Bulk Handling News - Bruks Siwertell customer magazine issue 2, 2022

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BULK HANDLING

NEWS BRUKS SIWERTELL CUSTOMER MAGAZINE

#2/2022

Alumina unloading 18 efficiency exceeds expectations


CONTENTS

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CONTENTS 4 News in brief 7

Our People: Pedro Alfaro

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Mexico’s new ultra-efficient agri-bulk terminal underpinned by Siwertell unloader

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Customized air-cushion conveyor meets niche cotton seed handling needs in Arizona

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Improved screw-conveyor lifetimes deliver direct cost savings

18 Road-mobile alumina unloader exceeds expectations in France 22 New company values guide Bruks Siwertell Group


EDITORIAL

ABOUT BRUKS SIWERTELL 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 ship loading, ship unloading, conveying, storing, stacking and reclaiming dry bulk materials, alongside equipment for chipping, screening, milling and processing wood for the the bioenergy, 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

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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: Bruks Siwertell AB P.O. Box 566 Gunnarstorp SE-26725 Bjuv, Sweden Editors: Emily Brækhus 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 Image sources: Shutterstock and Bruks Siwertell

By your side for over 125 years Dear reader, I do not need to tell you that these are unsettled times, we are all navigating new challenges arising from a pandemic, the global disruption to supply chains, and ensuing political turmoil and crises. Since 1897, we have stood by our customers, both through the good times and the difficult ones; and we are keeping this promise now. The pandemic highlighted the critical nature of our industry and the role we all play in the global transfer and processing of dry bulk materials, maintaining the supply of fuel and food. Ports, more than ever, need to rely on the efficiency of their technology, discharging vessels as fast as possible to free up jetties and reduce back-logs. For us, these times have brought a renewed focus and clarity, leading to the development of new company values: impact, commitment and teamwork. We are working hard on our sustainability goals, considering all aspects of environmental impact, and striving for positive change. We are dedicated to these processes and our integral commitment to enhancing our customers’ operations. Teamwork underpins all our activities. Part of our company ethos is the commitment: ‘we do it together’. We exhibit these capabilities throughout this issue. We have completed a recent innovative research and development (R&D) program to extend the lifetime of the vertical screw conveyor. It yields extremely positive results, delivering significant through-life cost savings and reducing environment impact. The magazine highlights how our conveying and wood-processing systems contribute to the global shift towards e-commerce and sustainable construction, and the continuing drive to look for bioenergy sources. It also features our unloading systems and how these are positively contributing to the grain handling capabilities of Mexico and the alumina industry in France. I hope that you enjoy reading about these, and much more, in this issue of Bulk Handling News.

Printed by: Exakta Print AB, Malmö 2022

Peter Jonsson, Group CEO BULK HANDLING NEWS

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NEWS IN BRIEF Siwertell ship unloader meets Quezon’s doubled power demands A new Siwertell ST 790 D-type ship unloader now serves Quezon Power Ltd Co’s newly built coal-fired San Buenaventura power plant in Mauban, the Philippines. The 500 MW facility is the country’s first supercritical power station and is located next to an existing Quezon power plant. Since coming online, the operator’s energy output has doubled, requiring an equivalent doubling of coal intake to around three million metric tons a year. These needs are now met with two rail-traveling Siwertell ST 790 D-type unloaders, which share the same jetty, rails and belt conveyors.

long-term value from high jetty utilization rates, reliability and the long service life of wear parts. “Quezon knows that our machines deliver excellent operational and environmental credentials,” notes Wahlström. “The company’s satisfaction with its existing unloader certainly played a part in it ordering a second one.”

The first Siwertell ship unloader was delivered in 1998 and has been in operation for almost 25 years. The latest unit was delivered, fully assembled via heavy-lift ship, to the site in early 2022. Both unloaders have a continuous rated capacity of 1,400t/h and are able to discharge vessels up to Panamax size. “The jetty has significant weight restrictions, making the Siwertell unloader a stand-out choice for this installation,” says Per Wahlström, Project Manager, Bruks Siwertell. “Its high capacity to weight ratio was likely to have made it the only equipment with sufficient capabilities that could be installed.” Environmental protection is also a major priority for Quezon, and any coal spillage is not permitted. Siwertell screw-type ship unloaders are one of most efficient and environment-friendly types of unloaders on the market. They deliver totally enclosed dry bulk material handling, eliminating spillage and dust emissions, and also ensure 4

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Together, two Siwertell unloaders handle nearly three kilotons of coal per hour for Quezon


NEWS IN BRIEF

Road-mobile ship unloader ordered for dust-free cement handling in Sweden Later this year, Swecem AB, a subsidiary of Peab Group’s Swerock, will take delivery of its Siwertell 10 000 S next-generation road-mobile ship unloader. Ordered to secure environment-friendly, dust-free material handling in the port of Helsingborg, Sweden, it will deliver a continuous cement unloading capacity of 300t/h, discharging vessels up to around 10,000 dwt. “Environmental protection is a key consideration for Swecem’s operations and it adheres to very strict Swecem will meet increasing environmental demands with its new Siwertell unloader standards,” explains Jörgen Ojeda, Sales Director Mobile Unloaders, Bruks Siwertell. “With this in mind, sustainable steps,” Ojeda continues. “Sweden has a Swecem was looking for a ship unloading solution that mounting legislative drive to reduce the environmental could deliver continuously high through-ship capacities, impact of the country’s cement industry. However, the but at the same time, ensure enclosed dry bulk material same industry has to maintain, and even exceed, current handling to minimize any environmental impact. ship unloading capabilities to keep up with growth, posing “This is also an important order because it is part of a a potential future gap in supply and demand. Our systems growing picture that will see all operators taking more can, and will be, part of this positive change.”

Bruks waste handling system boosts sustainability at PCA mill A new material waste handling system will soon be operational for Packaging Corporation of America (PCA). The receiving hopper, screw conveyors, and a conventional idler belt conveyor will handle rejects from old corrugated cardboard (OCC) to fuel boilers for power production at the company’s Jackson, southwest Alabama, US, containerboard mill.

PCA is the third largest producer of containerboard products and the third largest producer of uncoated freesheet paper in North America. Equipment from

“OCC rejects handling systems help operators convert waste into valuable energy,” says Pedro Alfaro, Project Development Engineer, Bruks Siwertell. “They are a good sustainability step and also deliver significant economic advantages, enabling operators to offset substantial energy demands.” BULK HANDLING NEWS

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NEWS IN BRIEF Bruks Siwertell is a feature at several of its eight mills and 90 corrugated products plants. To meet a growing strong demand for US domestic packaging, the company made the decision earlier this year to convert production machinery (No 3) from paper to linerboard at the Jackson mill. PCA plans to convert the 365,000 ton/year paper machine to a 700,000 ton/year high-performance, virgin kraft linerboard machine in a phased development over the next three years.

As part of these changes, it needed robust, proven equipment that was capable of handling coarser OCC rejects at high efficiencies, and a system that could meter the flow of the waste material as well. The Bruks equipment has a combined OCC reject handling capacity of 5.4 to 10.9 metric tons/hour (6-12 short tons/hour). “Our design delivers the reliability and robustness that the mill requires, and is cost-competitive,” adds Alfaro.

Doubled cement handling demand in Kuwait port will be met by Siwertell ship unloaders A high-capacity ship unloader order is underway for returning customer, Kuwait Portland Cement Co. The ST 490-M Siwertell unit, equipped with a new side tilt motion for enhanced through-ship efficiency, will join another cement handling Siwertell ship unloader in Shuaiba Port, Kuwait City, Kuwait, which has been operating for over two decades. “Kuwait Portland Cement has benefited from 20 years of experience using our Siwertell screw-type technology,” says Peter Göransson, Sales Manager, Bruks Siwertell. “It knows what our unloaders deliver; time and again the technology has proven its capabilities, demonstrating reliability, efficiency, and environmental protection in terms of emissions and noise. “In fact, the main reason why the operator returned for a second unit is the outstanding operational performance of its original delivery,” continues Göransson. “Our ongoing service support, along with Bruks Siwertell’s throughlife commitment to maintenance and spare parts were other major deciding factors.”

the chance of airborne emissions from avalanches in the cargo hold. The side tilt function adds to this capability,” Göransson notes. Planned for delivery to the port in mid-2023, the railmounted unit will handle various cement types and deliver a continuous material handling capacity of 800t/h, discharging vessels up to 50,000 dwt. It will be installed on an existing jetty next to the operator’s older ST 490-F, rail-mounted Siwertell unloader. Like its predecessor, the new unloader is also designed to operate in Kuwait’s extreme climate. To accommodate predicted temperature rises in the region, the latest unit can withstand ambient summertime temperatures of up to 55 degrees Celsius.

The new unloader will deliver even higher levels of performance and through-ship efficiency to Kuwait Portland Cement. “It features a new side tilt motion, which offers an enhanced reach into the corners of the cargo hold as well as under the hatch coamings,” he adds. “As a result, less material is left for the clean-up phase, which reduces vessel turnaround times, raising the utilization rate of the jetty and therefore profitability. “Also, all Siwertell unloaders offer a layerby-layer unloading process, which minimizes 6

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The rail-mounted unit will deliver a continuous cement handling capacity of 800t/h


OUR PEOPLE

OUR PEOPLE Pedro Alfaro PROJECT DEVELOPMENT ENGINEER

In 1999, Pedro Alfaro emigrated to the United States from El Salvador; now, as a Project Development Engineer, he has become integral to the fabric of Bruks Siwertell, using his engineering skills and inquisitive mind to enhance customer projects

AGO, initially

to woodyard products. I am responsible for making estimates, producing layouts and sales drawings, and proposals for our customers, which means that I have to have detailed knowledge of how our systems fit and work together, on the macro-scale. We tend to sell a lot of systems that way.

I since worked in power generation, prototyping, and the natural gas industry, so as well as studying, I acquired many of my competencies there. But by then, I wanted to work in a different industry.

I also carry out project management of installations. This includes the logistics of delivering material and components to the site, and the financial aspects. I also get to work with a wide range of stakeholders including site engineers, purchasing departments, project managers, engineering firms, and legal departments. As part of this job I am constantly traveling, seeing new parts of this country, which is awesome, and of course, I am bilingual, which helps a lot.

Open opportunities

Fluidity and freedom

In 2019, I applied for the position of Project Development Engineer, based in Bruks Siwertell’s offices in Alpharetta, Georgia. I mentioned my immigration status to Ken Upchurch, Senior Vice President, Sales and Marketing, Bruks Siwertell, and he told me that Bruks Siwertell would be willing to sponsor my permanent residency process; a fantastic opportunity.

I would say there is a fluidity and a freedom in our products. We benefit from being an international organization, which means that if there is a better way of doing something, we can offer equipment that will extend those benefits to our customers.

I STARTED MY LIFE IN THE US OVER TWENT Y-THREE YEARS

being allowed to live here through the Temporary Protected Status (TPS) program. After having become ineligible to multiple full-ride scholarships at other schools due to my immigration status, I studied at the University of Southern Indiana (USI), earning my Bachelors in Mechanical Engineering.

In my job, I get to work with a wide range of products from mobile unloaders, conveyors, truck dumpers,

We have the flexibility to adapt quickly to local ways of working, as well. It keeps us busy, and the work varied. Every day is different: there are no ‘down’ days, and I am constantly engaged in my work. BULK HANDLING NEWS

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MEXICO’S NEW ULTRA-EFFICIENT AGRI-BULK TERMINAL UNDERPINNED BY SIWERTELL UNLOADER A new Siwertell ship unloader in the port of Veracruz, Mexico, is offering such high levels of grain handling efficiency that it is expected to meet its owner’s planned growth for the next forty years TEXT

Patrik Henryson

PHOTOS

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Bruks Siwertell

BULK HANDLING NEWS


AGRI-BULK TERMINAL THE PORT OF VERACRUZ, in east-central Mexico, is being developed into one of the most advanced port terminals in the world. Accessing global waters via the Gulf of Mexico gateway, the port is undergoing a USD 5 billion redevelopment project, which will quadruple its installed capacity to reach more than 90 million metric tons by 2030. Part of this development is five new terminals and a new cargo processing and logistics area.

Integral to this development is Grupo Gramosa’s Puertos Especializados Transnacionales (PETRA) new agri-bulk terminal. It was planned, designed and built for the specialized handling of solid, liquid and semiliquid agricultural bulk, with a storage capacity of 126,000 metric tons of dry bulk and 38,400 metric tons of liquids. PETRA is now operational, and from the outset, its dry bulk import facility has been able to offer unmatched grain handling and environmental protection. Underpinning these exceptional capabilities is a single rail-mounted Siwertell ST 640-M ship unloader. It has a continuous rated capacity of 1,200t/h and a peak rate of 1,320t/h, 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 (DDGs), and canola seeds without any loss of efficiency.

Efficiency reduces costs

more materials into the plant at a lower cost due to greater efficiency,” explains Jesus Mil Linares, Terminal General Manager, Grupo Gramosa. Talking about its new Siwertell unloader, Linares could not speak more highly. “The Siwertell unloader is formidable! With this system we are positively contributing to our beloved country, Mexico, reducing the ‘market basket’ cost by being more efficient in our logistics chain. “The unloader minimizes terminal operating costs. In addition, there are close-to-zero dust emissions, no disturbing noises, and no spillage,” Linares notes. “This means no cargo losses, which is particularly important when it comes to expensive commodities such as corn, which is currently priced in the region of USD 350 per metric ton and DDGs at USD 650 per metric ton.”

The Siwertell unloader is formidable! JESUS MIL LINARES, TERMINAL GENERAL MANAGER, GRUPO GR AMOSA

“Grupo Gramosa invested USD 85 million in the PETRA terminal as it saw an opportunity to reduce the cost of raw materials for an animalfeed facility, achieved by getting BULK HANDLING NEWS

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AGRI-BULK TERMINAL

agricultural bulk, and the preparation of balanced animal feedstocks. It originally ordered the Siwertell ship unloader in 2018. Bruks Siwertell delivered the unit fully assembled in 2019, with commissioning and operator training being carried out in 2021. Gramosa chose Siwertell technology because it out-performed all other competitor systems during a fourmonth selection process; particularly the two 600t/h pneumatic systems it was initially considering.

For the next 40 years, PETRA’s growth expectations will be met by its Siwertell unloader

Decades of growth “Furthermore, if you consider commodity prices scaled up alongside logistics, with a vessel costing up to USD 35,000 a day, we are in a much better position to negotiate more favorable rates. We are faster than any other agri-bulk terminal in Mexico, and offer as low as 0.01 percent losses, with others reaching around 0.5 percent, if not more,” he explains. “One operator is required for the unloader, which means we are using fewer resources as the terminal is fully-mechanized from unloading to truck or rail-car loading,” Linares says. “They can comfortably sit in an air-conditioned control cabin, or operate the unloader via remote control, which gives us great flexibility.” Linares highlights that the efficiency of its Siwertell unloader will meet 10

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the terminal’s planned growth for the next forty years. Other benefits include the capability of accommodating an extended draft. “We can cater for larger vessels with a draft of 20m, while other terminals are limited to 13m,” he says. “The terminal also has a highly efficient, looped rail network, which is connected to the region’s two main railway lines, Ferromex and Kansas City Southern de México.” PETRA’s main Siwertell unloader operator, Eric Marquez Martinez, compares the Siwertell unloader to driving a Ferrari. “A few times the captains have asked me to slow down as I’m going too fast!”

Chosen on performance Grupo Gramosa is a progressive company dedicated to the commercialization and transformation of

The analysis showed that a single Siwertell ST 640-M ship unloader would be a more economical solution in the long term. 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. A statement from Gramosa at the time of the order states that: “The Siwertell system was selected after considering many factors and multiple equipment comparisons. Analysis included operating principles and mechanisms, investment costs, as well as operating costs. “An important factor was cargo loss and damage. We will handle a number of different grains at the new terminal such as corn, rice, wheat, soya beans and canola seeds. The low conveying speed of the Siwertell screw-type unloader means that the grain is not damaged during handling, which will give us added value and differentiate us from our competition.


“Another consideration in the selection of Siwertell equipment was the balance of performance across multiple grains such as soybean meal and DDGs. Other systems on the market did not compare. For example, in the case of pneumatic equipment, it is very efficient at handling grains, but offers very low efficiency, translating to high operating costs, in soybean meal and DDGS.”

A competitive edge

AGRI-BULK TERMINAL

We are faster than any other agri-bulk terminal in Mexico JESUS MIL LINARES, TERMINAL GENER AL MANAGER, GRUPO GR AMOSA

“It is a great endorsement of our technology, not only for it to be chosen following detailed analysis for several months to compare it with other equivalent capacity systems, but also now that it is operational, for those comparisons to be a reality for the owner,” says Patrik Henryson, Sales Manager, Bruks Siwertell.

largest cargo that Bruks Siwertell machines handle,” Henryson explains. “We understand that grain handlers have to meet some of the most challenging dry bulk material demands, and their dry bulk equipment must match these, offering consistently high capacities for maximum profitability, but also maintaining the quality of shipments through sensitive handling.

“Thanks to the tremendous growth in the agri-bulk segment over the last few years, grain is now the third

“We talk about our systems offering grain handlers a competitive edge, and this is exactly what PETRA’s

new Siwertell system is now delivering. The unloader is very well suited to the job it has been ordered for. It is so efficient that it directly lowers operating costs, and enables Grupo Gramosa to negotiate better commodity rates. “The advantages offered are incomparable to other technology, and the Siwertell unloader is so efficient that it will reliably meet the terminal’s growing capacity requirements for decades,” Henryson concludes.

The unloader’s efficiency enables Grupo Gramosa to negotiate better commodity rates

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CUSTOMIZED AIR-CUSHION CONVEYOR MEETS NICHE COTTON SEED HANDLING NEEDS IN ARIZONA A bespoke version of The Belt ConveyorTM has been ordered to deliver enclosed, efficient cotton seed handling at BASF Corporation’s Arizona-based agricultural solutions facility, Maricopa

TEXT PHOTOS

to meet the unique requirements of retrofitting new dry bulk material handling arrangements, is a recent air-cushion conveyor contract from BASF Corporation for its Maricopa agricultural solutions facility in Bapchule, Arizona, USA. HIGHLIGHTING THE ABILITY TO TAILOR TECHNOLOGY

Headquartered in Florham Park, New Jersey, BASF Corporation is the North American affiliate of diverse German company, BASF SE. For almost four decades, BASF Maricopa has been serving the company’s agricultural solutions segment, which specializes in supplying 12

BULK HANDLING NEWS

Pedro Alfaro

Bruks Siwertell

and developing a range of products and services to help farmers achieve better yields.

Innovation reduces environmental impact Key to BASF’s overall agricultural development strategy is its commitment to the reduction of environmental impact through innovation and more sustainable approaches, most recently supporting this by opening a center for sustainable agriculture in North Carolina earlier this year. “BASF is a new customer for Bruks Siwertell,” notes Pedro Alfaro, Project Development Engineer, Bruks


Siwertell. “It approached us as we have a leading reputation for air-supported conveying, and Maricopa needed a small, bespoke installation, with a lot of design restrictions, for the efficient, enclosed handling of very lightweight cotton seeds. “Maricopa is looking to retire its long-serving drag chain conveyor,” continues Alfaro. “Any new conveyor design had to integrate into the limited existing space and accommodate a steep slope for material transfers. It was soon obvious that a conventional conveyor installation or alternative, would simply not work. “As a result, we have designed a customized version of our Bruks The Belt Conveyor. It will have a cleated belt and an ultra-high molecular weight polyethylene (UHMW) return to accommodate the angle of repose,” he explains.

Significant benefits on offer The new conveyor installation will effectively form a 10m (33ft) link between one of Maricopa’s feeding hoppers, manually maintained by front loaders, and another, transferring the cotton seeds into the machinery that separates the fiber from the seed. It will offer a rated capacity of around 25 metric tons per hour. “The Belt Conveyor will also deliver significant advantages over the existing system,” Alfaro adds. In comparison with traditional conveyor systems, Bruks Siwertell’s air-cushion conveyor range, which includes both The Belt Conveyor and Tubulator, eliminate the use of idlers to support the conveyor belt; therefore, significantly reducing maintenance costs, and the risk of friction fires from seized idler cans. Both systems offer highly-efficient, low-friction enclosed material handling, and substantially lower operating costs, as a result of lower maintenance requirements. In the case of The Belt Conveyor, each 3m section of belt has access to a common header of pressurized air, and under the carry-side pan is a 3m pressurized air enclosure system. Material glides on the belt, similar to the puck on an air hockey table. A further benefit of The Belt Conveyor is that its rolled plate matches the profile of a 35-degree idler crosssection, without the rollers. This allows the system to conform to the industry-standard calculations for

AIR-CUSHION CONVEYING

The Belt Conveyor will deliver significant advantages over the existing system PEDRO ALFARO, PROJECT DEVELOPMENT ENGINEER, BRUKS SIWERTELL

the USA’s Conveyors Equipment Manufacturers Association (CEMA).

An ideal conveying solution “Cotton seeds are not particularly dusty, but the system needs to be enclosed because they are so lightweight, and have static cling,” Alfaro notes. “Although the Tubulator was considered, The Belt Conveyor provided the ideal solution, and in addition to lower operating costs, ensures no material degradation, preserving this delicate commodity for maximum use.” The separated fiber is destined for use in BASF’s fiber-reinforced concrete, enhancing both the sustainability of concrete and its performance and durability. Essentially, fiber-reinforced concrete uses these natural fibers to reduce crack widths due to plastic and long-term drying shrinkage and thermal changes. Their presence in concrete offers faster construction speeds and can extend its useable life, with a reduced maintenance burden and labor costs. Meanwhile, the separated seed is sold on to farmers. Air-supported conveyors from Bruks Siwertell benefit from a modular design that can easily be shipped and constructed. The new conveyor system will be delivered in component parts towards the end of 2022 and will be assembled on site by BASF. “The conveyor is planned to be up and running, shortly after delivery,” says Alfaro. “We hope that this new, very efficient link in Maricopa’s material transfer network will deliver the many benefits of air-cushion conveying, and demonstrate that, when retrofits are required to replace ageing equipment, our technology can be customized to meet both capacity and installation requirements.” BULK HANDLING NEWS

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IMPROVED SCREWCONVEYOR LIFETIMES DELIVER DIRECT COST SAVINGS

A new research study yields significant improvements in the lifetime of the vertical screw conveyor and its wear parts, delivering substantially lower total maintenance costs for operators TEXT

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Per Hansson

PHOTOS

BULK HANDLING NEWS

Bruks Siwertell

Businesses often pay much more attention to the answer to this question than their end consumers might. Considering throughlife costs, when machinery is earmarked for decades of operation, is a very wise strategy, as this could mean vast cost savings for a terminal over equipment lifetimes. HOW LONG DOES NEW EQUIPMENT LAST?

Siwertell unloaders have a global reputation for reliability and service longevity, and their component screw conveyors offer some of the market’s longest wear times.


R & D A D VA N C E S

The program, which began in 2021, involved analyzing key elements of the vertical screw conveyor; given its critical role in Siwertell dry bulk handling technology. The results are extremely positive, extending its service life even further. Bruks Siwertell’s entire portfolio of new and existing screw-type equipment including Siwertell ship unloaders, loaders and conveyors, can now benefit.

“As well as considering alternative production methods and techniques, we reviewed the entire supply chain. This has enabled shorter lead times and has resulted in making the entire chain more effective and environment-friendly as well,” he highlights.

The vertical screw conveyor is totally enclosed and built up from screw sections, outer tubes and intermediate bearings. In ship unloaders, the vertical screw conveyor elevates bulk material from below the cargo level in the hold up to the horizontal conveyor.

The grain handling market was taken as the program’s core segment for analysis. “This was for numerous reasons,” Hansson explains. “Thanks to the tremendous growth in the agri-bulk segment over the last few years, grain is now the third largest cargo that Bruks Siwertell machines handle, so we have a lot of knowledge in this area.

Screw-type conveyors have minimal energy consumption demands, and already provide excellent through-life efficiencies, as they have few moving parts, and free-flowing cargo throughput under continuous torque loads. This generates predictable patterns of wear-and-tear.

A tough sector to choose

New ways of thinking

“The grain handling sector demands an incredible amount from its dry bulk handling equipment, not only in terms of intensity, but it is also an extremely competitive market that places substantial expectations on component lifetimes and through-life costs. What better sector, then, to use as a basis?”

“Although these are already great products, the starting point of this R&D project was to not assume anything; we really questioned already proven designs and processes to see if they could be improved and updated, and invariably they could,” says Per Hansson, Sales Director, Bruks Siwertell.

Siwertell screw-type ship unloaders can discharge grain and other agri-bulk commodities at rated capacities up to 1,800t/h. Our grain-handling attributes also include the highest continuous rated loading capacities, which are in excess of 3,000t/h.

“Throughout the program, several different configurations of vertical screw unloading were tested, incorporating variations in production methods and materials used to make the parts. The aim: to provide a major increase in the length of maintenance intervals, based on the circumstances they face in real-world conditions, and without a corresponding increase in costs for customers. The testing leveraged the latest breakthroughs in materials science. “Every element has been carefully considered and verified, prior to products being available on the market,” Hansson continues. “The result is an advanced solution that offers the best of previous generations in a more resilient package, with lower operator costs. It also benefits the environment. The very concept of ‘sustainability’ encompasses keeping existing equipment and components running for longer and therefore not incurring the requirement for machinery to be replaced as often.

“We have grain, soya bean and soya meal handling systems operating in Brazil that run up to 4,000 hours per year,” Hansson notes. “These systems work to some

Longer screw lifetimes ensures a better balance between cost and component longevity PER HANSSON, SALES DIRECTOR, BRUKS SIWERTELL

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R & D A D VA N C E S

of the agri-bulk industry’s tightest seasonal schedules, with import and export terminals subject to massive surges in intake from the seasonality of crop harvests. There is no capacity for any unplanned downtime. “In this region, many of our customers are dependent on their Siwertell screw-type ship unloaders being able to handle one year’s full intake of grain,” he stresses. “Several customers do not have any other equipment to unload incoming material or their supplementary equipment is simply not suitable, as grain unloading has to happen so quickly and frequently, only their Siwertell unloader is up to the task. “These very high-use conditions naturally have an inevitable impact on wear parts. When combined with the remoteness of some of these operations, many of these customers often carry a large stock of critical spare parts, minimizing the risk of unexpected stoppages. However, being able to offer longer screw conveyor lifetimes ensures a better balance between cost and component longevity, so we can meet the needs of this sector in a more effective way,” Hansson says.

The advantages of original The R&D program, and the significant advantages offered by these longer component lifetimes, highlight the substantial rewards of choosing original equipment manufacturer (OEM) parts, in particular. Decades of investment, expertise and knowledge are channeled into Bruks Siwertell’s product development, and this is a continuous process, delivering

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truly compatible wear components that are guaranteed to offer the very best reliability, longevity and operational performance. OEM parts are intrinsically valuable along with OEM labor, service support, and tailored training programs. As the Siwertell operators in Brazil highlight, a robust service strategy pays dividends. They can plan for the availability, purchase and budgeting of any spare parts that are needed and have it available at these service intervals; planned maintenance is almost always less expensive than emergency support.

Simplified screw replacements The enhanced durability and wear resistance means that screw components do not have to be replaced so often. This delivers longer, reliable equipment availability, and longer periods between servicing, so fewer services are required. When it is time to replace screw-components, Bruks Siwertell has already made this easier with the introduction of a new self-supporting service tower that substantially simplifies and lowers the cost of fitting replacement screws on its market-leading Siwertell ship unloaders. Principally, it eliminates the need for cranes, which are traditionally used to lift the screws. This reduces costs and improves the overall safety of the operation. Also, because the tower is specifically designed for the task, the whole process is faster.

The result is an advanced solution that offers the best of previous generations PER HANSSON, SALES DIRECTOR, BRUKS SIWERTELL

BULK HANDLING NEWS


R & D A D VA N C E S

OEM wear components are guaranteed to offer the very best reliability, longevity and operational performance

A replacement screw is 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 is achieved using the same equipment, but in reverse. By using adaptors, the service tower can accommodate the various screw lengths and sizes of the Siwertell product range. Also, although specifically designed for screw replacements, it can be built with

additional levels to service and inspect other areas of the vertical conveyor.

R&D offers wide benefits Bruks Siwertell’s commitment to improve owner benefits, set ever higher standards for intelligent solutions, and drive positive, sustainable change, mean that this R&D program is one of many that are underway. “It is exciting to think of all these progressive changes, and how research, science and innovative thinking through collaborations, can result in tangible product advances that not only have a direct positive impact on our customers, but also the environment,” concludes Hansson. BULK HANDLING NEWS

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ROAD-MOBILE ALUMINA UNLOADER EXCEEDS EXPECTATIONS IN FRANCE Trímet France’s new Siwertell next-generation road-mobile unloader is now operational, handling shipments of alumina so efficiently that it is exceeding owner expectations; the unit’s remote control and digital capabilities are also proving beneficial TEXT

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Jörgen Ojeda

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BULK HANDLING NEWS

Bruks Siwertell


ALUMINA HANDLING HANDLING ALUMINA, the valuable, powdery bulk commodity used in the production of the endlessly recyclable metal aluminum, is a Trímet France speciality. At the end of 2021, Bruks Siwertell enhanced these capabilities further with the delivery of a new Siwertell 10,000 S nextgeneration road-mobile unloader to the company’s alumina import facilities in France’s largest port, Marseille.

Trímet France, part of Germany-headquartered, Trimet Aluminum SE, principally receives vessels from Greece and Ireland, with the largest standing at around 14,000gt and the smallest close to 6,000gt. Shipments of alumina are discharged to silos, ready to be sent in rail wagons to a long-established aluminum-producing factory in SaintJean-de-Maurienne, south-east France.

Speeding up at the berth “One of the biggest challenges for us has been to reduce the time that a vessel stays at the berth,” explains a spokesperson for Trímet France. The faster vessels can be turned around the higher the utilization rate of the jetty, delivering better profitability for the terminal. With an expected alumina intake of around 50,000 metric tons into the port in 2022, the majority of which will now be handled with the new road-mobile unloader. Siwertell unloaders are based on screw-conveying technology and offer high, continuous through-ship efficiencies. They can reach into the corners of a vessel’s hold, including under the hatch coamings, because of the range of movement in the horizontal conveyor and the pendulum capability of the vertical arm, which also means that assistance from payloaders is kept to a minimum.

We are happy to reduce emissions with this electric Siwertell version TRÍMET FR ANCE

The new unloader features advanced digital capabilities

“The mobility of the equipment’s conveying arm is definitely an advantage for achieving faster vessel turnarounds, and allows us to operate everywhere in the holds,” says Trímet France.

Exceeding unloading expectations For around a year and a half, Trímet France leased an older Siwertell 10,000 S unloader from another Bruks Siwertell customer. “We did this before deciding to buy a new, next-generation electric-drive model,” says the company. “Environmental issues have an important place in our mind. So, we are happy to reduce emissions, and the noise of the engine, with this electric Siwertell version.” The new unloader has a designed rated capacity of 130t/h for discharging vessels up to 10,000 dwt, it also features advanced digital capabilities. Fitted with the Industrial Internet of things (IIoT) device, CompuLab, owners of next-generation models have safe, remote access to extensive monitoring, follow-up support, diagnostics and troubleshooting. Trímet France highlights the additional performance capabilities of its next-generation road-mobile unloader. “The remote control is particularly useful,” says the company. “Operators are able to see precisely if the unloading is efficient, so we can reach a discharge BULK HANDLING NEWS

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ALUMINA HANDLING

They also operate with a layer-by-layer unloading process, which minimizes the chance of airborne emissions from avalanches in the cargo hold. This is further reduced because of the equipment’s excellent hold reach. For road-mobile unloaders, a dust filter is installed at the top of the loading conveyor. It creates negative pressure and minimizes the risk of dust emissions at the transfer point where material leaves the unloader and enters the receiving equipment. It automatically returns the collected dust to the conveying system.

Minimizing degradation maximizes profits All Siwertell ship unloaders have a totally enclosed conveying line, offering dust-free operations

capacity of 150t/h. This is over what we expected. Also, the digital capabilities mean that Bruks Siwertell is able to check any problem that occurs on this Siwertell unloader in real time.” During commissioning Trímet France noted that the remote control needed further attention. “We were grateful to Bruks Siwertell for its reactivity to solve the issue, and are continuing to work together to find a solution to reduce noise from the screw because we are situated very close to neighbours,” it adds.

Enclosing the dust Environmental protection legislation is often a driver for the adoption of enclosed dry bulk handling equipment, and prior to the Siwertell unloader installation, Marseille’s port administration had requested that Trímet France reduce its dust emissions. All Siwertell ship unloaders have a totally enclosed conveying line from the hold, where the inlet feeder draws material into the vertical screw conveyor from beneath the surface, to the receiving facility, offering close-to-zero dust emissions and eliminating any wasteful spillage. 20

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In addition to offering efficient, environment-friendly alumina handling, with no spillage and very low energy consumption, the Siwertell unloader minimizes material degradation, which delivers a particular benefit to the alumina industry that goes further than the port. Alumina is sensitive to degradation and therefore has a high propensity for the production of powdery fines. These have a significant impact on a smelting plant’s energy consumption; the lower the percentage of fines, the lower the temperature required in the process.

We can reach a discharge capacity of 150t/h; over what we expected TRÍMET FR ANCE


ALUMINA HANDLING

“In the midst of soaring energy prices, any reduction in fines has a huge economic impact, and offers better cost control for the plant,” explains Jörgen Ojeda, Sales Director Mobile Unloaders, Bruks Siwertell. “We are not only keen for more port operators to benefit directly from our market-leading alumina handling capabilities, but in addition to this, for these advantages to extend to substantial savings for the global alumina industry as a whole.”

Support beyond deliveries

ALUMINA: A BILLION DOLLAR POINT Bruks Siwertell’s ship loaders and conveyors are well-established as preferred bulk material handling systems for alumina across the world, but it has even more to offer.

Siwertell road-mobile unloaders provide a flexible, efficient solution for customers that have operations at more than one location. They can be folded down and relocated in under an hour. In the future, Trímet France plans to trial these capabilities, and transfer the equipment to its other sites to test if this solution could be successfully transposed elsewhere.

Bruks Siwertell can demonstrate that Siwertell screw-type unloaders outperform established alumina unloading methods, including grab cranes and pneumatics, to such a degree that across the global alumina industry, savings could reach the billion US dollar mark.

“We have really had a chance to get to know Trímet France and its operations, initially over its leasing of the older road-mobile,” continues Ojeda. “This was a valuable experience and over this time, we supported the company with any servicing needs.

Alumina is an expensive dry bulk commodity, and its spillage costs the industry millions of dollars every year. During alumina unloading, some grab cranes can spill up to one and a half percent of a shipment. In contrast, independently-observed tests with Siwertell road-mobile unloaders showed no loss of bulk material. Eliminating spillage and minimizing dust creation deliver additional savings in clean-up costs as well.

“We hope that Trímet France will continue to benefit from the enhanced capabilities of its new road-mobile unloader for many years to come, and we look forward to helping the company with its plans for the future,” he concludes.

Pneumatic systems do not incur spillage on the scale of grab cranes, but they are less efficient, demand more energy and cause significantly higher material degradation than Siwertell unloading systems. Alumina degradation, and the presence of powdery fines, has a major impact on energy costs in the smelting process; reducing fines, reduces production costs. Few investments can totally transform an industry, but by making the switch to a Siwertell screw-type unloading system, this is exactly what is on offer, saving alumina plant owners and operators a fortune and delivering major environmental benefits. Siwertell unloaders minimize material degradation, delivering huge benefits to the alumina industry

BULK HANDLING NEWS

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NEW COMPANY VALUES GUIDE BRUKS SIWERTELL GROUP New company values set Bruks Siwertell on its future path, ensuring the Group’s sustainable growth and the acceleration of positive global change TEXT

Peter Jonsson

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Shutterstock

BRUKS SIWERTELL GROUP HAS LAUNCHED A NEW

– impact, commitment, and teamwork – which will act as a future guide for the Group as a whole and define its working culture and intentions. SET OF COMPANY VALUES

“It has been four years since we merged and formed Bruks Siwertell, and I am delighted with the progress and opportunities that our combined capabilities are offering our customers and our wider organization,” says Peter Jonsson, CEO, Bruks Siwertell Group. “We have now fully integrated our business areas, and have taken this time to consider our common ground and shared direction. “Our new company values will take us forward as a cohesive market-leading technology group, into a future that will require deep levels of environmental commitment and a continuous engagement in sustainability,” notes Jonsson. 22

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IMPACT


C O M PA N Y VA L U E S

“When we talk about impact, we are referring to our intention to have a positive influence in all that we do. This is deeply ingrained with our sustainability goals, including the use of our expertise and technology to accelerate positive global change.” He continues: “We are in a position of trust, not just from our customers, but from our personnel and owners as well. We value this, and believe that having these strong, underlying, positive aims put us in the best position to reward this trust.

COMMITMENT

“Commitment underpins our company, from contract to delivery and through-life support, and always has done, but highlighting it reaffirms our intention to keep it in the spotlight. Our focus is on the delivery of quality in our products, solutions and services, and through the collaborations that we engage in.

“We always keep our promises, which I believe is an important statement to make as we see the global landscape shift and we navigate ourselves through a new era. Our customers should always feel secure in our continuing accountability,” Jonsson says. “Our third value, teamwork, really strengthens our resolve and intention to achieve the best results for our customers, owners and personnel by working together,” he explains. “Through transparent dialogues with each other within the company and externally with our customers, we reinforce this collaborative approach. Successful teamwork is built on good communication, and we are committed to open exchanges at every stage of each project.

“The very process of assessing our common ground and renewing these values has drawn us closer together,” Jonsson says. “This unified approach ensures that decisions made by everyone within the company, from individuals to whole business units, are considered within a set, shared framework.

This will instinctively strengthen our ability to achieve the company’s vision and goals.” Bruks Siwertell’s new company values are now being embedded throughout the Group through a series of strategic programs that will maximize their impact and engagement.

TEAMWORK BULK HANDLING NEWS

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ABOUT BRUKS SIWERTELL 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 ship loading, ship unloading, conveying, storing, stacking and reclaiming dry bulk materials, alongside equipment for chipping, screening, milling and processing wood for the bioenergy, 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 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 customers whenever and wherever it is needed.

SHIP UNLOADING · SHIP LOADING · TRUCK UNLOADING STORAGE & RECLAIMING · CHIPPING · GRINDING & MILLING CONVEYING · SCREENING · WOOD RESIDUE PROCESSING

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