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Siwertell

Customer magazine 2/2015

News siwertell.com

Advanced belt conveyors

set new standards


Contents

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Next-generation mobile unloaders Siwertell’s upgraded mobile unloaders incorporate the most significant advances in mobile bulk unloading the industry has seen for almost 25 years. Major revisions and upgrades have been carried out and shipping of the nextgeneration units will begin early in 2016.

youtube.com/siwertell

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Let’s keep in touch


Editorial 04

Siwertell lifts belt conveyor technology to new levels

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Floating terminal in Brazil increases export volumes by three million tonnes

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Next-generation mobile unloader range launched

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26 years of service for operator and machine in China

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Siwertell’s latest news

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Customised unloader rises to the challenge in the Philippines

Industry thrives on strong cooperative links Networks and cooperative arrangements are vital to business at all levels. At Siwertell we seek to form strong, mutually advantageous relationships, locally and globally. A short story from Taipei in Taiwan provides a good example of this approach (page 22). Elsewhere in this edition of Siwertell News, you’ll find case studies from the Amazon and the Philippines that demonstrate the importance of our unloaders’ lightweight construction and compact footprint (pages 8 and 24). This is in addition to their well-known attributes of reliability, efficiency, high performance, cleanliness and longevity. From China, we hear about Mr Wang, a man who has spent the greater part of his working life operating the country’s first Siwertell unloader, which is still going strong after more than 25 years (page 18).

Siwertell News is Siwertell’s customer magazine Publisher: Siwertell AB, part of Cargotec, P.O. Box 566 Gunnarstorp, SE-26725 Bjuv, Sweden Editors: Emily Brækhus Cueva, Malin Pekberg (emily.cueva@cargotec.com, malin.pekberg@cargotec.com) Layout and production: Emily Brækhus Cueva Cover: Siwertell Printed by: Tryckaren Engelholm The opinions expressed by the authors or individuals interviewed do not necessarily represent the views of Siwertell.

Siwertell ship unloaders and loaders are based on unique screw conveyor technology, in combination with belt conveyors and aeroslides, and provide a totally enclosed dry bulk handling operation. Virtually any dry bulk cargo can be handled. The Siwertell portfolio includes ship unloaders, mobile ship unloaders, ship loaders, horizontal and vertical screw conveyors as well as complete dry bulk terminal solutions. All Siwertell solutions are designed to ensure sustainable and efficient cargo operations. Siwertell is part of Cargotec Corporation. siwertell.com

Back in Sweden our research and development programmes continue to deliver benefits for customers. Our new range of modular belt conveyors features improved standards of cleanliness, efficiency and economy, while providing downstream conveying capabilities that can meet the needs of our latest very high capacity unloaders (page 4). On page 16 you can read about the major upgrades to our next generation road-mobile unloaders. For those in the aluminium trade, our unlimited buy-back offer has been extended to the next generation range. If you buy one for alumina handling and it does not meet the guaranteed performance, we will take it back and the full contract amount will be returned. I think this shows the confidence that we have in our excellent products. I wish you a pleasant read and a successful year ahead.

Per Karlsson President


Bulk conveying text JONAS ANDERSSON and JUHA HUOVIL AINEN photos / illustrations SIWERTELL

Belt conveyor technology

lifted to new levels

Siwertell’s new range of modular belt conveyors delivers improved standards of efficiency, economy and environmental impact; it also provides the capability to match downstream conveying capacities to Siwertell’s latest very high capacity screw-type unloaders

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hen it comes to handling dusty dry bulk materials in areas where scrupulously clean operations are essential, you cannot beat Siwertell’s market-leading range of totally-enclosed screw-type conveyors. They have the additional advantages of being lightweight with a very small physical footprint.

Keeping ahead of market demands

Siwertell recognises that total containment and space-saving dimensions are not necessary for all cargoes in all circumstances. The company manufactures and supplies other types of conveyors, all of which display excellent environmental credentials. Siwertell recently completed an important development programme for its belt conveyor technology.

“Anticipating customer requirements for dust-free, high capacity conveying systems, we have been putting a lot of design hours into developing our belt conveyors to an even higher standard with even higher capacities.”

This focused predominantly on applications for grain, fertiliser, cement and coal, but Siwertell’s belt conveyors can be used for all bulk materials whose characteristics make them suitable for belt transportation. 4

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“At Siwertell we do not stand still,” says Jonas Andersson, Technical Director. “We are always looking at ways to develop our technologies to provide the best possible products for our customers in all the dry bulk market sectors.

New standards in belt conveyor In consultation with existing and potential customers, and building on its lengthy experience with all types of conveyors, Siwertell identified the factors necessary to progress belt conveyor technology.

“In our development programme we focused on low dust emissions as well as reduced installation time and cost,” says Mr Andersson. “We’ve also developed an enclosed transfer system for the jetty conveyor, allowing the loader/unloader to operate during travelling of the machine throughout the whole travelling length. “The new-generation conveyors take advantage of a modular approach. Jetty conveyors for Siwertell loaders and unloaders are built up from standardised modules. When installed as land-based conveying systems, they can be inclined when required.” “In common with other large Siwertell deliveries, our major belt conveyor systems are tailored for their particular operational circumstances, but the new modular nature of the system cuts both the lead and installation times,” says Juha Huovilainen, Sales Director.


Siwertell belt conveyors offer a very attractive proposition to the operator with an eye for economy and efficiency�

To cater for different materials and varying capacity requirements, the new conveyors can be supplied with belt widths ranging from 1m to 2.6m in increments of 0.2m. To keep dust creation to a minimum, the new conveyors have been designed with optional covers and spillage plates. So, although not totally sealed, the level of enclosure is good, and appropriate for the materials conveyed and the likely installation sites. They incorporate dust collectors, and when required they can also be equipped with water sprays.

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Siwertell belt conveyors are the ideal choice when very high capacities are needed. An important benefit is lower investment costs. “Combined with their excellent reliability and low maintenance costs, they offer a very attractive proposition to the operator with an eye for economy and efficiency,” says Mr Huovilainen.

Large unloaders need large conveyors The dry bulk market is very competitive and factors such as quick turnarounds and minimal clean-up requirements are important factors in saving costs. Siwertell offers very high capacity screw-type unloaders capable of discharging major bulk cargo, such as coal, at a rate in excess of 3,000t/h. There is the potential to develop unloaders with even greater rates, but most existing terminals would not be able to accept them because of downstream conveying limitations. Therefore very large installations tend to be used in new facilities such as coal-fired power generation plants.

Steel plants also have a great appetite for coal, but they traditionally use grab cranes to unload both the iron ore and the coal necessary for steel production. However, Siwertell recently made a breakthrough sale, delivering a high capacity screw-type unloader to serve as a dedicated coal intake for Formosa Ha Tinh Steel Corporation in Vietnam. The operators are expected to make massive financial savings because of the improved discharge times for the coal vessels. “The economic argument for dedicated coal intakes using Siwertell unloaders is unbeatable,” says Mr Huovilainen. “We confidently expect that other steel producers will take a lead from this breakthrough installation. “In addition to meeting the needs of our existing unloaders and loaders, these new, cost-effective, environmentally-friendly belt conveyors will be compatible with the high capacity ship loader that we will be launching next year, providing the perfect bulk handling package, all from a single, well-respected source.”

Belt conveyor highlights ++ Rated capacities up to 8,000t/h (coal) and 12,000t/h (iron ore) ++ Fixed speed ++ Enclosed system with dust collectors and water sprays ++ Easy replacement of wear parts ++ Inclined installation of land-based conveyors where required ++ Available in width sizes of 1m to 2.6m with 0.2m spacing

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CUSTOMER INSTALLATIONS

Higher capacity, lower investment


Bega grain terminal KLAIPEDA, LITHUANIA When Bega needed a new, flexible transfer terminal for the import and export of agribulk commodities and fertilisers, it turned to Siwertell for its design expertise and market-leading equipment. Belt conveyors were central to Siwertell’s 2012 turn-key delivery, which included two linked warehouses divided into eight compartments, a loading and unloading station for rail wagons and trucks and a Panamax size ship loader. Cargo arriving by rail or truck is conveyed to any one of the eight compartments via fully automatic overhead belt conveyors. Cargo can also be transferred directly from the shore intake to a ship, again by Siwertell belt conveyors. Inside the warehouse, payloaders feed bulk material onto two underground belt conveyors with capacities of 1,200t/h and 500t/h. The larger is used for loading ships; the smaller one for loading rail wagons and trucks. An underground belt conveying line is used for bulk cargoes arriving by sea.

Tuas biomass/coal terminal JURONG ISLAND, SINGAPORE Tuas Power’s plans for a power plant on Jurong Island had to meet Singapore’s strict environmental regulations; dust emissions were a particular concern. Siwertell’s screw-type unloaders were the natural choice on the jetty, but the downstream system also had to be scrupulously clean. Siwertell designed, manufactured and installed a tailor-made system capable of meeting all local regulations. Commissioned in 2012, it incorporates three bucket elevators and 13 covered belt conveyors for transporting fuel from the unloaders to three coal storage silos and the biomass flat storage area. For the belt conveyors, Siwertell designed a complete enclosure including a bottom plate. All transfer points are fully-enclosed and equipped with dust collectors. Siwertell also delivered the supporting steel structures, the HMI and the PLC control system. Belt conveyors offer particular benefits when ordered as part of a Siwertell complete ship-to-storage system, providing a very efficient, clean and economical fuel supply solution.

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Floating terminal

Floating terminal in Brazil

increased export volumes by three million tonnes text ANDERS SVENSSON photos SIWERTELL

The compact and light weight qualities of a Siwertell unloader, along with low energy consumption and good environmental credentials, made a Siwertell unloader the perfect choice for Cargill’s new floating jetty; Anders Svensson, Contract Manager at Siwertell explains the operator’s purchasing decision

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ith plans to more than double the capacity of its soya bean and maize processing site at Santarém on the River Amazon, a leading Brazilian food production company, Cargill Agricola S/A, had to find the most effective and environmentally-sensitive method of unloading bulk bean shipments arriving by barge at its riverside terminal.

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The tidal range can be as much as eight metres, which makes unloading operations very difficult alongside a conventional fixed concrete jetty structure. Therefore, Cargill opted for a floating terminal, so that the rise and fall of the tide has no impact on its position in relation to the barges that are being unloaded.

After careful consideration of all the unloading systems on offer, Cargill placed an order with Siwertell at the end of 2012 for an ST 790-M fully-enclosed screw-type barge unloader with a rated capacity of 1,500t/h. The floating terminal, including the roof top, was designed by Interocean. Siwertell worked closely with the company to design the appropriate ship unloader, accommodating all influencing elements.


I would highly recommend Siwertell unloaders to other operators”

In addition to Siwertell’s well-known clean performance and low energy consumption compared with other systems, key factors in Cargill’s decision to purchase a Siwertell unloader included its robust construction and compact dimensions, which enabled it to fit under the roof of the floating terminal. Components for the unloader were built in Sweden and China for final assembly and commissioning on site.

Operating well Cargill was impressed by Siwertell’s project engineering team; early in the assembly some interference was identified between the Siwertell unloader and existing conveyor equipment and the team dealt with it in a satisfactory time frame. The commissioning process also ironed out a few small issues to ensure the machine could achieve its full capacity; since then Cargill says it has operated very well.

Cargill had to make some changes to its existing bulk conveying and storage infrastructure to cope with the terminal’s increased discharging capabilities. Three metal silos were added to its land-based storage capacity. New conveyor belts were installed to serve the floating terminal. Bucket elevators link these with the existing belt conveyor system, which was modified to operate in a reversible manner, adding flexibility to the overall arrangement. SIWERTELL NEWS

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The expanded facilities allow Cargill to unload barges directly to seagoing vessels or to its warehouses for export at a later date.

Cargill Agricola S/A

High levels of redundancy

SAO PAOLO, BRAZIL

Prior to the terminal expansion Cargill used two pneumatic unloaders and although the Siwertell unloader now carries out the lion’s share of the work, these have been retained for sound operational reasons. Before the expansion project the terminal exported two million tonnes per year; that figure has been raised to five million tonnes. The Siwertell unloader is in almost continuous operation, with the workload split roughly 70 percent to Siwertell and 30 percent to the pneumatic unloaders. By retaining the pneumatic unloaders, Cargill has ensured that it has a good level of redundancy; this was always part of its expansion plans. It says that even if it can handle all its unloading requirements with its Siwertell machine alone, it is important to have both systems available to guard against any unforeseen issues.

Cargill Agricola S/A, based in Sao Paolo, produces, processes, and markets food and agricultural products in Brazil. It is a subsidiary of the US corporation, Cargill, which is a large privately-owned enterprise providing worldwide food, agricultural, risk management, financial and industrial products and services. Soya is the main commodity processed at Santarém; the terminal also handles maize. Barges bound for Santarém are typically loaded in Porto Velho, bringing agribulk cargoes from the west of the state of Mato Grosso via the Madeira and Amazon rivers. Cargill is constructing a new facility in Miritituba, to load barges with grain from the eastern and northern areas of Mato Grosso state. Ocean-going vessels departing from Santarém with cargoes of soya or maize are normally bound for ports in Central America, Europe and Asia.

First year’s experience

This level of redundancy is also an important element of Cargill’s longterm service and maintenance plans; for example, to maintain continuity of operations when it eventually becomes necessary to replace wear parts.

After the first year’s operational experience, Cargill says its Siwertell unloader is running very well. The elimination of cargo spillage is an important factor in raising overall efficiency, and the noise level is acceptable for a safe working environment.

Prudent spare parts policy

The unloader easily meets relevant environmental requirements, international, national and local.

For the next few years Cargill says it will be important to have support from the Siwertell team. As part of its contract with Siwertell, Cargill purchased a large spare parts inventory, preferring to keep certain of the most critical parts in stock. This prudent approach reflects Santarém’s remote location in a region that is far from major commercial centres.

Speaking for Cargill S/A Giovani Menoci, Building Project Manager, says: “Overall, I see a good project; good engineering and specifications, good quality fabrication, delivering reliable and efficient performance. I would highly recommend Siwertell unloaders to other operators.”

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Product launch

Next-generation

mobile unloader range ready for launch text JÖRGEN OJEDA photos SIWERTELL

Siwertell’s upgraded mobile unloaders incorporate the most significant advances in mobile bulk unloading the industry has seen for almost 25 years

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iwertell has carried out major revisions and upgrades to its market leading range of mobile unloading systems, first introduced to the market in 1991. Shipping of the next-generation units will begin early in 2016. “A number of key operating systems have been upgraded or replaced with more modern designs,” says Jörgen Ojeda, Director Mobile Unloaders. “By future-proofing our products, we are well-equipped for the challenges of tomorrow.”

Cleaner engines Next-generation units can be fitted with the latest environmentally-friendly diesel engine from Caterpillar. These meet the most stringent environmental regulations in terms of exhaust and sound emissions set by the US Environmental Protection Agency (EPA) Tier 4 and stage IV of the European emission standards. For some markets, the existing Caterpillar diesel engines will remain as standard. These engines meet the standards set by EPA Tier 3 and stage III of the European emission standards.

Trailer upgrades All next-generation unloader trailers will be equipped with an upgraded common electronic braking system (EBS) platform. Trailers will also benefit from a new improved lighting system. 12

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Designs for mobile applications The upgraded electrical system is mainly field bus-based. It has almost unlimited trouble-shooting potential, including the ability to conduct self-diagnostic system runs. Mr Ojeda says that from 2016 Siwertell will be able to remotely connect to the PLC to perform tasks such as re-programming and upgrades to the control software from its premises in Sweden, regardless of the unloader’s location. “We are moving away from the old type of PLC-system and introducing a modern one developed specifically for mobile applications by IFM. The field bus solution allows for a highperformance, cost-efficient remote monitoring system with the potential to reduce service and maintenance costs along with a reduction in downtime.” The new PLC will have a large screen allowing it to display more explanatory information, facilitating troubleshooting and information retrieval during operation. “The new main radio control box will have an LCD display enabling the operator to receive substantially more information; for example, fuel levels, loads, alarms and warnings,” says Mr Ojeda. To better determine the position of the conveying arm system, some of the limit switches have been replaced with inclination sensors, allowing a big reduction in cabling.


This also provides scope for software developments, which in the future might include automatic unloading, for example.

Reduced hydraulic oil requirements Next-generation unloaders will have a cyclone tank, reducing the amount of hydraulic oil required. A new oil cooler, pumps and pump drive gearbox ensure even better reliability and efficiency. Hydraulic valve control was previously based on a relay system. The new field bus main control valve provides better and more secure control of the unloader, reduces the amount of cable needed and so lessens the risk of malfunction due to cable breakage.

Remote re-programming and upgrades can be made regardless of the unloader’s location

Conveying system In addition, a re-design of the conveying system will result in the possibility to achieve higher capacities with heavier materials such as alumina and calcium oxide. Additional side-effects of the re-design have resulted in a lower power consumption when handling other lighter types of material such as cement, fertilisers and grain.

Automatic shifting as standard Previously offered as an option for units fitted with a double-bellows system, the automatic shifting function will be a standard feature on next-generation mobile unloaders. There is a new radio control unit for manoeuvring the bellows, replacing the older type with cable control.

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Service

26 years in service for operator

text SUN GUANGXIANG, STEPHANIE DONG and MATS LINDBERG photos SIWERTELL

and machine

China’s first Siwertell unloader was commissioned over 25 years ago and the man who has operated it from day one is now close to retirement; he still enjoys his work with a clean, efficient machine 14

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aking its debut in mainland China in 1990, the country’s first Siwertell screw-type ship unloader, an ST 490F CSU-type unit, has now been operating for over a quarter of a century. It has fulfilled its early promise, proving to be highly-efficient, spillage-free, environmentally-friendly, safe and reliable. The unloader was initially purchased by Xinhua Stevedoring Company and installed in the Port of Shanghai to unload fertilisers. In 2004 it was sold to Shanghai Chia Hsin Ganghui Co Ltd and moved as a complete unit across the


Huangpu River to its new site about 25km from its original location. In recent years it has been leased to the state-owned company, SBM, on a fiveyearly basis. This year, SBM has embarked on its second contract, which runs until 2020.

Impressive from the start No one knows the machine better than Wang Huanan, the person who has operated it since its introduction at the beginning of 1990. He has remained with the unloader under its different ownerships and remembers the reaction of his colleagues when it was first commissioned. “We had a successful test run first time round and all of us were very impressed,” Mr Wang says. “Discharging fertiliser on the jetty conveyor downstream was continuous and highly-efficient, with no air pollution and no material spillage.” Mr Wang and his colleagues appreciated features of the Siwertell unloader including its smooth operation, reliability, safety, effectiveness, and low environmental impact, all of which contribute to quality bulk cargo handling operations. The arrival of the unloader made an enormous difference to bulk handling operations in the port and represented a step-change in efficiency and environmental impact. “Before the screw-type ship unloader was purchased, fertilisers were handled by port grab cranes, transferring bulk from the ship’s holds to hoppers and then onto movable belt conveyors. Cargo spillage from the grabs, hoppers and movable belt conveyors caused severe atmospheric pollution on and around the deck and jetty, which resulted in a loss of profit due the loss of cargo.”

Capacity equivalent to three grab cranes With a rated capacity of 500t/h for fertilisers, the Siwertell unit could do the work of three port grab cranes. Mr Wang says that in addition to the environmental, economic and efficiency advances, safety was also improved in the cargo clean-up phase. Since its sale and relocation in 2004, the unloader has been used to unload cement. “It is also very good at handling cement,” he says. “Nowadays, unloading cement from ships up to about 5,000 dwt can take around 12 hours,

Wang Huanan (left) with Sun Guangxiang (right), Siwertell’s sales engineer and representative for the Chinese market

including the clean-up phase, which is very efficient. Its rated capacity for handling cement is around 500t/h, and even up to 600t/h, but this is limited downstream by the capacity of the conveyors.”

Long-term reliability Mr Wang says that the machine’s reliability has been very good throughout its 25 years of hard work. “The main reason for this reliability has been due to the good quality of Siwertell equipment and the fact that we check and maintain the machine according to the manual.” Asked if the owners are pleased with the unloader’s long and reliable life, Mr Wang replies: “Yes, absolutely.” Prior to operating the first Siwertell ship unloader, Mr Wang worked as a fork-lift driver in the Port of Shanghai, handling general cargo for the unloader’s original owners. When he was given his position as operator of the new Siwertell machine, he was trained in its operation and general maintenance. Although now approaching his retirement – planned in a couple of years’ time – Mr Wang hopes to continue operating the unloader for as long as possible. One simple reason for this is that he enjoys his work. “This is a good quality machine for bulk handling. Its operation is easy. I’ve also trained five apprentices to operate it.” He adds: “If the machine is well maintained, I believe it could continue to operate for many more years to come.”

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Have you ever seen a Siwertell in action?

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youtube.com/siwertell

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Siwertell news

Siwertell strengthens its commercial commitments in Taipei

PSR returns to Siwertell for a second roadmobile unloader Siwertell has secured a second order for a roadmobile ship unloader from Russian company PSR Primstroyresource, based in Vladivostok. The latest contract is for a next-generation, diesel-powered, trailer-based Siwertell 10 000 S unloader, fitted with a double bellows system and dust filter. It will be used to unload cement on the Island of Sakhalin at a rated capacity of 300t/h.

Siwertell has become one of the latest members of the Swedish Chamber of Commerce Taipei, in Taiwan. The Chamber’s growing list of 40 members was formed as a local entity to promote Sweden-related business relationships in Taiwan in an ethical, sustainable and environmentally-responsible way. The chamber in Taipei is a member of the Swedish Chambers International. Siwertell has joined the Chamber so that it too can benefit from participating in networking opportunities, both online and faceto-face, via activities such as seminars, breakfast and lunch meetings, and participation in the Joint Business Council. Siwertell also sees its membership as a resource for problem-solving, public relations and marketing opportunities in the region. The Chamber provides a forum for communication and is designed to promote, extend, and advance commercial and industrial relations, as well as investment and trade of Swedenrelated organisations and other interested parties in Taiwan. It also creates, promotes and grows relationships with other chambers, government bodies, legislative and advisory organisations, thinktanks and any other groups and organisations affecting members’ interests.

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“Siwertell received this order with great pride and considers it an acknowledgement of the success of PSR’s previous delivery,” says Jörgen Ojeda, Director, Siwertell Mobile Unloaders. “PSR chose Siwertell again mainly because of its experience with its first Siwertell road-mobile unloader, which was delivered in 2009,” says Mr Ojeda. “Other important factors were our reputation for quality and service, the unit’s flexibility and high capacity and its low operational and maintenance costs.”

Have you ever seen a Siwertell in action? youtube.com/siwertell The new unit has all the well proven attributes of PSR’s first unloader. However, as one of the next-generation units it benefits from a number of advances including a major upgrade of the hydraulic system, completely new and future-proof electrical system, PLC control system and radio equipment, and upgraded electronic braking system (EBS) on the trailer.


Sixth Siwertell unloader replacing a grab crane Siwertell has secured a contract to supply a sixth unloader for the Mai-Liao power plant in Taiwan. Five large Siwertell unloaders are currently in operation supplying coal to the 4,200MW facility, the third largest in the country. Three of the unloaders were delivered in 2001 and two in 2006. “This contract strengthens Siwertell’s position as the number one in coal unloading,” says Per Karlsson, Managing Director, Siwertell. “Since 2000, the company has sold more than 50 coal unloaders. More than half of these have a rated capacity of 2,000t/h or more.” Siwertell will deliver this ST 940 DOB-type ship unloader on a turn-key basis. Designed to unload coal from vessels of up to 180,000 dwt at a rated capacity of 2,000t/h, it will replace an existing grab crane. It will also be used to unload salt at a rated capacity of 2,200t/h. The operator already has experience of Siwertell’s multi-cargo capabilities, as one of its existing unloaders is used to handle both of these commodities. The power plant is co-owned by the Mai-Liao Power Corporation (MPC) and Formosa Petrochemical Corporation (FPC). In addition to the five Siwertell unloaders in Taiwan, FPC operates one Siwertell unloader in China and one in the US. It also operates two high capacity unloaders in Vietnam. Mr Karlsson says delivery of these unloaders was a major market breakthrough for Siwertell, because they were the first dedicated coal unloaders provided for a steel production plant, offering massive operational savings for the owners.

Global orders reinforce Siwertell’s market-leading position In the past twelve months Siwertell has secured many new orders from businesses across the world; a significant number are from returning customers, strengthening Siwertell’s market-leading position as the preferred provider of bulk-handling solutions. “Siwertell offers ideal solutions for operations that need dependable, high capacity, efficient and clean bulk handling equipment,” says Juha Huovilainen, Sales Director, Siwertell. “The increasing number of customers returning to Siwertell to replace ageing units or to make additional investments speaks volumes about the good service they receive from our wide range of bulk handling equipment. We believe that Siwertell equipment can bring benefits to every bulk sector.” Important ship unloader contracts have been won in Korea, Taiwan, the Philippines, the UK and Jordan, and a large alumina loader contract has been secured in the USA. The unloaders have been ordered for handling a variety of bulk cargoes including cement, limestone, coal and biomass. The biomass contract will see two ST790-D screw-type unloaders delivered to Associated British Port’s (ABP) Immingham facility in the UK. They are the first Siwertell unloaders delivered to the UK for combined coal/biomass handling and may represent a growing trend, as governments across the world seek to reduce the amount of coal consumed in power plants. The year’s mobile ship unloader contracts have predominately focused on cement-handling and include orders from operators in Saudi Arabia, India, Kuwait, Libya and Russia. “Siwertell mobile unloaders were originally designed for handling cement. Their reliable, environmentally-friendly and durable qualities continue to make them the natural first choice for the job,” says Mr Huovilainen. “They do not need any civil engineering works, so they are immediately able to start operations. Siwertell can offer very short lead times for mobile units, so the period between placing an order and going operational can be remarkably short.” SIWERTELL NEWS

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Coal handling

Customised unloader text DANIEL FROSTBERG photos SIWERTELL

rises to the challenge

The combination of Siwertell’s excellent environmental performance, lightweight construction and customised safety features delivered the ideal unloader for Quezon; seventeen years on the owners know they made the right decision

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n 1998 the global engineering, construction and project management firm Bechtel needed to select a ship unloader for handling coal at the Quezon power plant at Mauban in the Philippines. The company had to find equipment that could address a number of challenging issues. Excellent environmental performance was a top priority. The existing jetty was narrow and not strong enough to accept heavy machinery without considerable reinforcement. Finally, although the plant is located in Lamon Bay where conditions are relatively calm for the South China Sea – even during the monsoon season – ships alongside the

jetty can be subjected to considerable movement because the sea swell can be as much as five metres.

Comprehensive study It was vitally important to make the best decision possible, so Bechtel carried out a detailed investigation to determine its ideal course of action. Clamshell-type unloaders were unacceptable because of concerns over coal dust pollution. Two types of unloader were considered capable of meeting the environmental requirements, a Siwertell screw-type unloader and a more traditional continuous bucket-type unloader.

However, the larger physical size and much greater weight of the buckettype unloader meant that there would be additional jetty construction costs of about US$3 million. Furthermore, the purchase price of the bucket-type unloader was around US$2 million more than the price quoted for a Siwertell machine. Because of the sea swell, it was important to minimise the potential risk of damage to ships, the unloading equipment and the jetty and to provide a safe working environment for personnel. Therefore, Siwertell proposed that the hydraulic system for moving the horizontal arm up and down should be fitted with overflow valves that would

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operate if the pressure became too high as a result of contact caused by vessel movements. This means that the horizontal arm has the freedom to move upwards under the influence of swell induced motions, minimising the risk of damage or injury.

Valuable support from Siwertell Based on the findings of its investigation, Bechtel decided that Siwertell offered the best proposition and ordered a Siwertell model ST 790-D unloader. It weighs 466 tonnes and handles coal at a rated capacity of 1,400t/h. It was delivered and installed in 1998.

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Maintenance Superintendent for Pearl Energy Philippines Operating Inc, operator of Quezon Power, Ivan Chlapecek, says that Siwertell’s expertise was valuable right from

I would come to Siwertell for advice and equipment if the company were planning a new terminal today and I would encourage others in a similar position to do the same”

the planning stage. “Siwertell has experienced staff to help and support operation from planning, design, fabrication, procurement and support services.” He says Siwertell provided training for employees at Quezon, and for the first five or six years all major maintenance work was carried out under Siwertell’s supervision.

Unloader meets expectations Mr Chlapecek says that once the terminal was up and completely ready, it functioned as planned and its operations are very environment-friendly. There have been no concerns or complaints from the local community or the environmental agencies.


The unloader discharges two vessels each month, handling about 1.5 million tonnes per annum. A vessel containing 70,000 tonnes of coal can be discharged in as little as three and a half days. He considers three and a half to four days to be good unloading performance. The company adopts a very cautious attitude to adverse swell conditions to avoid damage to the berth, vessels and its single unloader. Naturally the equipment needs regular maintenance, service and the timely replacement of wear parts. He says that Siwertell support service is at a high level, along with the quality of spare parts and their procurement and delivery.

Upgrades extend efficient working life Siwertell takes pride in its long-term commitment to customers and their equipment. Appropriate service and

maintenance ensure reliability. Timely upgrades bring a machine up to the latest specifications, extending its working life while improving efficiency. The unloader at the Quezon power plant has benefited from an upgrade of the slewing drive from hydraulic to electrical operation. “This has resulted in much smoother operation and an extended lifetime for the slewing bearing,” says Mr Chlapecek. “The unloader has also had a control system upgrade and is currently undergoing an upgrade of control and power cable reel gearboxes.” When an outside contractor was not able to tune the variable frequency drive (VFD) controller to Mr Chlapecek’s satisfaction, Siwertell stepped in. “Siwertell helped us to tune the system to perfection. Now it is working very well with no issues.” Siwertell also supported recently completed critical inner hinge replacement work. The Siwertell design

office prepared proposed modifications for approval by the owners. Materials and special tools were delivered to the plant well in advance of the work. Siwertell prepared inspection and test plans including detailed lifting procedures, approved by the plant engineer.

Siwertell helped us to tune the system to perfection” Mr Chlapecek says the work on site was carried out smoothly with no trouble or rush. Overall, he is very satisfied with the hardware and service from Siwertell. “I would come to Siwertell for advice and equipment if the company were planning a new terminal today and I would encourage others in a similar position to do the same.”

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This is Siwertell Siwertell is a global market-leading company in dry bulk handling. Customer-driven Siwertell engineering and service solutions are employed in hundreds of import and export terminals worldwide. Our reliable and efficient ship unloaders, road-mobile unloaders, ship loaders and complete bulk terminal installations provide the cleanest dry bulk handling performance available, with minimal environmental impact. All conveying systems are totally enclosed, reducing dust emissions to a minimum and eliminating spillage completely. An extensive global service team offers support to Siwertell customers whenever and wherever it is needed.

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Siwertell News - Issue 2 - 2015  

In this issue, learn about Siwertell advanced belt conveyors, new-generation mobile unloaders and hear what some of our customers say about...