Telestack’s innovative mobile shiploaders find favour in the Ukraine
Telestack Limited has recently installed four innovative and
unique grain handling mobile shiploaders to form an integral part
of the largest transshipment terminals in the Ukraine. These
shiploaders are part of a half a billion dollar investment by
Nibulon Ltd in ten new grain transshipment terminals in the
Ukraine, including the installation on the rivers in Kamyanka-
Dniprov’ska, Dnipro and Grady’zk regions. This investment came
from the growing export demands of Nibilon for barley, wheat
and oilseeds, especially to Japan and Asia.
On a single mobile chassis each shiploading unit consists of
the key functions including, rail mounted parallel travel, radial
slewing, luffing and telescopic features. Telestack Limited
continues to excel in providing customized bulk material
handling solutions to its wide customer base. The company
offers the ship and barge loading/unloading industry highly
innovative and customized mobile conveying systems. Telestack’s
success derives from achieving sustainable value for the client;
using mobile bulk handling technology to enhance operational
efficiency, minimize environmental impact and maximize product
flexibility, serviceability and availability.
The TS 227 parallel/radial telescopic conveyors load 3,000dwt to
5,000dwt barges/vessels at a rate of up to 250tph (tonnes per
hour) fed from a slatted conveyor installed on site. The
shiploader is fed from an overhead slatted conveyor system with
specific discharge points. This system is fed directly from the
grain silos onto the overhead conveyor and directed to the
selected discharge chutes.
The shiploader is installed with electric driven rail bogie units,
which are used to move the unit in parallel mode to the predefined
transfer points from the slatted conveyor. The entire
unit moves smoothly down the quayside to each specific
discharge point, which is controlled from the central control
panel (optional remote control) and ensures loading change
times are minimized to enhance production rates.
As the unit is installed on the rails, it eliminates the need for
further operators to move the shiploader, with only one person
required to operate the machinery during the entire loading
process, with all control/monitoring signals integrated into the
fully diagnostic control panel within the shiploader.
The most distinctive feature of this unit is the ability to move
from parallel travel to radial travel at the pre-defined discharge
points which are aligned at the centre of each hatch (see
pictures below). This is achieved by the hydraulic jacking legs
which lift the machine from the front rail (closest to the
barge/vessel) and lower the unit to the hydraulic driven radial.
This feature allows for complete radial trimming of the hatch
and specific area of the barge/vessel. The radial feature also
enhances production rates, as it allows the operator to load a
larger area of the barge/vessel from the single feed-in point,
which minimizes the required movements and ensures the
barge/vessel can be easily balanced with an equal load during the
loading process. Once the loading sequence is complete, the
machine is lifted (via the hydraulic jacking legs) back onto the rail
and moved parallel to the next loading point. This method
ensures an efficient loading cycle while trimming the entire hatch
of the barge/vessel.
The telescopic feature adds further operational flexibility
during the loading cycle, as it allows the operator to load (In
conjunction with the radial facility) the complete area of each
hatch from the single feed-in point. This process is replicated
over the four hatches to ensure that the barge is loaded evenly
throughout (see picture top, right). The combination of these
features ensures the operator has the maximum
flexibility/mobility for an efficient and effective loading cycle.
A major consideration when handling grain materials is the dust
emitted when the material is aggravated, this was a key feature
identified by the customer. Telestack took this into
consideration by custom designing unique dust suppression/
extraction features to meet the needs of the application. This
included the design of the hydraulically raising transfer chute
which connects to the slatted overhead conveyor which
eliminates dust emissions and spillage at the transfer points. This
allows the operator to move parallel to each specific discharge
point and raise/lower this chute with ease, confident that no
material/dust is escaping from the discharge point. This is
further enhanced by the completely sealed feed-boot and
integrated primary and secondary skirting. The outer conveyor
and innovative inner conveyor telescopic dust covers on the
shiploader ensure that dust is eliminated when material is on the
belt. This feature protects the material from the rain/wind and
ensures the quality of material is maintained.
This is further enhanced by the 8.5m telescopic free fall chute
with integrated dust extraction, which eliminates dust as the
material is fed into the barge/vessel. The telescopic chute also
ensures complete flexibility when the loading cycle begins as it
can trim all sections of the vessel with ease. The telescopic
chute raises up/down during the loading cycle to reduce the
drop height of material and in conjunction with the built-in dust
extraction system, it eliminates dust emissions.
Telestack has used all these systems in previous projects i.e.
parallel travel, dust suppression/extraction, radial movement,
however the incorporation of the options in these units has
identified Telestack’s drive to push the barriers of engineering to
succeed and to expand the capabilities of the equipment. The
success of this innovative custom engineering is shown in the
mobility and operational flexibility of these units to improve and
sustain an efficient and affective loading cycle. The combination
of the site mobility, flexibility and customization of these units
has highlighted Telestack’s emphasis on meeting the design
criteria of all customers within a short lead time.
The undoubted ingenuity and success of these units is
demonstrated clearly as the customer has ordered a number of
other units in line with the expansion of other terminals
throughout the Ukraine in the Autumn 2010. These units will be
of similar design and manufacture, with an increased capacity to
meet the needs of the application and the exporting demands of
the customer.
Liebherr unveils Pactronic hybrid power booster for mobile harbour cranes
Liebherr, a major manufacturer of mobile harbour cranes, has
announced the industry’s first hydraulic hybrid drive for mobile
harbour cranes. The new Pactronic® hybrid drive system
addresses two critical issues: increasing handling performance
and reducing fuel consumption.
The Liebherr Pactronic® is a revolutionary new hydraulic hybrid
drive system. It is characterized by an energy storage device. A
hydraulic accumulator supplements the fluid pump in delivering
power to the system. It serves as a pressure storage reservoir
incorporating gas in conjunction with a hydraulic fluid. Energy is
stored in this compressed gas to be released upon demand.
The Liebherr Pactronic® is also an impressive power booster.
Hoisting as well as lowering speeds are increased substantially —
without the need for a bigger diesel engine with more output.
Thus the crane’s efficiency reaches new levels with higher
turnover figures. In addition, the crane’s fuel consumption is
significantly reduced. This is achieved by fully utilizing the reverse
energy and surplus power within the system. “We believe
Pactronic® is one of the most important innovations we’ve come
up with to date,” says Dr. Klaus Schneider, Director Drive
Systems. “Pactronic® delivers customers a level of handling
performance and power efficiency never seen before.”
The conventional, hydrostatic hoist system of a Liebherr mobile
harbour crane is driven by a hydraulic motor, a pump and the
prime mover (diesel or electric engine). With Pactronic® a
secondary energy source is added to the drive system. Charging
of the accumulator is done by regenerating the reverse power
while lowering the load. In addition, the surplus power of the
primary energy source is also used for charging.
The stored energy of the accumulator is transferred back to
the system when the crane requires peak power during hoisting.
Consequently, the total hoisting power is the sum of the
conventional hydrostatic power and the secondary energy,
provided by the accumulator.
The accumulator is based on proven energy storage
technology and has a designed service life equal to the crane.
For increased efficiency, Pactronic® allows fast charging and
discharging of the accumulator. The system is virtually
maintenance free and is not affected by ambient temperature.
The accumulator just needs visible inspections every ten years
and in addition, it is 100% recyclable. The Pactronic® formula:
30% less fuel consumption and 30% more turnover
Pactronic® is most useful in situations where peak power is
required, such as dedicated bulk handling for example. In
comparison to Liebherr mobile harbour cranes with a
conventional drive system and identical turnover (tonnes/hour)
the Pactronic® hybrid version needs 25–35% less fuel
(litre/tonne) depending on the crane’s operation mode.
In the current challenging economic times, it is important that
large hybrid energy developments such as the Liebherr
Pactronic® continue for sustainable carbon emission reductions.
In-line with the fuel consumption, CO2 emissions are also
decreased by 25–35%.
It is also beneficial for those users operating their cranes
near residential areas where noise emissions are a crucial
criteria as another key advantage of the Pactronic® is its reduced
noise exposure. When an application is started that requires the
additional power, the Pactronic® can transfer power back to the
system and increase the hoisting capabilities of the crane. When
comparing the Pactronic® drive system with a conventional
Liebherr Mobile Harbour Crane with identical primary energy
(diesel engine or e-drive) installed, hoisting power is doubled
resulting in an increased hoisting and lowering with up to 100%
higher speeds. With a focus on turnover (tonnes/hour), the end
user benefits from the increase in performance of 25–35%
depending on the crane’s operation mode. Sustainable
technologies have always been high on Liebherr’s agenda.
Production and products are constantly optimized to help
reduce CO2 emissions and pollutants. Pactronic® stands for
innovative, economical and environmentally friendly technology,
energy recovery and increased performance with hybrid power.
“Offering a unique combination of extremely low fuel
consumption and supreme performance, Pactronic® represents
an essential milestone in Liebherr’s strategy on the way to
genuine ultra-efficient, low-emission cargo handling. Liebherr-
Werk Nenzing GmbH looks forward to working with all
customers to ensure that the Liebherr Pactronic® drive system
will boost their cranes’ performances in line with a revolutionary
new hydraulic hybrid drive system”, says Schneider.
New custom-configured TeleStacker conveyor systems from Superior Industries
Superior Industries, a major manufacturer of conveyor systems and components, offers a range of cost-efficient barge and ship loading/unloading solutions with its TeleStacker® Conveyor systems, which are customconfigured to meet the requirements of specific marine handling applications. While delivering the advantages of a lower capital investment, shorter lead times and quick onsite assembly, Superior TeleStacker Conveyor systems are an ideal and environmentally-friendly alternative to the use of labour-intensive cranes and clamshell buckets, cable stackers, and other more costly stationary ship loading systems. Systems are sized for the application with conveyor lengths from 110-feet to 190-feet; belt widths from 30- inches to 72-inches; and capacities ranging from 500- to 5,000tph (tonnes per hour).
Each customized TeleStacker Conveyor system is designed and engineered to perform both load and unload functions, while providing highly mobile flexibility with the three key travel modes required for effective marine material handling: 1) an inline travel mode;
2) a dock travel or transverse travel mode with 360° rotation; and
3) a radial travel or tow mode.
Systems are equipped with a mobile pivot base that allows free-ranging transfer point mobility; and a fixed-width head axle with a swiveling wheel carriage that allows rotation into each mode. Axle jacks relieve the weight, a hydraulic pin is released, and the unit swivels into the next position. With push-button operation on the control panel, changing from one mode to another is quick, easy and safe. All load and unload functions can be operated via the control panel or with a wireless remote belly pack.
A complete range of options are available for environmentally sound operation and precision loading. Mainframe and stinger belt covers eliminate any dust emission or material spillage, while full-length drip pans prevent carryback material from spilling onto the dock or polluting water resources.
A telescoping discharge chute is available to control dust emission and material drop height during loading; and a 360°, rotating trimming spoon can be combined with the telescoping discharge chute for clean, even and fine-tuned trimming around the hatches when loading.
For any customized barge or ship load/unload system, Superior Industries engineers and service technicians are available from consultation through design, engineering, and manufacturing, and into installation and startup.
Headquartered in Morris, Minnesota, Superior Industries designs and fabricates a full line of portable and stationary conveying equipment including telescoping conveyors, truck unloading systems, feed systems, and design-build conveyor systems; and a complete line of idlers, pulleys and other conveyor components.
Gottwald MHC undergoes successful trials in India
Jindal Steel & Power Limited (JSPL), India, has recently
successfully completed a performance trial with a Gottwald
G HMK 6407 B mobile harbour crane (MHC) in continuousduty
coal handling.
With an average capacity of more than 1,000tph (tonnes
per hour), the four-rope grab crane unloaded an entire
Panamax vessel carrying 62,324 tonnes of coal in only 61
hours and 2 minutes. “We are very satisfied with the results
achieved,” said Amulya Kumar Das, Manager Ports, JSPL. “We
were particularly impressed by the peak rates, i.e. a peak
capacity of 1,526tph and the maximum peak handling of
28,634 tonnes per 24 hours.”
Jindal Steel & Power Limited (JSPL), a part of the Jindal
Group, is a leading player in steel, power, mining, oil & gas and
infrastructure projects. At Paradip Port the company handles
imported coking coal used for its steel plants. To this end,
JSPL brought into service one four-rope grab Gottwald MHC
for professional bulk handling in 2009. The G HMK 6407 B, a
Model 6 variant, with a lifting capacity of up to 100 tonnes
and a 50-tonne grab curve, is capable of servicing bulk
carriers up to Capesize.
“We are committed to the highest quality standards, as
reflected by numerous awards, that’s why we asked Gottwald
to conduct a performance trial with our G HMK 6407 B
crane, i.e. to record the performance data of the crane in
unloading coal from a Panamax vessel,” explained Ashish
Bhardwaj, Sr. Manager Corporate Projects, JSPL. Prior to the
trial, which was conducted under carefully monitored
conditions in April 2010, a three-day training workshop for
JSPL’s technicians was performed. The most important project
and performance data are shown in the table.
“All in all, our expectations regarding the reliability and
handling performance of the G HMK 6407 B crane have been
completely met,” said Ashish Bhardwaj. “We attribute these
impressive results both to proven technology, including high
hoist speeds and easy operation, and to intensive training
provided by Gottwald. We consider our decision in favour of
Gottwald to have been totally justified. All the more so since
apart from the performance features of the crane, we have
particularly enjoyed the very good co-operation with
Gottwald Port Technology GmbH, based in Dusseldorf,
Germany and a subsidiary of Demag Cranes AG, is a
manufacturer of harbour cranes and terminal automation
technology. With a total of over 1,300 mobile harbour cranes
sold, the company is a world market leader in this product
sector. In the field of terminal automation, Gottwald Port
Technology offers system solutions that incorporate both the
company’s own software and hardware. Gottwald Port
Technology supplies customers in around 100 countries.

Promoting harbour export logistics with true efficiency
Terex Fuchs is a major supplier to the bulk handling market, and
its product range includes mobile equipment for use in ports
and terminals.
The company was established in 1888, and since that time has
been a driving force behind innovative solutions in mechanical
engineering. In the course of its 110-year history, Terex Fuchs
has evolved from its roots as a handicrafts-based business into
an enterprise in the Terex Group, where it is a specialist
technology provider and global player on the world market for
loading machines and handling units. Terex Fuchs has more than
100 years of experience in mechanical engineering and the most
varied of production methods form the basis for the tradition of
continuous product improvement and further development.
Those in the harbour logistics sector today need modern
equipment to succeed against tough competition.
That’s why the Dutch recycling specialist Van Dalen Metals
Recycling depends on the high harbour operations capacity of
the MHL365 from Terex Fuchs for the million metric tonnes of
steel scrap exported to European and East Asian countries each
year from its 17 steel recycling centres. The loading system with
its angled boom, large cactus grab and reach of 18 metres
together with hydraulics providing high precision to match their
enormous power ensure that thousands of tonnes of steel can
be moved between the ship, freight vehicle, stockyard and tracks
in the shortest time possible. The MHL365 is equipped with an
extremely rugged steel structure and an undercarriage with an
extra large support area and extra large outrigger pads. There’s
also the 1.40 metre high pylon between the undercarriage and
the superstructure, which not only significantly improves visibility
but also facilitates optimal use of the working range with high
sided vessels due to the higher pivot point of the boom. It’s
clear to the decision-makers at Van Dalen Metal Recycling and
many others that the MHL365 is an ideal solution for the
challenging harbour logistics of the steel recycling business with
its high-volume export and handling requirements.
  for moving mass: 55.0 tonnes operating weight with load
hook, 56.8 tonnes with 0.8m³ cactus grab and powerful DEUTZ
186kW 6-cylinder turbo diesel engine;
  •   designed for port handling: 1.4m pylon for optimized pivot height and visibility on all sides even with high-sided vessels;
  •   extremely stable: larger undercarriage for safe anchorage and better handling performance with the heaviest loads as well as reduced surface pressure;
  •   enormous working radius: angled boom loading system with 18m reach;
  •   first-class ergonomics: joystick control facilitates safe work with ideal visibility and no steering wheel; automatic camera switch-on automatically when backing up minimizes the risk of accidents;
  •   for low light conditions: powerful xenon spotlights on the boom, stick and roof of the operating cab;
  •   safety first: overload warning system and pipe rupture safety valves on boom and stick cylinders; and
  •   maintenance without acrobatics: service catwalks on the left and right side of the superstructure and a convenient access system.

Mobile harbour cranes: E-Crane reports on latest developments and contracts
E-Crane Worldwide is continuously expanding its client and
project inventory worldwide, with successfully installed E-Cranes
for bulk and scrap handling purposes, some mobile harbour
cranes on low or high gantry portal or crawler-mounted, others
on fixed or free standing pedestal or even floating.
The mobile scrap handling E-Crane® loading Handymax vessels in
the Port of Ghent, Belgium (client Van Heyghen Recycling, Galloo
Group) is just one of the successful E-Crane®
installations in 2009 (see ‘E-Crane installed at
recycling plant’ on pp30–31 of the May issue of Dry
Cargo International). This crane has now been in
operation for half of a year, and E-Crane® has
confirmed that the client is now able to load an entire
Handymax vessel using only the new 2000 Series
E-Crane® (see picture, right), whereas before two
cranes were needed.
Other units that have been operational since the
end of 2009 is the second 1000B Series E-Crane® for
TISCO Taiyuan Iron & Steel Company in China (see
picture, above) and the second 1500B Series E-Crane®
for the Icdas steel producing plant in Turkey (see
picture on p50).
The 1000B Series, model 7317B GA-E E-Crane®
has been successfully working alongside the first
E-Crane® at TISCO, a similar model. Its tasks include
loading baskets, offloading trucks, and so forth in the
scrap yard in the Shanxi Province.
The 1500B Series, model 9317B CR-D E-Crane® on a high
gantry was taken into service at Icdas on 18 November 2009,
after careful testing. The static tests established that, after 50
minutes, the 14-tonne test weight was still hanging at the same
height above ground level. Once this test was done, E-Crane’s
engineers were able to attach the grab and drive the crane to its
work spot at the scrap receiving dock, where it was connected
to the electricity network via a long power supply cable.
The most recent installation of an E-Crane® mobile harbour
crane was only a few weeks ago at the end of July 2010 for
E-Crane’s client Sherwin Alumina in Texas, USA.
Sherwin Alumina has been producing alumina (aluminium oxide)
near Gregory, Texas, USA, for more than 50 years. This is the
primary function of the plant. Alumina, short for aluminium
oxide, is extracted from bauxite ore. The method used to
extract aluminium oxide is called the Bayer process. This was
invented by a Russian named Karl Bayer in 1887 and remains the
principal process to refine bauxite into alumina. Alumina is then
shipped to a smelter plant where an electrolytic process is used
to extract aluminium from its oxide alumina.
Sherwin Alumina has the capacity to produce 1.4mt (million
tonnes) of smelter-grade alumina and 300,000 tonnes of
chemical grade alumina hydrate. In order to produce this much
finished product, the plant must receive and process 4.4mt of
The bauxite ore is received at Sherwin on oceangoing vessels
from Jamaica and Brazil. The vessels arriving from Jamaica are of
the Handymax size, while the vessels from Brazil are the
Panamax class. Unloading these mammoth oceangoing ships
requires specialized equipment.
Since the 1980s Sherwin has used two continuous ship
unloaders (CSUs). These are big machines with an L-shaped
bucket elevator suspended from the CSU’s boom. The bauxite is
scooped up by the horizontal segment of the ‘L’ while the
vertical segment transports the material to the top of the boom,
where it is unloaded on a belt conveyor. While these machines
are impressive mechanical designs, the reality of constant and
high cost of maintenance along with poor reliability has caused
major unloading delays. Sherwin Alumina could not unload the
ships on time, causing high demurrage penalties. As the cost of
replacing the CSUs was too high, Sherwin needed a low-cost
reliable means of offloading and they needed it fast.
At the end of 2008 and because of seeing an E-Crane
advertisement, E-Crane International USA was contacted by a
material handling expert who was working with Sherwin Alumina
in Corpus Christi, Texas, to provide stevedoring services for
unloading bauxite from oceangoing ships at the plant.
The third-party material handling consultant had experience
in material handling and logistics and believed strongly that the
unique E-Crane® was the right solution for bauxite ship unloading
at this facility. In parallel, Sherwin Alumina was independently
studying what would be the best unloading solution for the
future. SAC engineers studied all possible unloading equipment
and visited working examples of the two biggest mobile harbour
crane manufacturers as well as several working E-Cranes.
After a detailed analysis of all possible ship unloading
solutions, E-Crane International USA was selected to provide
two new ship unloaders for this facility.
E-Crane® was able to provide two 2000 Series E-Cranes
custom-designed to match the existing dock infrastructure at a
cost of less than half of the price of one CSU. Furthermore,
E-Crane® was able to deliver the cranes less than one year after
the initial down payment.
E-Crane International USA signed the contract with Sherwin
Alumina for two 2000 Series, model 18450 GA-E rail mounted
E-Cranes on 12 November 2009. Each unit offered a capacity of
25 metric tonnes, and came equipped with a 17 cubic yard
clamshell grab. Average cycle time is 60 seconds.
The new E-Cranes were built in the E-Crane Worldwide
facility in Adegem Belgium, assembled complete on a dock in
Flushing, The Netherlands, and then transported to Sherwin
Alumina in Texas, USA on a special heavy lift transport vessel
where they were installed on the client’s dock using the ships
cranes to minimize downtime there.
E-Crane® provided one week of classroom training for all 32
operators. After a written test, operators moved on to
‘simulator’ training. After each operator had passed a practical
exam in the cab simulator they moved on to ‘in-the-seat’
training, and E-Crane® technicians monitored the operators 24/7
for a further two weeks until management was satisfied they
could function on their own.
Since then, the cranes are in 24/7 continuous operation at the
docks in Corpus Christy, on the Gulf of Mexico. By the middle
of August, the south E-Crane® had operated 1,100 hours and the
north E-Crane® 550 hours, and operation is running smoothly
and without incident.
A 2000 Series E-Crane®, model 17359 GA-E is being shipped to
Finland at the time of writing, destined for the Port of Kokkola.
This E-Crane®, with a lifting capacity of up to 28 metric tonnes
and a maximum outreach of 36 metres, has a design capacity of
1,000tph (tonnes per hour) and will be mainly used for the
discharging of vessels up to Panamax size with zinc concentrate.
The installation is scheduled for the first half of this month
(September 2010).