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 Rails Tracks Wheels

Track Mounted Wheel Mounted

Rail Mounted

4. All Travel Mobile Ship-loader

Driven Wheels for In-line, Parallel, Radial and Steering Movement

In-Line Parallel Radial Steering

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 unit

Direct 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 Direct feed by Trucks to Ship loader

Fed by FELs to Hopper and Ship loader

Fed by gravity reclaim to Ship loader

6. Vessel Sizes

TELESCOPIC TECHNOLOGY

• >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 - AFRICAMOBILE SHIP LOADING

Model - TS 2058 and HF 2020Peak Capacity - 2000Tph Iron OreSystem 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 7 Hold 6 Hold 5 Hold 4 Hold 3 Hold 2 Hold 1

1     8000            

2         8000     2 65

3     3700         2 65

4           8000   3 100

5   8000           4 135

6             8000 5 165

7 8000             6 200

8       8000       3 105

9   3700           2 70

10           4000   4 135

11         3300     1 35

12 3540             4 135

13             1760 6 200

14       4000       3 95

15 1000             3 105

16             1000 6 200

Totals 12540 11700 11700 12000 11300 12000 10760 54 1810

  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

ruttingc)Material – very abrasive, claggy and sticky in rainy

season d)Skill levels of local operativese)Robustness to take constant feed from CAT 988

KEY TECHNICAL CONSIDERATIONS.

CASE STUDY 2 – LATVIAMOBILE SHIP LOADING

Model - TS 542, TL 530 and HF 514Peak Capacity - 500Tph FertiliserSystem 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

Latvia

200 metre conveying distance

• 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 OreSystem 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.

The Final Solution – TU 1015 R fed by Trucks

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 Rakesb)Rail Wagon loading when rakes present.

KEY TECHNICAL CONSIDERATIONS.

CASE STUDY 4 - MALAYSIA

MOBILE RECLAIMING AND BLENDING

Model - TU 1015 R Peak Capacity - 1000Tph CoalSystem 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 Settings100 – 1000Tph

Weighing Systems – Methodology.

Manual Settings100 – 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

Blue Chip Clients

CONCLUSION

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.