive experience that making these sessions interesting is essential to embed learning.
“People naturally ease-off their concentration over time and it is our responsibility, as trainers, to help maintain it and ask the right questions. This helps to ensure that important information is being absorbed.”
Mixed approaches bring benefits “There are also benefits to having a change in approach to ‘live’ online training, as trainers are more accessible; the downside, for us, is the difference in time zones. As to whether they continue after, or if the travel restrictions can be lifted, I think a mixed approach needs to be taken. For clients that already have a good working knowledge of their Siwertell unloader, then this can definitely be a successful approach. However, for those who are completely new to our systems, I would prefer to carry out on-site training. There is a lot to learn, with many different interlocking procedures that we need to demonstrate. This is a lot more challenging when working through an interpreter as well. “There is also a great deal of value being with an operator, and carrying out training using their unloader. New operators naturally have a lot more questions and we can answer them as they crop-up,” notes Nilsson. “Saying this, the online training sessions that we have had to conduct through the initial acute phase of the pandemic have been really successful. For example, an operator in Mexico was thrilled that we were able to do the training online. It was reaching its deadline for the project, and today the ship unloader is up and running. “Like many things, it was a challenge at first, as this way of working and set-up was completely new to us, and for the project team, but when everyone put their efforts into it, we managed to train the operator and they now have a fully functioning ship unloader in peak operation,” concludes Nilsson. BULK HANDLING NEWS 2 1
DIFFICULT WASTE WOOD HANDLING DEMANDS MET WITH EASE Recovering energy from multiple resources paves the way for a sustainable future; by working closely with biofuel specialist, ICM, Bruks Siwertell helps the company showcase a biorefinery at its best TEXT
Ken Upchurch  PHOTO Shutterstock
AS COUNTRIES SHIFT from fossil fueldriven economies to renewable ones, there is an increasing focus on the use of waste. Making an energy product from it is one of the most sus-
22  BULK HANDLING NEWS
tainable power-generation strategies available today. This is exactly what a process called gasification can do. It can turn carbon-
based feedstocks, under high temperature and pressure, into synthesis gas, or syngas. Furthermore, by combining gasification with advanced catalysts that speed up chemical
BIOFUEL
reactions, ethanol fuel can be created from a wide range of biomass. This includes distillers grain, left over from alcohol production; agricultural by-products such as postharvest leaves, stalks, and cobs of corn, grass, wood pulp, animal waste; and even shredded tires and general rubbish. Gasification’s versatility means that it is gaining increased industry interest. Leading USA-based technology specialist, ICM, started operations in 1995, developing commercial dryers to improve the longevity and quality of grain for distillers. Its biofuel industry advances, including patented gasification equipment, have continued since then, and the company cites that plants using ICM technology collectively produce 8.8 billion gallons of ethanol annually. Much of the company’s focus is adding value back into industry through designing biofuel plants and supplying technology that enables producers to diversify and make something valuable from their waste products.
Biofuel industry advances As part of its development strategy, ICM, in joint venture with ethanol specialists The Andersons, has built a state-of-the-art biorefinery, Element, adjacent to ICM headquarters in Colwich, Kansas. The plant will be used to demonstrate and showcase advanced renewable fuels technology; a part of this process required expertise from another quarter, Bruks Siwertell.
Waste wood to energy “The new plant needed a system capable of handling and processing
“
ICM approached us for our extensive experience in handling difficult wood waste KEN UPCHURCH, VP SALES AND MARKETING, BRUKS SIWERTELL
difficult waste wood products,” explains Ken Upchurch, VP Sales and Marketing, Bruks Siwertell. “The waste wood is used to fuel ICM’s advanced gasification technology, driving a combined heat and power generator that will offset a considerable portion of the plant’s natural gas requirements and electricity demands,” notes Upchurch. “Our extensive experience in dealing with and handling difficult wood waste residues, similar to the target materials destined for use by the facility in its processes, was one of the reasons why it approached us,” he continues. “Actually, the very start of our conversation was meeting ICM representatives at an international biomass conference event in 2014.” Bruks Siwertell was contracted by ICM for a complete woodyard, capable of truck receiving, conveying, and processing. “It is a complex, yet beautifully laid out system,” says Upchurch. It comprises a 4.9m (16ft) dual truck-receiving hopper, four heavy-duty belt conveyors, a disc
screen and hog-sizing transfer tower, magnetic separator, three stoker floor reclaimers and a screw conveyor.
A plant with a difference Its owners note that the refinery’s features, which differentiate it from others in the industry, including its waste wood heat and power-generation capabilities, are its high protein distillers dried grains (DDGs) production for onward use as livestock feeds, and cellulosic ethanol production using corn kernel fiber feedstock. “Our heavy-duty machinery is an integral part of the plant’s efficiency and distinguishing features,” adds Upchurch. “All our equipment is known for robustness and reliability and its ability to operate 24/7 in extreme conditions, handling a variety of difficult materials.” The Bruks Siwertell system was installed at the beginning of the year and now supports the plant’s aspirations to be the most efficient dry mill facility in the US, producing low-carbon intensity ethanol. BULK HANDLING NEWS 23
BLACK GOLD: MAKING SUSTAINABLE STEPS For centuries, coal has provided a cheap, stable source of heat and power for millions, but times are changing; a collective approach to reduce its environmental impact and drive sustainable energy generation is needed, explains Per Karlsson, President, Siwertell AB, part of Bruks Siwertell Group TEXT
Per Karlsson PHOTOS Studio E, Bruks Siwertell and Shutterstock
24 BULK HANDLING NEWS
S U S TA I N A B L E F U E L H A N D L I N G COAL IS A MAJOR DRY BULK CARGO traded all over the world for use in power plants and industrial processes such as steelmaking. It is required in huge volumes, with the World Coal Association (WCA) estimating that international trade reached 1.2 billion metric tonnes in 2019. However, the WCA notes that this figure only accounts for about 21 percent of the total coal consumed, as most coal is used in the country where it is mined.
In the face of coal’s continuing popularity, there are significant industry strides to make its use more sustainable. In the spotlight are high-efficiency, low-emission (HELE) coal-fired power plants, which employ carbon capture, use and storage (CCUS). The WCA cites that by increasing the current average global efficiency rate of coal-fired power plants from 37.5 percent to 47.5 percent, CO2 emissions could be cut by two gigatons. The WCA is confident that near-zero emissions from burning coal is a possibility with the use of these new power plants. However, for sustainability, every part of the coal logistics chain has to come under environmental scrutiny. This includes the way it is handled and received by ports. Dominating the port skyline for decades are grab cranes. Solid, flexible machinery that was best on the market when introduced. Now, with no containment for dust emissions and a spillage rate of up to two percent per load, we have to question whether these are still acceptable for handling coal. Spilled cargo is wasted cargo, fundamentally impacting the environment, and the efficiency and profitability of an operation. We believe that we can do much better in terms of efficiency and the environment.
“
Spilled cargo is wasted cargo PER K ARLSSON, PRESIDENT, SIWERTELL AB
The Ligna Biomass terminal in Liverpool, UK, is equipped with two ST 790-D high-capacity Siwertell unloaders
Out-performing efficiencies For ship unloading, we define the efficiency of our machines by comparing the actual through-ship unloading capacity against its rated capacity. A grab crane, for example, offers efficiencies of between 50 and 60 percent, and, in comparison, our totally enclosed Siwertell screw-type ship unloaders deliver efficiencies of 70 percent or more. When considering average capacity, for our calculations, this always includes all movements between the different holds, as well as handling the excavator in and out of them, down to a machine clean level; sweeping is excluded. To understand how unloading methods and machines stack-up against each other and genuinely perform, you need to compare the same parameters and take everything into account. For example, a performance test was carried out with two Siwertell unloaders, each with a rated capacity of 2,200t/h, discharging a 80,000 dwt vessel, fully loaded with coal. The unloaders delivered an average capacity above 77 percent; the time it took to completely unload the vessel including all movements as well as handling the excavators. This performance is outstanding if you take into account that as rated capacities increase, it is more difficult to keep a high average capacity because of the larger differences between clean-up and rated capacities. BULK HANDLING NEWS 25
S U S TA I N A B L E F U E L H A N D L I N G
Supporting sustainable switches There is also a very special thing that a Siwertell unloader can do; it can efficiently support coal-fired power plants with co-firing – burning coal and biomass – through to their complete transition to only burning biomass and achieving carbon-netral, sustainable power generation.
Siwertell unloaders can efficiently discharge both coal and biomass, supporting power plants with their carbon-neutral transition
Greater efficiencies explained The steady, continuous unloading profile offered by a Siwertell ship unloader is maintained regardless of cargoes levels in the hold. In comparison, with grab cranes, for example, at the beginning of an unloading operation, the grab only travels a very short distance to reach the cargo. However, as more bulk material is unloaded, the greater the distance the grab has to travel, into and out of the hold. Therefore, the efficiency progressively decreases. A Siwertell unloader’s conveying arm can also reach under the hatch coamings and into the corners of a hold. This capability adds to their high average through-ship capacities, impacting the efficiency and profitability of a terminal. By overcoming containment, through an enclosed conveying line, eliminating spillage and dust emissions, and by offering the highest average through-ship capacities on the market, a Siwertell unloader tackles two of the main environmental drawbacks of unloading coal with a grab. They also out-perform other heavy machinery including bucket chain unloaders. These are not completely enclosed in the material transfer between the vertical and horizontal conveyor, so fugitive dust is still an issue. Meanwhile, chain unloaders are enclosed, but cannot withstand any digging forces, making them less suitable for compacted bulk like coal. 26 BULK HANDLING NEWS
On average, biomass is about half the density of coal with only two-thirds of its calorific value, driving up required volumes for the same energy output.
This step-up in demand is not as simple as it sounds, in addition to these increased volumes, biomass requires careful handling as pellets are fragile, and break down if not unloaded, stored and conveyed correctly. They are also very dusty and prone to self-ignite; other factors that systems that unload them have to accommodate. A Siwertell ship unloader is the only totally enclosed unloader capable of this. Switching from coal to biomass makes good use of the carbon emissions already imbued in the construction of the power station itself and its infrastructure. Furthermore, if biomass is sourced sustainably and carbon-capture from burning it is adopted, then it holds great promise.
Phasing out coal power Power stations already making that switch are numerous, and they are backed-up with our expertise. In the UK, Drax has almost made a complete transition away from coal; it represented three percent of its power generation in 2019, down from 30 percent in 2016. The power station supplies the UK with about six percent of its renewable power. The lion’s share of wood pellet supply for Drax’s boilers are US imports, which are processed and handled using our Bruks wood-processing equipment, truck receiving and ship loading systems.
“
S U S TA I N A B L E F U E L H A N D L I N G
A Siwertell ship unloader is the only totally enclosed unloading system capable of safely discharging biomass PER K ARLSSON, PRESIDENT, SIWERTELL AB
Drax receives biomass unloaded at several UK locations including the Immingham Renewable Fuels Terminal (IRFT), operated by Associated British Ports, where the US wood pellets arrive on dedicated self-trimming bulk vessels of between 25,000 and 50,000 dwt. Since 2014, these cargoes have been discharged by two rail-mounted ST 790-D Siwertell ship unloaders and prior to that they handled coal. In 2016, the Ligna Biomass terminal in Liverpool, UK, came online. Operated by Peel Ports, the material terminal can store up to 110,000 metric tons of biomass. Like IRFT, Ligna is equipped with two ST 790-D highcapacity unloaders, which supply the power station with up to ten train loads of pellets per day and account for up to 40 percent of the total biomass consumed by Drax each year.
For our part, a rail-mounted high-capacity Siwertell ST 790-D unloader has operated in the Avedøre harbor since 2013. Again, originally ordered for unloading both coal and biomass cargoes interchangeably. It now handles 100 percent biomass, after Ørsted converted the plant for full-biomass operation in 2016. In Asia, biomass often takes the form not only of wood pellets, but also palm kernel shells from Indonesia and Malaysia. In southeast Asia, at the Tembusu Multi-Utilities Complex (TMUC) on Jurong Island in Singapore, a combination of energy production, desalination, and wastewater treatment is powered using coal, wood chips, and palm kernel shells. Two ST 640-M rail-mounted Siwertell unloaders have served TMUC since 2012, alternating between unloading coal and various biomass cargoes in a seamless and environmentally friendly way.
Clear sustainability targets So, the shifts in sustainable power are present, and we are responding to these market changes in the most efficient way possible. Many arguments are still ongoing as to the environmental impact of biomass, but one thing is clearly evident, to be sustainable, a dry bulk unloading system must be efficient, and absolutely cannot waste valuable material through spillage, or pollute the environment with dust emissions.
Denmark, like many of its Scandinavian neighbors, has also made significant strides towards sustainable energy production. The Avedøre combined heat and power (CHP) station is one of the most efficient in the world, able to burn coal with as much as 94 percent efficiency by converting 49 percent of its potential energy into electricity and distributing the other 45 percent as residential and industrial district heating. Operator Ørsted, formally Denmark Oil and Gas (Dong Energy), has reduced its coal use by 73 percent since 2006, replacing it at its various power plants with biomass, as part of its target to ultimately phase out coal power completely by 2023.
Significant industry strides are being made to make coal handling more sustainable
BULK HANDLING NEWS 27
CUSTOMIZED TRUCK UNLOADER DELIVERS DUST CONTROL WITH A DIFFERENCE A specially designed truck unloading solution, which not only ensures fast, efficient truck unloads, but also prioritizes environmental protection, has been installed at a US biomass plant TEXT
Alex Alderks and Christopher Duffy PHOTOS Bruks Siwertell
TECHNOLOGY IS OFTEN ABOUT GETTING THE RIGHT BALANCE ,
sometimes gains in one area of performance are traded against others to deliver a final product that is ideal for a task, but not always. An area that leaves little room to compromise is environmental protection. Increasingly strict regulations, enforcement by air quality agencies, and environmentally conscious operators
28 BULK HANDLING NEWS
are driving some of the biggest advances in controlling dust emissions in the processed wood industry. Bruks Siwertell has recently been asked to go one step further in dust control by a wood biomass plant. The US facility needed a solution to efficiently unload a variety of dry biomass material from bulk trucks while controlling dust emissions above and beyond standard levels.
“Over the years we have supplied various other equipment to the customer’s network of plants and mills,” notes Alex Alderks, Design Engineer for truck dumpers and stacker reclaimers, Bruks Siwertell. “These systems have served the company really well, which is why it approached us when it needed something out of the ordinary; a complete, innovative truck dump receiving system.”
TRUCK DUMPER
The new contract called for Bruks Siwertell to supply a back-on truck dumper with a receiving hopper and dust collector, which combined to ensure close to zero fugitive dust emissions. “We listened to what was needed and worked together to develop the best solution for its biomass-receiving needs,” says Alderks. “The discussions resulted in a customized solution, which delivered high levels of dust control, without compromising on efficiency.”
“Our systems have a low-profile design,” explains Alderks. “This means that trucks tip their load as close to the ground as possible, which reduces the impact of material flowing out the truck and landing in the hopper in a cloud of dust. This strategy is sometimes enough dust protection, but not in this case, where the materials the plant receives are very dusty.” The new receiving hopper is covered on all sides and totally contained, protecting the surrounding environment against potential dust emissions and minimizing any material losses. A dust collector enhances this capability by negatively pressurizing the air to capture any dusty material in the receiving area and reintroducing it back into the system for use, further adding to the facility’s efficiency.
Total dust control The system comprises a platform and a set of hydraulic cylinders used to lift the entire truck. It is designed to rise to a maximum angle of 63 degrees, causing the free-flowing material to dump out of the back of its trailer and into a fixed, covered receiving hopper. The full lift and lower cycles are completed in approximately four minutes and the new truck dumper has the capacity to unload biomass at a rate up to 85t/h.
“
“Since its commissioning in early 2020, the system has significantly reduced dust emissions, improved material handling efficiency and strengthened the customer’s sustainability drive,” notes Alderks.
Popularity based on performance “Controlling dust emissions from handling dry materials is an important concern at many such facilities,” continues Christopher Duffy, Area
Controlling dust emissions from handling dry materials is an important concern CHRISTOPHER DUFF Y, BRUKS SIWERTELL AREA SALES MANAGER
BULK HANDLING NEWS 29 29
TRUCK DUMPERS
Sales Manager, Bruks Siwertell. “While wet chips and barky fuels are not that dusty, dry sawdust, planer shavings, and many agricultural materials are very dusty, and can easily be problematic if left unchecked and uncontained. “Chip trucks are used throughout North America as an efficient and flexible way to transport pellets, hogged fuel, wood chips and other cargoes,” Duffy explains. “But unloading them needs consideration, if these dust emissions are to be controlled. “Our Bruks truck dumper systems are relied upon throughout the North American wood products industry, and time and time again have proved to be by far the most effective method for receiving these materials. “A key element of their popularity is that they can offer very efficient unloading cycles, but added to that,
Bruks Siwertell’s truck dump platforms offer an expected service life of two million tipping and lowering cycles
also specially designed, covered receiving systems that are so wellmatched to the tipping platform, that they minimize dust emissions to negligible levels. The covers can
be fixed or articulating, depending on what is needed, but any configuration combines to deliver the most sustainable, optimized, safe unloading process.”
DIFFERENT TRUCK DUMPERS TO SUIT ALL APPLICATIONS With around 75 installations worldwide, Bruks Siwertell’s truck dump tipping platforms are one of the fastest, most effective ways to discharge free-flowing materials, such as processed wood, from bulk trucks. They deliver long-term, cost-effective operations and have been designed to reliably perform under very high-use conditions, offering an expected service life of two million tipping and lowering cycles, which exceeds 25 years of full-time operation.
BRUKS SIWERTELL’S RANGE INCLUDES THREE MAIN TRUCK DUMPER SOLUTIONS: • BACK-ON TRUCK DUMPERS are much as the name describes, drivers back their trailers onto the platform where raised tire guides keep them positioned as the cab reverses. Average times between trucks is usually less than ten minutes including backing on, lifting and lowering the load, closing the back doors, and then driving off the platform.
30 BULK HANDLING NEWS
• DRIVE-OVER TRUCK DUMPERS allow for trucks to be driven straight onto the tipping platform in a forward position, crossing a pit bridge. The average time between trucks is eight to nine minutes, making this process slightly faster as the driver does not need to reverse a trailer into place. • EXTENDED ARM TRUCK DUMPERS enable the rapid unloading of free-flowing dry bulk material into a receiving hopper, which is tilted and positioned above ground. This minimizes civil engineering costs by reducing overall truck ramp requirements. The extended tipper arm allows material to fall from the trailer into the angled hopper. With the trailer dumping at this raised elevation, material cannot build up inside the trailer, potentially increasing cycle times. This enhances efficiency and maintains an optimum truckprocessing capacity.
OUR PEOPLE
OUR PEOPLE Mats Lindberg KEY ACCOUNT MANAGER, SERVICE
Even after more than two decades working with Siwertell machines, Mats Lindberg’s curiosity has not wavered; collaborating with customers, finding solutions for their challenges are as rewarding now as they ever were with a unique manufacturer, Bruks Siwertell. I have an inquisitive mind, interested in both new and old technology and I have worked with Siwertell products for 23 years; every day I still find something to be curious about. BJUV, SWEDEN, IS A SMALL TOWN
My main roles are in account management, working closely with colleagues in Asia and with customers, supporting them with service and spare parts sales. Our machines are incredible. They stand out on the market, like no other dry bulk handling product.
Years of service We work together with customers and within our organization to make sure that all technical aspects of the Siwertell unloader or loader that they operate work as well years down the line as they did on the first day of service. This takes commitment and a sustained dialogue between customers and ourselves. Day in, day out it is a privilege to work with so many great colleagues, sharing an interest in doing a great job. This, of course, extends to the many people that
work with our machines at installations all over the world. Humor and a positive attitude are essential to our encounters. Finding solutions for customers is part of our job and one that I find extremely rewarding. It is great to solve a problem and for that to be appreciated; I am not sure I will tire of that. Many things have changed over the years and it is great to be able to offer these advances to operators as and when they are developed. But, the fundamentals of the machinery remain essentially the same; it is as remarkable now as it has always been.
Freedom to grow Meeting customers ‘in their own backyards’ and learning from their experiences has also been an enlightening part of my role and is an important aspect of understanding an operation. It is wonderful to get to know many different cultures as well. As an organization, Bruks Siwertell offers many opportunities to grow your career and develop in the areas that interest you. I have always had the freedom to advance within my field. In these times, I am currently missing the ability to travel, but I am enjoying living life to the full in this small, interesting town with my family and our cat. BULK HANDLING NEWS 31
BRUKS SIWERTELL GROUP Bruks Siwertell is a market-leading supplier of dry bulk handling and wood processing systems. With thousands of installations worldwide, our machines handle your raw materials from forests, fields, quarries and mines, maintaining critical supply lines for manufacturers, mills, power plants and ports. We design, produce and deliver systems for loading, unloading, conveying, storing, and stacking and reclaiming dry bulk materials, alongside equipment for chipping, screening, milling and processing wood for the biofuel, board, sawmill, pulp and paper industries. We are global and local. You will find our main offices in the US, Sweden, Germany, China, the Philippines, Russia and Taiwan, supported by a dedicated network of hundreds of representatives and dealers worldwide. An extensive global service team offers support to all Bruks Siwertell Group customers whenever and wherever it is needed.
SHIP UNLOADING · SHIP LOADING · TRUCK UNLOADING STACKING & RECLAIMING · CHIPPING · CONVEYING MILLING · SCREENING · WOOD RESIDUE PROCESSING
bruks-siwertell.com
