Telestack solutions are in use in numerous ports and river terminals around the world handling a wide variety of dry bulk materials from coal, iron ore, aggregates, grains, fertilizer, wood chip and many more materials.
More and more customers are turning to Telestack to solve their material handling problems and the company has a proven record of performance of supporting customers around the world before, during and after the sale.
Within its UK facility, Telestack designs, manufactures and fully assembles to test all functions, before it ships the equipment to its customer. Telestack’s ISO 9001:2008 status demonstrates that it has processes in place to help ensure it delivers on time and within budget what the customer has ordered.
Hitachi launches the new ZW220-5 wheel loader
Hitachi Construction Machinery (Europe) NV (HCME) has introduced a new wheel loader, the ZW220-5. Hitachi designed the new wheel loader to satisfy the requirements of its European customers for machines with an exceptional level of comfort, as well as excellent productivity, advanced technology, and a range of features for enhanced sustainability, safety and easy maintenance.
Comfort was one of the most important considerations for the design of the new ZW220-5. The cab is more spacious than the previous model, because the heated air-suspension seat can slide further back, providing more leg room. The tilting telescopic pop-up steering column has also been repositioned to create additional space.
The air conditioning system regulates the temperature inside the cab, and an optional filter is available for industrial waste job sites. Sound insulation reduces noise levels from the local environment and improves the operator’s overall experience.
The ZW220-5 wheel loader complies with EU regulations on emission standards, but does not compromise on productivity. It has a 7.8-litre six-cylinder water-cooled turbo engine that enables a powerful digging performance, impressive travel speeds and excellent fuel consumption. The new ZW-5 wheel loader is easier to manoeuvre than the previous model, which also results in higher levels of productivity. A new clutch cut-off system allows for smooth operation when it is loading.
Two simple work modes provide an appropriate level of performance for a particular task. In Standard mode, the engine speed is controlled, which allows for smooth and efficient acceleration during loading, regular operations and travelling on level terrain. Fuel consumption is reduced by up to 10%, enhancing its environmentally friendly performance. The P mode is useful when greater traction force is required for heavy-duty excavation and travelling quickly uphill.
When changing work modes, the ZW220-5 has a quick power switch, an example of its advanced technology, which boosts the power when required. The wheel loader also features a new hydraulic circuit, which facilitates the combined operation of the bucket and lift arm for loading, and prioritizes the use of the bucket for unloading.
The optional auto-engine shutdown function avoids fuel wastage while the wheel loader is long idling. In addition to lowering fuel costs for the customer, this enhances the sustainability of the ZW220-5. It also has a muffler filter to capture air pollutants, which are automatically burnt thanks to an oxidation catalyst and exhaust temperature control.
To enhance safety on the job site, the ZW220-5 offers greater visibility from the operator’s seat thanks to a pillar-less windshield and large sun visor. The counterweight is also now visible from both sides of the machine. The shift-up delay to third gear makes the wheel loader safer to operate in confined spaces, because it can perform excavating and unloading tasks more safely in first and second gear.
A variety of easy maintenance features has been incorporated into the design of the ZW220-5 to ensure maximum availability. For example, the redesigned engine and radiator cover can be opened fully, providing quick and convenient access for daily inspection. The greasing points, oil levels and fuel filters can all be accessed at ground level. For operation in dust-filled environments, the ZW220-5 wheel loader can be equipped with an optional wide- pitch fin radiator to prevent clogging. Another useful feature for routine maintenance is the automatic reversible cooling fan, which allows for easy cleaning of the radiator with its one-minute automatic reverse rotation every 30 operating minutes.
Tadayoshi Aoki, HCME Engineer for wheel loaders, is looking forward to the reaction of the European market to the launch of the ZW220-5. “We believe that the new wheel loader not only meets our customers’ expectations of high quality and reliability, but also provides a safe working environment, a comfortable cab with easy-to-use controls, and overall, a machine that responds quickly and precisely.”
RDS launches LOADMASTER α100 on-board weighing system
RDS Technology has launched its new LOADMASTER α100 on- board weighing system, described by the UK-based manufacturer as being the new industry benchmark in terms of accuracy and ease of use in difficult conditions and terrains.
This on-board weighing system is ideal for use on mobile equipment such as front-end loaders.
The RDS LOADMASTER α100 is an all-new CAN-based system combining cutting-edge sensor technology and signal processing techniques providing precise and consistent weight information.
With the ever increasing focus on productivity, LOADMASTER α100 has been designed to operate within the fastest loading environments and toughest of conditions compensating for uneven, sloped ground and restricted loading areas reducing cycle times and maximizing tonnes per hour performance.
Loading correctly first time eradicates return trips to the stockpile reducing vehicle movement, fuel usage and machine and tyre wear.
The new RDS LOADMASTER α100 uses a 7” colour, resistive touch screen display and additional physical keys providing a modern and ergonomic operator interface. Suitable for use with up to ten different attachments e.g. buckets or forks, the system can be retrofitted onto wheeled, telescopic and tractor type loaders. The system continually measures hydraulic pressure using up to four sensors. The pressure signals are captured and filtered through a weighing ‘arc’ provided by inclination sensors measuring the angle of the main boom. All signals are processed in the RDS Smart Box and the resultant weight calculation is sent to the terminal mounted in the cabin.
SQL database capability with up to eight reference fields providing virtually unlimited inputs of products, customers, trucks, hauliers, locations, destinations, mix blends and notes. There is a blend facility with an infinite number of mixes and products.
GPRS or Wi-Fi connectivity provides one or two-way communication with the back office to send and receive job information.
Video input for switching head unit into reversing camera mode removes the need for additional screen, releasing valuable cab space.
Buttimer’s mobile loaders match flexibility with durability
Buttimer has been designing and fabricating high-quality mobile harbour equipment in Ireland for many years. Its core product range includes ship unloading units, custom-designed to handle grain, coal, ores, aggregates, biomass and other dry bulk products. The units can discharge to trucks rail and conveyors, depending on port requirements, and can be fitted with a range of dust control and aspirations features. Many of the units supplied by Buttimer are self-drive vehicles on sturdy rubber tyres; however they have also been mounted on rails, static structures and driven by their feeding crane. Buttimer’s mobile harbour equipment has been developed with knowledge of requirements in a busy port environment, with flexibility and durability in at the heart of their design.
Buttimer’s most recent equipment order, from Associated British Ports (ABP) in the summer of 2013, has been for two mobile ship unloading hoppers for the Port of Hull, England. The two state-of-the-art ship unloaders will primarily handle wood chip and wood pellets as part of the port’s new biomass handling capabilities. Buttimer won this project by specifically meeting the client’s handling needs, and was selected above products from a number of very well-known port equipment brands. Existing units are operating effectively, some many years after commissioning, at ports including Cork and Dublin in Ireland and Gdynia, in Poland.
Buttimer is preferred by its customers for a number of reasons, but all arise from a practical understanding of the demands placed on mobile harbour equipment in practice at busy bulk terminals. A number of key innovations allow Buttimer equipment superior durability and flexibility than competitor products, a few of these are:
- sound structural design: including a detailed estimation of forces and loads to be borne on the ship unloading hopper’s frame and wheel structure. It is not uncommon to hear of damaged unloading hoppers even where equipment has not been overloaded, this is often due to poorly designed equipment which hasn’t been designed to withstand the loads on stress points and structural twisting during the loading process. As no port wall is level and mobile unloading hoppers can be up to 14m wide, 14m long and 18m high, there can be deviations of up to 1m over the diagonal length of the unit. In conventional units, the structure is made in a way to take up these differences but as the structure twists it puts very large torsional loads on the structure with obvious consequences. Buttimer’s engineers have designed a hydraulic suspension system to take up the differences in levels and hence keep a constant loading on each corner. Buttimer’s equipment is designed to be robust enough to accommodate the full rigour of bulk product handling, the occasional accidental bump from a grab, and manoeuvring to and from the quay wall — the full impact of a busy port!
- manoeuvrability: a limited commodity at the majority of bulk ports is space. Buttimer has developed patented steering and wheel technology, designed to give equipment a very tight turning radius, making units highly manoeuvrable and efficient even in tight quay areas. An impressive tight turning radius, coupled with an ability to tolerate variations in the level or surface of the quay wall, give Buttimer’s equipment an ease and speed of repositioning and manoeuvrability that belie their robust frame and structure.
- customizable environmental controls: each bulk product, port and environment will require different levels of dust suppression, aspiration and environmental control functionality from its mobile port equipment. Buttimer can design and fabricate a wide range of dust suppression features on all units, to the client’s and product’s requirements. Buttimer offers solutions such as a 3m-high grab-enclosure thimble with a mechanical dust suppression system; a built-in dust suppression flex-flap system, and inserted cassette filters that return the dust into the product. These options combined with out-loading dust suppression chutes allow for a greater control of emissions and mitigation of explosion and fire hazards; whether feeding into a conveying system, direct to trucks, train wagons or barges.
Buttimer has also manufactured a range of other port equipment, ranging from entire material handling systems, to bespoke pieces of equipment. Last year Buttimer developed an innovative mobile conveyor shiploader, in partnership with Telestack Ltd. The unit used an innovative six-wheeled chassis to quickly change from parallel, radial and straight drive modes, allowing rapid movement between hatches, and optimized efficient loading of iron ore at 2,000tph. The unit was developed for ArcelorMittal and is in operation in Buchanan, Liberia.
Buttimer is an expert in the mechanical handling of dry bulk products. The design and manufacture of port equipment for handling bulk goods is one area of its business which also includes turnkey bulk port design, and material handling solutions, design and consultancy for industries such as mining, power generation, food, malting and brewing and animal feeds.
IBT develops concepts for mobile stacker conveyors
IBT has developed a few concepts relating to mobile stackers that are directly, or indirectly, linked to a feeding hopper.
MOBILE STACKER WITH FEEDING HOPPER
In the concept of the mobile stacker with connected feeding hopper, the stacker (5) is permanently linked with the hopper (1). The feeding hopper is provided with a set of double tyres and has a flexible connection with the mobile stacker.
The feeding hopper can be loaded from the rear. The width and height of the inlet can be customized according to the requirements of the customer. The available capacity ranges from 500tph (tonnes per hour) up to 2,000tph.
The stacker has a boom (5) with an adjustable inclining angle up to 25°. On request the boom can be provided with a dust reducing hopper or a loading spout. In order to prevent run- back of product, the belt can be provided with 32mm-high chevrons.
Depending on the needs of the customer, the belt widths can range from 800mm to 1,400mm, which offers a wide range of capacities. All the wheels (3) of the stacker are swivel-mounted, so the machine can move directly forward, in any direction or at rightangles to the mobile stacker. All the wheels can rotate over 360°, allowing movement in any direction. All of the stacker’s wheels are electrically powered via frequency converters, enabling variable speeds.
This concept is unique in that the stacker can slew around its central point (4) while the feeding hopper remains motionless. The advantage is that the feed hopper follows the movements of the stacker while travelling.
The total empty weight of the feeding hopper (1) in the toughest implementation is approximately 18.5 tonnes. The weight of the stacker including the counterweight — but without product — is approximately 30 tonnes.
The feeding hopper (1) and the stacker (5) are provided with plug connections so that the individual parts can be transported separately.
The unit can be used for loading ships, and for the storage of bulk materials in an open or closed storage. For rough or unpaved terrain, the stacker can be mounted on tracks without compromising flexibility.
MOBILE STACKER WITH LINKED CONVEYORS
This mobile unit (see graphic on p91) consists of a mobile stacker (7) connected to two mobile (4) conveyors. The fixed loading point (2), that is integrated in the first mobile conveyor, can be loaded from another mobile conveyor or directly from a feed hopper.
The last link in the three parts of this mobile unit is a the height-adjustable mobile stacker (7). The stacker is connected by two mobile conveyor belts in line. The first in line connected is provided with a sliding loading point (2). The loading point will stay in a fixed position and will only rotate while travelling with the stacker.
All conveyors are equipped with tyres (1, 3 and 6) so that total unit as a whole can travel. All the wheels are steered in such a way that the direction of the moves of the connected conveyors can be determined by the operator.
By providing flexible connections (5) between the individual components and a sliding connection (2) below the loading point, the stacker is able to travel over dozens of metres without having to interrupt the unloading. By choosing a central loading point, the stacker is able, depending on the specifications of the individual components, to travel from 35 to 60 metres without changing the position of the loading point. The fixed loading point (2) makes it possible to provide the electrical power connection at this point. The design of this concept is based upon a capacity of 500tph up to 2,000tph, with a belt width of 800mm up to 1,400mm. The individual length of the conveyors are 12 up to 20 metres for the connected belt to the stacker, and 20 up to 32 metres for the belt conveyor with the sliding loading point.
The conveyor system is ideal for the loading of sheds, an open-air storage facility, or for shiploading — or even for the loading of trains. A feed hopper could be used to feed the above-mentioned systems.
ADVANCED MOBILE STACKER WITH INPUT BUNKER
The option of a mobile stacker with feeding hopper can, by the integration of two mobile belt conveyors be completed up to a four-piece unit.
The options listed here are all basic concepts and will vary depending on the product specifications and capacities in a ‘custom made’ implementation.
The control cabinet is found in all situations on the stacker. The position of the electrical connection is on the fixed point of the sliding support of the belt conveyor.
Equal to any challenge: the SENNEBOGEN 870 M special at Wismar seaport
Thanks to its central location,Wismar seaport in Germany is an important logistical hub for freight traffic between Central Europe and the Baltic. For flexible loading and unloading, Seehafen Wismar GmbH relies on the dependable, mobile SENNEBOGEN materials handling machines. A new SENNEBOGEN 870 M was put into service in the summer of 2013.
Wismar seaport can look back over an eventful 800 history, since the 13th century. Today in Wismar on 66 hectares, approximately 7mt (million tonnes) of bulk cargo and piece goods are transferred and shipped throughout the world. Since 2008, Seehafen Wismar GmbH has relied fully on the SENNEBOGEN Green Line material handling machines for demanding transshipment of bulk cargo, scrap or round wood. In June 2013, the company, LST Bau- und Industriemaschinen GmbH, was able to transfer a new 870 M special to the seaport. The machine is part of a multi-year rental contract and supplements the existing two 850 M machines and an 840 M. The new machine is particularly impressive with its extensive range of 24m and the robust and reliable design. Equipped with a 2m HGT log grapple, the SENNEBOGEN 870 M mainly works in timber loading applications and thus achieves work rates of up to 140tph (tonnes per hour). The comfortable maXcab, which can be elevated 3m and moved forward 2.6m, offers significant advantages, particularly when unloading ships. In this configuration together with the 0.75m mast, the new 870 M provides an ideal overview of the work area and an optimal view into the hull of the ship.
Ships with loads of up to 5,000 tonnes and a maximum length of 120m are unloaded by the SENNEBOGEN machines in Wismar. The flexibility of the mobile machines is a particular advantage when the task at hand is to approach different berths or to unload large ships piece-by-piece. The powerful 300 kW Deutz diesel engine ensures the necessary force reserves and is designed for ease of maintenance and ease-of-service.
Driver Sven Dominik has special praise for the camera system with rear and side-view camera and seven monitors, that ensures an optimal all round view — a valuable plus for safety, and which is provided as standard equipment. Dominik's experience confirms that the extensive range of 24m and the special materials handling equipment together with the curved banana boom and long grapple stick make the SENNEBOGEN 870 M the perfect machine for unloading ships.
The machine is also used for loading on truck and rail. Operation up to 24 hours per day can frequently occur; this kind of work requires reliable and robust components. The local sales partner, LST Bau- und Industriemaschinen GmbH, handles regular maintenance and service and ensures smooth operation of the SENNEBOGEN machines.
“We have profited from our long-standing collaboration with SENNEBOGEN, and again we decided on a machine that perfectly meets our requirements. As a modern seaport we always want to be equipped with the latest technology to satisfy customer requirements. With the new SENNEBOGEN 870 M we have had outstanding success in this endeavour,” says Michael Kremp, CEO — Seehafen Wismar GmbH.
Staying on the move with mobile unloaders from VIGAN
VIGAN Engineering SA manufactures a range of bulk materials handling systems, including mobile equipment. Its main product range includes:
- mobile pneumatic conveyors or vacuvators or grain pumps;
- pneumatic continuous barge unloaders and mechanical barge loaders;
- mechanical and pneumatic continuous ship unloaders for vessels up to post-Panamax; and
- mechanical loaders for any size of ships. VIGAN’s capabilities include also complete turnkey projects for port terminal including shiploading and unloading, storage facilities and bagging operations.
Among the mobile equipment offered by the company are, notably, its portable pneumatic unloaders, commonly called ‘mobiles’ or ‘grain pumps’:
Model T120: working in ‘suck only’, ‘suck & blow’ or ‘blow only’ mode, their capacity ranges from 100tph (tonnes per hour) to 170tph, depending on configuration and product transported; and
The high-capacity model T200 is able to unload at rates of up to 250tph in sucking-only mode, without producing any dust emissions. Products are discharged by gravity, optionally through an integrated belt conveyor. It is equipped with an automatic self-cleaning filter with air-compressor.
These mobile portable unloaders are particularly adaptable, as they can be put on a ship’s deck or on quay: directly on the ground, on a frame or on a hopper (see picture above). With a wide range of accessories available, they can be customized to meet customer’s needs for cargo handling in many different working configurations: from vessels to trucks/railcars/ conveyors/silos or warehouses and inversely to load ships, but also for transshipment for instance.
Their compact dimensions (≈ 4.5 x 2.5m without booms) and low weight (≈ from 5 to 15 tonnes depending on the model and accessories) make them among the most flexible of all grain handling equipment.
For higher capacity requirements (from 200tph up to 800tph) and annual throughput (over 250,000 tonnes per year),VIGAN designs and manufactures pneumatic continuous ship unloaders (CSUs) on gantries, called ‘NIV’ models. Self-propelled on tyres or rails, they can be powered by diesel engine or electrical motors with cable reels.
The most frequent combinations found are either rail- mounted/electrical/discharging into quay conveyors to ensure a regular movement parallel to the quay conveyor, or on tires/diesel/into trucks for ports which are not equipped with rails and conveyors. Each gantry is designed bespoke according to the port requirements (dimensions, wheel load and/or rail span, etc.). Boom length, piping system diameter and length, airlock size volume, filter size and number of turbo blowers all determine the expected unloading rate. Many optional devices are available.
The mobility on the dock alongside the boat allows highly efficient unloading of vessels up to Panamax size, following the typical required unloading chart of the holds.
Furthermore,VIGAN’s range of equipment also includes a mobile mechanical continuous ship unloader called ‘SIMPORTER’ designed to meet very high discharging rates up to 1,500tph (metric). It is particularly suitable for large bulk carriers up to post-Panamax. The twin-belt SIMPORTER technology offers major benefits: efficiency, cost-effectiveness (minimum energy consumption, reduced operational and maintenance cost) and environment-friendly qualities (minimum noise, dust control, etc.).
VIGAN pneumatic unloading machines are suitable to convey all types of cereals, beans, seeds, most of the raw materials for animal feeding and also many other products such a chemicals, alumina, soda ash, and more — not only in powdery form but also in pellets (granules) or prills for instance.
Generally speaking, the products must be free flowing — or, in other words, must flow down freely when a certain amount of product in your hands is released when progressively opening them.
The natural angle of repose is usually around 30°: the particle size and physical form must allow this free-flowing nature.
Usually the apparent density is around 0.5 to 1.5: i.e. 500kg/m3 to 1,500kg/m3. Humidity and/or fat content should be adequate to avoid the product sticking when travelling into the pneumatic pipes.
For slightly compacted material such as soy bean meal (SBM), VIGAN has engineered a special efficient accessory to free flow the material before its suction.
According to the product characteristics (its delicate nature), VIGAN will suggest the appropriate equipment to minimize breakage.
Mechanical unloading machines like Simporter are able to handle other products but each product in bulk has its own behaviour and specific handling techniques are required:VIGAN engineers have more than 40 years’ experience in those areas.
For the loading of ships, almost all products in bulk with a granular form including fertilizers can be ideally transported by VIGAN equipment.
The most common products handled by VIGAN machines are: wheat, rice, corn, soybeans, soybean meal, rape seed, oats, rye, barley, malt, palm kernels, cocoa beans, coffee beans, wood pellets and other pellets from the agricultural industries; most feedstuffs; alumina, soda ash, and a few fertilizers.
Materials which are not suitable for transport by VIGAN machines include: sand; cement; coal and minerals such as bauxite and iron ore.
VIGAN’s major clients include: v port authorities which manage and operate port equipment; v independent port operators which offer loading and/or unloading services to their customers by using their own port equipment; v direct customers which have their own handling equipment for their private usage: for instance a flour mill along a river with its own quay — for example, the Cargill group has many large industrial plants with VIGAN machines for its own usage.
There are of course variations to this — for instance, a port operator can have port authorities among its shareholders as well as some of its customers also as shareholders to guarantee sales volume.
The CSU market is very competitive with experienced manufacturers mainly from Europe and/or North America countries.
Some new competitors from fast-emerging countries such as Brazil, China, India,Turkey for instance can be also active with equipment of quality.
For more than four decades,VIGAN has forged its reputation by offering reliable equipment adapted to the customer’s requirements: technical characteristics most suitable to each particular project with value-for-money machines.
Guarantee of long term supply of spare parts from most well- known suppliers and highly professional technical assistance also remain first choice criteria that decision makers are considering for their industrial assets which are most critical for the profitability of their business.