Presentation on theme: "Mobile conveyors - An alternative and cost effective way to handle bulk material in Ports and Inland terminals. By: Philip Waddell."— Presentation transcript:
Mobile conveyors - An alternative and cost effective way to handle bulk material in Ports and Inland terminals. By: Philip Waddell
Common Misconceptions of Mobile conveying equipment. 1 - Dust Containment and Extraction not possible on mobile Equipment 2 - Spillages at transfer points and under belts
1 + 2 = Dust Containment and Suppression Full length dust covers, Sealed transfer points, Undertrays (Spillage), Side Wind protection, Dust Extraction / Suppression systems and 360 degree trimmer chutes
Common Misconceptions of Mobile conveying equipment 3 - Limited Mobility Options Available. 4 - Takes too long to move from hatch to hatch on larger vessels.
3. Complete Site Mobility Options Available Wheels and RailsTracksWheels Track MountedWheel Mounted Rail Mounted
4. All Travel Mobile Ship-loader Driven Wheels for In-line, Parallel, Radial and Steering Movement In-Line ParallelRadialSteering
Common Misconceptions of Mobile conveying equipment. 5 - Limited Options Available for Discharge chutes and trimming. 6 - Mobile Conveyors can only be used for smaller vessels at smaller capacities.
5. Telescopic Cascade Chutes Telescopic Cascade Chute -Up to 20 metres Long with Optional Trimmer. -Chute blocked load of 10 Tonnes material. -Customised to suit the particular material characteristics.
Telescopic Free-fall Chute 5. Telescopic Freefall Chutes -Typically Up to 10 metres Long -Customised to suit the particular material characteristics. -Optional Dust Extraction Units.
6. Vessel Sizes - River Barges and Coasters Direct feed by Trucks to wheel mounted unitDirect feed by Trucks to Track mounted unit Fed by FELs to Track and wheel mounted unit Fed by FELs to Track mounted unit
- Panamax / Baby Cape Vessels Direct feed by Trucks to Ship loader Fed by FELs to Hopper and Ship loaderFed by gravity reclaim to Ship loader 6. Vessel Sizes
>20 metre Telescopic (in / out) ability allows for complete trimming of Handymax vessel for maximum flexibility Telescopic fully raised and extended c/w 360 degree trimmer chute Telescopic fully lowered and retracted c/w 360 degree trimmer chute Raise / Lower (> 20 Deg Range)of conveyor for differing draft/ tide heights when loading. Telescopic and Luffing Abilities
Radial (left/right) feature allow several hatches to be loaded from one single feed-in point Driven radial wheels for left/right travel >3 x Hatches from single feed-in point Radial Trimming Abilities
Alternative to Mobile harbour crane loading a Vessel
CASE STUDY 1 - AFRICA MOBILE SHIP LOADING Model - TS 2058 and HF 2020 Peak Capacity - 2000Tph Iron Ore System Fed by - CAT 988 FELs.
-System: All Travel Mobile Ship loader and Hopper feeder -Material: Iron Ore – 2.4 t/m3 – 2000TPH -Application: Loading iron ore to Baby Capesize vessels from wheel loaders HATCH TO HATCH IN 2 x MINUTES
Africa HATCH TO HATCH IN 2 x MINUTES Up to 16 metre Freeboard Heights Up to 43 metre Beam Widths Up to 25 metre Outreach
Loading Sequence and Hatch Change Calculations /Timings. -Typically 16 Number of Hatch Changes -Typically Hatch Distance of 1810 Metres -TS 2058 Parallel Travel speed of 1 km per hour. -Single Hatch Change travel period in 2 minutes Typical Loading Sequence for Panamax Vessels Hatch Moves (No) Hatch Move Distance (Metres) Hold 7Hold 6Hold 5Hold 4Hold 3Hold 2Hold 1 1 8000 2 265 3 3700 265 4 8000 3100 5 8000 4135 6 80005165 78000 6200 8 8000 3105 9 3700 270 10 4000 4135 11 3300 135 123540 4135 13 17606200 14 4000 395 151000 3105 16 10006200 Totals1254011700 12000113001200010760541810 82000
Phase 1 of production Ramp up – up to 6 million tpa. Reliability of System – Required load 1- 2 panamax vessels per week. Previous systems proved unreliable. Productivity – 2000tph system and up to 500,000 T/ month. Designed to cater for testing conditions – a)Weather Conditions – high moisture and high temps. b)Ground Conditions – Rainy season with potential for rutting c)Material – very abrasive, claggy and sticky in rainy season d)Skill levels of local operatives e)Robustness to take constant feed from CAT 988 KEY TECHNICAL CONSIDERATIONS.
CASE STUDY 2 – LATVIA MOBILE SHIP LOADING Model - TS 542, TL 530 and HF 514 Peak Capacity - 500Tph Fertiliser System Fed by - Liebherr 458 FELs.
Latvia -System: TS 542 Radial Telescopic ship loader, mobile links and mobile hopper -Material: Fertiliser (Dust extraction and covers on entire system) -Application: Ship-loading from warehouse
Phase 1 of production Ramp up – up to 1 million tpa. Dust Extraction and Containment – Required to comply with EPA standards with close proximity to Riga City. Sealing of transfer points and Spillage prevention – no spillage on jetty and completely sealed transfer points. Productivity – 500tph system and up to 500,000 T/ month. Designed to cater for testing conditions – a)Weather Conditions – Low sub zero winter temperatures. b)Material – very corrosive to conveyor structures KEY TECHNICAL CONSIDERATIONS.
CASE STUDY 3 - INDIA MOBILE RAIL WAGON LOADING Model - TU 1015 R Peak Capacity - 1200Tph Iron Ore System Fed by - Trucks and FELs.
Client wanted a system to prevent damage to their rolling stock of wagons caused by pay- loaders as well as more accurate and even loading system.
TU 515R Tracked Mobile Radial Truck Unloader Rail Wagon loading directly from Trucks @ 500TPH
Accuracy of weighing critical – a)Penalties for overloading – 6 x Standard Cost. b)Maximum Efficiency of weight in Each Wagon (Max 70T/ wagon) c)Even loading of Rail wagons Reliability of System – a)Remote location b)Heavy application (Iron Ore Material Density 2.4–2.8T/m3) Multi Functionality and Mobility Criteria – a)Stacking at Railway siding when no Rakes b)Rail Wagon loading when rakes present. KEY TECHNICAL CONSIDERATIONS.
CASE STUDY 4 - MALAYSIA MOBILE RECLAIMING AND BLENDING Model - TU 1015 R Peak Capacity - 1000Tph Coal System Fed by - Trucks and FELs.
Design suitable for typical Stockyard layout with limited space between stockpiles and Stacker Reclaimer Belts and road access
The Final Solution TU 1015 R feeding coal onto Stacker Reclaimer conveyor line TU Radial Unit fed from wheel loaders operating between stockpiles and reclaiming line – 3D, Side and Plan Views
Accuracy of weighing critical – Blending purposes- pre set weights and manual settings option on control panel Reliability of System – Required to feed furnace during breakdowns/ maintenance of SR. Communications with Central Control room – WIFI and Ethernet Connections Multi Functionality and Mobility Criteria – a)Blending – Accurate from 100Tph – 1000tph. b)Emergency Reclaiming – SR Breakdown or Maintenance. c)Stacking in passive areas of Stockyard. d)Inter yard Transfer of material. e)General Stockyard duties. KEY TECHNICAL CONSIDERATIONS.
Weighing Systems Control Settings on Panel Mimic Pre set Weights Blend% Tph 10% 140 20% 280 30% 420 40%560 50%700 60% 840 70% 980 Total Reclaim Rate: 1400Tph Manual Settings 100 – 1000Tph
Weighing Systems – Methodology. Manual Settings 100 – 1000Tph - Dual Idler Weigh Belt Scales weigh the product on incline belt. -Pulse Signal is sent back to PLC every 10 Seconds. -Based on this signal the PLC adjusts the speed of the Feeder to maintain the preset weight required for blending/ reclaiming. -Used in conjunction with Stacker Reclaimer to send a accurate blended coal to the furnace
GLOBAL CLIENTS USING MOBILE CONVEYING EQUIPMENT
WHY USE MOBILE CONVEYOR SYSTEM? Ideal for Rapid Deployment for Phase 1 and 2 of export facilities. Can be redeployed to stockyard for phase 3. Enables quick revenue stream for material being exported in first year of operation. Can be used in rental fleets for short term contracts and moved from site to site. (Contract loading) Limited civils infrastructure required for jetties. Can also be complementary to fixed installations. Innovative and operating cost saving solutions. Limited Planning Requirements. Resale Value of the equipment. Dual Functionality of the Equipment. Improve Carbon Footprint. Improve Health and Safety.