“Repositioning a shiploader’s feed point or loading hopper cuts off the material flow from loader to ship, resulting in costly downtime,” says Vice President of Engineering Bob Domnick. “Our goal is to reduce the number of times a feed point needs to be moved and then speed the time it takes when relocation is required.”
Superior Industries first introduced telescopic conveyor technology into its products back in 1997. Since then, the 40-year-old company has manufactured almost 1,000 conveyors equipped with the technology.
In marine terminal applications, the Stingray mobile shiploader’s telescopic conveyor allows the equipment to extend an additional 30%. This means the new shiploader reaches out to multiple hatches from the same feed point. In addition, while positioned over a hatch, extension and retraction of the telescopic conveyor means fully trimmed hatches.
“We know of one client who compared a unit without this conveyor technology to one of our telescopic units,” says Domnick. “According to their load sequence, our telescopic conveyor reduced the amount of moves required to load their vessel from 35 to seven.”
In addition, Superior says a commitment to conveyor mobility is another variable for accelerated load times. Each Stingray mobile shiploader is manufactured with expanded mobility packages at both the feed-point or tail of the conveyor and at its radial or drive tyres.
Often manufactured with track technology, portability at the shiploader’s feed-point allows for rapid relocation from hold-to- hold and simplifies movement on, off and throughout a terminal or port. In addition to the 360° rotation at the tail, the conveyor’s drive tyres are equipped to move inline, transversely and radially.
“We have invested a lot of time into products that focus on conveyor mobility,” says Domnick. “In fact, our founder started this business after seeing a need for better portable conveying equipment. Since then, we have manufactured more than 5,000 mobile conveyors.”
New to Superior, says the company, is a camber or slight arch shape to the conveyor’s structure. This allows the Stingray mobile shiploader to maintain a tight clearance between the conveyor and the deck of the vessel.
This design benefits owners because it reduces the shiploader’s drop height to eliminate dust, preserve material integrity and reduce the length of discharge chutes, a costly component.
Lastly, Superior says it is intentionally armed with a massive engineering department to work closely with clients on custom, individual applications and specifications. Common to any port or terminal client, local environment plays a crucial role in how each shiploader is individually designed.
Common components and conveyor enhancements include galvanized or epoxy finishes, belt covers, dust suppression/ extraction systems, onboard power, remote controls, spillage defence, telescopic chutes, hoppers and a multitude of other options.
Superior’s experience includes engineering and manufacturing work of some of the most complexly engineered conveyors, including the world’s highest-capacity mobile telescopic radial
travel conveyor. The 72-inch (1,800mm) wide by 190-foot (58m) long unit moves 5,000 tonnes per hour at the Port of Tampa in Tampa, Florida, USA. The first Stingray mobile shiploader is designed for Panamax vessels, but can be altered to accommodate other dimensions of dry bulk vessels and barges.
Superior Industries has a reputation for engineering and manufacturing groundbreaking, bulk material handling conveyors and cutting-edge conveyor components. From its headquarters, it supplies stackers, transfer conveyors, feed systems, shiploaders; plus idlers, pulleys and accessories to lower operating costs and increase production. The company manufactures from additional plants in Arizona and Georgia, USA.
Bedeschi offers creativity, innovation and experience when handling dry bulk material carefully and efficiently.
Bedeschi manufactures and supplies various types of shiploaders, for both onshore and offshore applications mainly operating in Columbia, India, Indonesia, USA, Greece, Italy, Philippines.
Each shiploader is designed to fit the specific project requirements and expectations; there is therefore no ‘standard’ shiploader, rather Bedeschi supplies customized shiploaders to maximize efficiency.
Raw commodities suppliers (Vale,Vedanta, Salgaocar,Timblo, etc.), terminal operators (Yara, Peureto Brisa,Titan, etc.), and floating terminal operators (Rocktree, Swire CTM, MBSS, MSI, Coeclerici, etc) rely on Bedeschi shiploaders to export cement, clinker, coal, petcoke, iron ore, urea, mineral concentrate, bauxite, limestone, agribulk (grains, soya meals, sunflower seed) and fertilizers.
According to the features of the project, some shiploaders have shuttle type delivery boom with reversible belts, while others have a retractable mechanism capable to extend the outreach; some have been fitted with a straight delivery spout while others have incorporated a distributing chute designed to deliver cargo in all parts of the holds in order to avoid broken spaces.
Furthermore, some shiploaders have even been fitted with lifting mechanisms to transfer bulldozers into the holds of the vessels.
In general, Bedeschi shiploaders are designed in such a way to maximize the working range of the shiploader and to minimize the risk of cargo clogging and spillage. Dust suppression devices, like water sprinklers or bag filters, can be incorporated as well. Trimming chutes are specifically designed to suit the cargo to be handled. Metal detectors, online weighing devices and automatic sampling devices are some of the other features provided as optional in various projects.
Besides shiploaders, Bedeschi also manufacturers other related equipment like hoppers (to receive cargo from cranes), feeders (to extract cargo from hoppers and deliver onto conveyors), belt conveyors, trippers, storage facilities, etc.
Bedeschi has successfully pursued the strategy of expanding beyond port and stockpile cargo handling facility and, thanks to the support of Logmarin Advisors and Liebherr (when integrated solutions are required), can work with its valuable client to find the most efficient integrated cargo handling solutions for loading, unloading and storage dry bulk commodities at any stage of the supply chain.
Bedeschi believes creativeness is the best way to stay ahead in the competitive environment: innovative designs developed together with Logmarin Advisors are the result of years of experience and application of the feedback received from the ongoing operations.
BedeschiandLogmarin’steam-working hasledtoinnovative projects: Logmarin carries out feasibility studies (market analysis, simulation models), project implementation (design and engineering, construction supervision) and operational support (commissioning and performance assessment) complying with the project features/merging its know-how with Bedeschi’s experience.
Bedeschi, Logmarin and Liebherr (the world-renowned maritime crane supplier), which are the individual constituents of the consortium Bulk Logistics Landmark (BLL), firmly believe that only state-of-the-art, integrated solutions are successful on a long term period. Properly planning the whole project means improving operating efficiency, productivity and cutting future maintenance time and costs: high-level engineering leads to profitability maximization.
Since each project has its own features, BLL works together with the client in order to provide cost-effective and reliable cargo handling solutions: by merging skills and expertise with its partners, Liebherr and Logmarin, Bedeschi provides dependable and complete projects to convey the dry bulk commodity to industry smoothly and efficiently.
BLL provides the widest range of high-technical solutions: from a single product up to turn-key projects (including commissioning,crewtraining,after-salesupport,etc...).
Bedeschi, Logmarin and Liebherr are committed to provide innovative solutions in order to bridge the infrastructural gaps from mine to clients.
Willingness to keep customer’s requirements and feedback as paramount considerations and to develop a solution to suit those requirements, rather than pushing a standard product and compromising the customer’s needs, is BLL’s distinctive strategy. BLL repeat orders from satisfied clients demonstrate efficiency and effectiveness of the projects carried out.
Stay on the right course: efficient use of waterways with SMB shiploaders
Using waterways is a cost-efficient transport alternative, particularly in countries with poor infrastructure. In order to reach remote inland harbours without having to reload the freight, smaller ships are loaded from the outset. The prerequisite for this type of cost-effective transport is to load ships quickly and safely and to exploit the entire freight hold available.
SMB International provides an optimum solution particularly for these tasks. In the last 20 years, SMB has provided more than 80 shiploading systems in many countries — the company’s international references range from Western Europe and Russia to Latin America and even Southeast Asia. Loading systems for ships from 5,000dwt to 90,000dwt have been developed and built, regardless of whether a stationary loading system is used or whether mobile loading systems travel back and forth on rails along the quay wall. The faster a ship is loaded with fertilizers, rice, corn, slag or cement bags, the shorter the idle periods are, resulting in more cost-effective transport.
SHIPLOADING SYSTEMS FOR A VARIETY OF APPLICATIONS
For the loading of bulk materials, cascade chutes optimize the flow speed of the material and thus ensure largely intact grain structure of the bulk materials. Moreover, an encapsulated suction system minimizes the emission of dust. The damage risk of sensitive goods is significantly reduced due to the chutes; high insurance and transport costs are avoided
For bag loading, an extension arm combined with a conveyor belt is swivelled above the ship. Through the spiral chute, which is vertically attached to the extension arm, the bags slide into the freight hold. A swivelable rotating table with a telescopic conveyor belt that can be extended up to three times ensures precise bag positioning to the centimetre, even in the most remote corners of the freight hold.
With the combined shiploading system, the spiral chute for bags and cascade chute for bulk materials are both installed at the same extension arm; loading can optionally be performed for bags or bulk goods.
SMB — PLANT AT QUICKBORN NEAR HAMBURG IN GERMANY — ENABLES A LARGE VERTICAL MANUFACTURING RANGE
All mechanical and electrical components and modules are developed and produced by SMB employees at its plant in Quickborn, near Hamburg, Germany. This is a good basis for efficient project implementation and for later on-site assembly. The large vertical range of manufacture ensures reliability with regard to quality and delivery periods. SMB’s 3-D animations of construction components are particularly useful. They facilitate common workflows since they provide a better overview for customers during the planning phase.
For modification and capacity increase of existing systems SMB also offers various options. Thus, individual adjustment to existing systems is not only interesting for ship owners.
SMB International provides its customers with an all-round carefree package: maintenance agreements including intensive training of staff on site; installation of a digital interface for remote transmission and diagnosis; and even camera surveillance. All options are imaginable and can be realized.
“Our SMB shiploading systems are capable of loading ships to sizes between 5,000dwt and 90,000dwt, to lengths up to 150 metres and widths up to 40 metres. The systems handle up to 2,000 tonnes per hour but significantly higher outputs are feasible,” explains Dipl.Ing.Andreas Heckel,CEO of SMB Group.
SMB International and MBA Instruments: two brands — one idea. SMB and MBA have focused their business activities in the area of ‘material handling’. Planning, development, manufacturing, global distribution and service of highly complex, automatic loading systems, filling systems, level and conductivity measurement technology, palletizers, conveyor systems, compact high-bay warehouses and ship loaders are part of its product range.
Quite consciously, the SMB Group has opted for a high proportion of in-house production at its plant in Quickborn, near Hamburg. In this way, customer requirements are spontaneously and targeted implemented quickly using a consistently high Mechanical and electrical components are designed and produced in-house, which has led to high production values, and ensures reliability in terms of quality and delivery time. Installation and service teams work on national and international projects. The global sales network ensures quick and targeted information and co-ordination.
E-Crane offers flexibility and efficiency to shiploading market
While shiploading/offloading systems can be costly and inflexible, E-Crane is just the opposite, providing the solution for loading and offloading bulk materials in seaports and river ports throughout the world.
MOBILE HARBOUR EQUIPMENT
E-Crane offers its customers the choice between several different types of undercarriages which are customized to their needs.
Along with the fixed pedestal and the free-standing pedestal lowers, E-Cranes can be installed on either low or high gantry portals on rails, or on crawlers. The balanced design also provides great stability, making it the perfect solution for a floating barge mount.
When choosing the type of undercarriage, E-Crane will work closely together with the customer to find the best solution for that customer’s operation. All options can be utilized in ports, but mobile options are especially frequently used in shiploading and offloading. Both rail mounted and crawler mounted solutions allow the E-Crane increased flexibility and mobility because the crane can travel alongside the ship in order to optimize the loading operation.
New and repeat customers know why E-Crane is an ideal solution for mobile harbour requirements. E-Crane’s fundamental ‘Equilibrium’ design allows gravity to work for its customers, instead of against them, offering savings on maintenance and power costs. These economic advantages, along with high ship loading and unloading rates, are behind the E-Cranes’ high popularity.
E-Crane also designs and supplies two types of custom- engineered attachments and grabs: the hydraulic clamshell grab and the orange peel grab.
Not only are these grabs very competitively priced, with short delivery times and easy shipping, both also have major advantages for shiploading in seaports and river ports.
E-Crane’s positive grab control provides operational precision, push-down force and overall productivity with very little clean up needed. The main advantage of an E-Crane grab is that the grab is hydraulically controlled and not cable suspended. With hydraulic control, the grab can be accurately positioned for material pickup and can provide a push-down force of up to 50% of the lift force in order to break up lumpy, sticky or frozen material. Additionally, hydraulic control over all machine movements promotes short duty cycle times and increased production.
If a company needs to use multiple attachments (sometimes necessary depending on the company’s operation), E-Crane has a quick change solution which allows the client to switch attachments in a matter of minutes. E-Crane can easily modify existing grabs to fit the quick-change twist-lock pattern. This mechanical coupler is a more efficient and safer way to switch between attachments, and saves clients time and money due to downtime while changing attachments.
E-Cranes also come with a new, reliable and user-friendly control system called the EMM, or Electronic Machine Manager. This built-in system allows for real time data collection of things such
as running time, how many times the E-Crane hits a fault while in operation, whether there is an overload or overheat, and more. Some even stream live, real time video of the E-Crane while in operation.
The EMM system provides the link between the operator and the crane which is necessary for safe and productive bulk material handling. The software makes troubleshooting easy, by immediately displaying any warning or fault on the dialog module located right inside of the operator’s cab. E-Crane’s can also be remotely diagnosed by E-Crane service technicians anywhere in the world through the EMM system.
E-Cranes are broken down into five different machine series based on capacity requirements; the 700, 1000, 1500, 2000 and 3000 series, E-Crane features a unique design with a moveable counterweight and a parallelogram-style linkage than can provide up to 150ft/50m reach and up to 49 tonnes duty cycle capacity. It provides a fast, easy, low-cost-per-tonne method of unloading bulk materials from barges and ships up to and including Panamax vessels. Further, with the E-Crane’s® modular design, each E-Crane® is tailored to meet the customer’s specific needs and preferences.
NEUERO Industrietechnik: dust-controlled shiploading solutions
In recent years, NEUERO Industrietechnik has developed shiploading solutions that take into account today’s ever more stringent dust control regulations.
The company’s main export markets are to countries such as Russia, the Ukraine and Brazil. However, recently NEUERO has supplied equipment to Poland, and also within Germany. Because of a lack of access at the site, it was necessary for NEUERO to assemble the equipment outside and to ship it to the site in Poland using a floating crane. Because NEUERO manufactures its own components, it can supply equipment of the highest quality. One example was the retrofitting of the tower of an existing shiploader in Nikolaev in the Ukraine. The customer had experienced problems related to high wear and, particularly, dust pollution. NEUERO supplied new loading systems with integrated dust suppression, and the pipes were made of Hardox. The winches are also designed and manufactured by NEUERO.
Another example of the company’s custom design is its work at Russia’s Taman Grain Terminal. The task was to make it possible to load a vessel from both sides, or one side. The idea was to save precious time. Loading from both sides increases risk, especially if equipment does not follow the strict geometry of quay edge and ship inclination angle. Please see the photo at the bottom of p90). In Germany, NEUERO supplied a loading system for fertilizer made completely of stainless steel. This is especially difficult because not all steel shapes and parts are easily available in the market. However, this type of product is essential to ensure a long life.
Also in Russia, NEUERO has just commissioned two 600tph shiploaders, both in Kaliningrad. These shiploaders form part of the Sodrugestvo expansion project, where NEUERO has also supplied two ship- unloaders, which are set to be commissioned this year.
Successful shiploading with VIGAN
Well recognized for the supply of ship unloading equipment worldwide,VIGAN Engineering S.A. is also a provider of flexible and customized loading solutions.
VIGAN loaders are designed for almost any kind of products in bulk (with density from 0.2 to 1.8), and are suitable for all size of barges or vessels. Whether fixed, tractable or mounted on a self-propelled gantry (on rails or on rubber wheels),VIGAN loading machines guarantee a capacity of up to 1,200tph (metric tonnes per hour), and work with an electrically driven motor or with a diesel power unit.
The loading takes place mechanically: for instance, the cargo can be transported into the loading boom by an integrated belt or chain conveyor and discharged by gravity into the ship hold thanks to a telescopic loading chute. The loading boom is usually mounted on a slewing ring and can reach up to 25 metres. The combination of telescopic and rotating movements allows continuous and uniform loading operations of the ship holds.
A NEWCOMER IN VIGAN’S HISTORY: THE PORT OF LIEPAJA
In 2012,VIGAN supplied an electric shiploader to Danstore, part of Copenhagen Merchants. This unit can be used on vessels up to 60,000dwt, and has a capacity of 1,000tph when handling grain with a bulk density of 0.75.
Installed in the Port of Liepaja in Latvia, the new machine is gantry-mounted on self-propelled rails. The transfer of grain from the tripper conveyor to the foot of the bucket elevator is operated by an inclined chain conveyor. This chain conveyor is mounted on a slewing ring run by an electrical motoreducer.
A 24m bucket elevator on the gantry transfers the cargo to the upper transfer chain conveyor. A 9m chain conveyor transfers the grain from the bucket elevator up to the shiploading system.
The loading boom has an integrated 25m chain conveyor. The end of the loading boom is equipped with a telescopic loading spout, whose bottom is equipped with a large dust skirt at outlet. A level sensor controls the automatic luffing of the skirt at the bottom of the loading pipe during the loading process in order to control the dust emanation.
Dust control is today a major concern in ports. VIGAN shiploaders are equipped with state-of- the-art dust reduction devices, such as air suction pipes nearby most critical parts of the equipment.
One or several filters ensure the cleaning of this air before its flowing out to the environment.
VIGAN innovates with permanent technical developments. Thanks to a team of talented engineering experts and the transmission of expertise,VIGAN delivers qualitative equipment recognized and appreciated worldwide for its long-term reliability.
During the last five years,VIGAN has sold shiploaders in Kazakhstan, Poland, France and Latvia with capacities varying from 350tph to 1,000tph.
VIGAN mechanical loaders are suitable for many applications. As each case is different, and each customer has specific requirements,VIGAN prepares special designs according to each specific bulk handling operation.
VIGAN shiploaders are fully customized and specially manufactured.
TMSA, the shiploader specialist in South America
TMSA Tecnologia em Movimentação S/A, is one of the major suppliers in the South American market for bulk solids material handling, especially in port terminals. TMSA specializes in heavy duty and long distance conveyors.
It is estimated that about one third of Brazil’s exports of grain/meals/sugar are handled by TMSA equipment. The company’s main activity is to design and manufacture shiploaders and belt conveyors, with their associated dust control systems. TMSA is able to fulfil Engineering, Procurement & Construction (EPC) contracts.
TMSA has supplied belt conveyors with capacities up to 20,000tph (tonnes per hour) and shiploaders for sugar, iron ore, coal, alumina, kaolin, and other heavy duty commodities with capacities of up to 4,000tph.
Based in Brazil, the head office is located in Porto Alegre, Rio Grande do Sul State, where TMSA has a large 32,000m2 manufacturing facility.
This facility is equipped with highly integrated engineering capabilities, with in house mechanical, civil, structural, electrical, automation and de-dusting specialists; all under ISO 9001:2000 certification.
The working team comprises approximately 500 employees, including the branch offices in Belo Horizonte at TMSA Minas and in Buenos Aires, at Bulktech Argentina S/A. TMSA’s large team of over 50 engineers and designers — of all ages — guarantee ‘state-of-the-art’ solutions, with long-term support from the company’s in-house mechanical, structural, finite element analysis, electrical, automation and dust control specialists.
Prominent in the Mercosur market for bulk loading port terminals,TMSA has a large portfolio of different shiploader designs. One of the company’s notable contracts is the turnkey supply of port terminal equipment to AGP in the Port of Grays Harbor in WA, USA. This project gave TMSA considerable experience with all types of American Standards and seismic zones.
TMSA SHIPLOADER PRODUCT LINE
This includes more than 70 references, including some retrofits, of six different types of ship and barge loaders supplied, as follows:
1. Fixed tower; luffing and slewing boom without counterweight; basculating or fixed telescopic spout.
Loading port terminals with piers are typically equipped with mobile shiploaders. Terminals without piers are usually equipped with stationary fixed loading towers with booms, which can be slewed, lifted and lowered. Towers can be built in steel or concrete.
Fixed tower shiploaders are an efficient and cost-effective solution. Ship hatches can be loaded individually or simultaneously by several loading lines. Their loading boom movements (lifting, lowering, and slewing) eliminate the need for time-consuming shifting of ships. The loading booms can be equipped with a kick or trimmer system to optimize loading, consisting of deflection shovels attached to the end of the loading spouts, increasing the loading area. Dust control loading systems are usually installed to satisfy operational and environmental requirements.
2. Fixed pedestal; luffing and slewing boom with counterweight; basculating telescopic spout.
This is a suspended, revolving type with a shrinkable tilting telescopic tube with swivelling revolving chute.
3. Travelling gantry; luffing boom; travelling telescopic spout (see pictures above).
Travelling shiploaders are composed of the main portal frame, an articulated boom with a moveable head conveyor, travelling bogies, telescopic loading spout and the required dust suppression system within all the mechanical, structural and electrical components.
Travelling systems normally travel at 20m/min with 32 wheels driven by motor reducer units with electromagnetic brakes and speed control by frequency inverter.
The boom hoisting system has a lifting angle from 0° to 60° with a hoisting drive with steel cable winch.
4. Travelling gantry; luffing and slewing boom; fixed telescopic spout.
The RUMO Logistica shiploader in Santos, Brazil, has a loading capacity of 3,000tph when handling bulk sugar, through a 60”- wide belt conveyor, equipped with a dedusting system for environmental control.
Blocking sensors stop the loader in case of proximity to other loader or obstacle. A set of electrical drives with PLC and exclusive supervisory system, provided with safety devices for product conveying, loading cells for overloads control of steel cables, sensors, emergency brakes and other standard devices.
The combination of movements makes it possible to reach all points of the vessel’s hatches.
The equipment has a boom rotating angle from 0° to 180°. The telescoping spout course is 20m. Maximum reach of the boom is 30.80m. Total installed power is 538 HP and the approximate total weight is 400 metric tonnes.
A similar machine is currently being installed for Copersucar terminal in Santos, Brazil.
5. Longitudinal travelling; luffing boom.
In the selection of the type of shiploaders, besides location and type of material supply, loading capacities and ship sizes, some parameters as water levels of rivers or sea tides are crucial.
This is a special loader for 4,000tph iron ore, for a river ship and barge terminal where the tides had a difference of 5m and needed an innovative solution: the loader is supported on a floating pontoon, having a special design to allow loading ships or barges.
6. Tower shiploader, slewing type with shuttle boom and telescopic loading spout.
Slewing angle of 180°, minimum of ±90° turns in both directions, in order to cover as much as possible the area of the vessel hatch. The boom is structurally fixed to support-out-of-service winds and has a storm anchorage system. The shuttle conveyor is supported on rollers and shuttles both sides to reach any loading point. Its total extension is 45 to 50 metres to make it possible to reach all the hatches of a 40,000dwt vessels as well as a 140,000dwt Capesize vessel. The telescoping loading spout can achieve an extended length of 20 metres and vertical travel of approximately 13 metres, allowing the spout to go until the mean water line. The chute is completely closed and sealed with a rotary trimming spoon that improves the efficiency of the loader and a better weight distribution on the ship.
telescoping loading spout can achieve an extended length of 20 metres and vertical travel of approximately 13 metres, allowing the spout to go until the mean water line. The chute is completely closed and sealed with a rotary trimming spoon that improves the efficiency of the loader and a better weight distribution on the ship.
TMSA SUPPLIES DUST CONTROL SYSTEMS FOR THEIR OWN OR EXISTING SHIP LOADERS TMSA supplies conventional designs, such as telescopic loading chutes, as well as its own innovative designs such the Dust Trap system or the new DSH – Dust Suppression Hopper from New Zealand.
ACCESSORY MOBILE EQUIPMENT FOR THE PORT TERMINALS
For port terminals,TMSA offers a truck unloading unit. This consists of a superficial hopper with a low-profile feeder and a Manutube conveyor. This is a totally dustless technology, designed by Absam Engineering, France. The Manutube is an enclosed belt conveyor with a belt sliding inside a plastic tube with no idlers, fully enclosed. For high capacity, over 1,000tph, and heavy duty applications,TMSA offers the Low Profile Feeder from Transmin, Australia".
To complete the range of equipment for ship and barge loading and unloading,TMSA represents in the Mercosur countries:VIGAN from Belgium, for ship-unloading;Telestack from Ireland, for mobile telescopic shiploaders; and Absam from France, for enclosed dustless mobile shiploaders.
TMSA, as a strong specialist in bulk material handling, offers different solutions for the conveying of the bulk material from ship-unloaders to the silos or from the silos to the shiploaders. Its wide technological portfolio offers belt conveyors that can be open, covered or enclosed, such as the RopeCon system, pipe- conveyors, overland conveyors or conventional trough conveyor belts with high capacities. TMSA has the knowledge and experience for the proper selection of a shiploader and conveying system which will better fit the needs and budget of each project.