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PUBLISHERS
Jason Chinnock
[email protected] WWW.DRYCARGOMAG.COM NOVEMBER 2021 issue
Andrew Hucker-Brown
[email protected]

EDITORIAL
Louise Dodds-Ely
[email protected]
Jay Venter
Editor

Deputy Editor
featuring...
[email protected]
Directories
TRADE & COMMODITIES
Samantha Smith
[email protected]
Bernice van Wyk Office Manager Sturdy coal trade boosts dry bulk 2
[email protected]
SOARING ENERGY COSTS FUEL FERTILIZER PRICES IN 2021/22 4
SALES
Matthew Currin Senior Sales
Executive
[email protected]
Zack Venter Advertisement Sales SHIPPING & TRANSPORT
[email protected] Executive Shedding light on port tariffs 12
CORRESPONDENTS Britannia Loss Prevention Insight: Carriage of grain and oilseed cargoes 14
Brazil Patrick Knight
India Kunal Bose FREIGHT MARKET BOOST FOR HANDYMAX BULK CARRIERS 20
Asia David Hayes THE ROLE OF OFTS IN DRIVING EFFICIENCIES AND SUSTAINABILITY WITHIN THE SUPPLY CHAIN 29
Europe Barry Cross
Malaysia Wira Sulaiman
Philippines
South Africa
Fred Pundol
Iain McIntosh PORTS, TERMINALS & LOGISTICS
UK Maria Cappuccio CSL and Viterra set grain load record at Port of Thunder Bay 31
UK Michael King
UK Richard Scott Castellón to introduce further anti-dust screens 31
USA Colby Haines Record fertilizer volumes arrive at ABP Ipswich 32
USA Walter Mitchell
TransContainer to move coal by container 35
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Trade Publishing International Limited The latest tippler trends in perspective 56
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Website: www.drycargomag.com SPREADING THE LOVE WITH THE RIGHT FERTILIZER HANDLING EQUIPMENT 89
Twitter: twitter.com/drycargomag A TRIP TO ITALY: ITALIAN ENGINEERING 99
ISSN 1466-3643
QUALITY MATTERS: AN ESSENTIAL REFERENCE GUIDE TO CONVEYOR BELT SELECTION 107
NOVEMBER 2021

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1
BULK CARRIER TRADE & FLEET OUTLOOK

Sturdy coal trade boosts dry bulk

ositive influences buttressing importers also may see increases. all other countries together declined.

P commodity imports are prominent

in many parts of the world amid
the recovery in economic activity.
Meanwhile, in the European Union plus
UK area, a rise of over a fifth, 9mt, could
result in the regional total reaching about
In the 2021/22 trade year now
starting, US Department of Agriculture
estimates indicate that world grain and
Growth in global seaborne dry bulk trade 50mt. soya trade could be about 3% higher at
has resumed and tentative indications 684mt. This result is derived from
point to a continuing upwards trend. IRON ORE expectations of a 1% decrease in China
A cautionary attitude is justified, Import demand for the principal raw contrasting with a 4% increase in all
nevertheless. The International material, iron ore, and also coking coal is other countries. But alternative
Monetary Fund’s analysis published last being boosted by strong steel forecasts indicate a larger downturn in
month suggested that “the global production trends. Recoveries in China after exceptionally high imports in
recovery continues but the momentum manufacturing industries and the past twelve months, which may
has slackened, hobbled by the construction activity are benefiting prevent world trade rising.
pandemic”. Consequently the world consumption of steel. The main
gross domestic product forecast was exception is China, where in recent MINOR BULKS
revised downwards, albeit only months a retreat from the earlier rising Seaborne movements of agricultural
marginally, to 5.9% in 2021 (following pattern has unfolded. commodities within the minor bulks
last year’s –3.1% slump), and 4.9% in The latest half-yearly short range category include oilseeds and meal, rice
2022. Short-term prospects have been outlook for steel demand, published last and sugar. After the global total reached
adversely affected by supply disruptions. month by the World Steel Association, an estimated 115mt in 2020, signs of
provides a generally upbeat perspective. further enlargement have emerged,
COAL Based on finished steel products, although sugar trade may not contribute
For coal trade the picture has improved. demand in 2021 as a whole is forecast to growth.
Expectations of an upturn foreseen since to grow by 17% in India, 13% in the
early this year have been reinforced by EU+UK, 10% in Japan and 9% in South BULK CARRIER FLEET
recent energy shortages in a number of Korea. Further increases are envisaged About two-fifths of the world bulk carrier
countries and higher prices for fuels. next year. By contrast, in China a fleet is comprised of ships in the
There now seems to be greater potential negative –1.0% this year and an Capesize category (vessels of 100,000
for coal trade support to remain elevated unchanged total in 2022 is predicted. deadweight tonnes and over), which for
into next year. statistical purposes includes bigger
Estimates suggest that imports of GRAIN & SOYA Newcastlemaxes and large ore carriers.
steam coal by the five main buyers in Prospects for grain and soya trade are As shown by table 2, capacity expansion
Asia could increase by over 20mt (million somewhat unclear because of difficulty was about 4% annually in the past two
tonnes) or 4% in 2021, compared with in forecasting China’s extensive imports. years, with the fleet reaching 361 million
last year’s volume, reaching 575mt, as In the trade year ending third quarter dwt at end-2020 based on Clarksons
shown in table 1. This calculation which 2021 expansion of imports into China, Research data.
includes India, China, Japan, South amid higher volumes of wheat plus corn This year’s growth could be similar,
Korea and Taiwan may prove and other coarse grains enabled global despite lower newbuilding deliveries, due
conservative. Some smaller Asian trade to increase. Volumes imported by to low scrapping.

TABLE 1: STEAM COAL IMPORTS IN KEY ASIAN COUNTRIES (MILLION TONNES

www.drycargomag.com

2016 2017 2018 2019 2020 2021*

Japan 115.8 121.0 119.8 116.8 110.5 113.0
South Korea 102.5 116.0 117.5 109.9 93.2 96.0
Taiwan 55.0 58.2 58.4 56.8 53.0 58.0
China# 124.2 118.7 122.4 124.6 132.3 140.0
India 148.3 152.7 171.3 186.2 164.0 168.0
Total of above 545.8 566.6 589.4 594.3 553.0 575.0
source: various & BSA estimates #excluding lignite *BSA forecast

TABLE 2: CAPESIZE (100,000 DWT & OVER) BULK CARRIER FLEET (MILLION DEADWEIGHT TONNES)
2016 2017 2018 2019 2020 2021*
Newbuilding deliveries 20.0 15.3 14.3 19.0 25.0 18.0
Scrapping (sales) 13.3 6.4 3.1 5.9 11.4 3.5
Losses 0.2 0.3 0.0 0.0 0.5 0.0
NOVEMBER 2021

Plus/minus adjustments –0.5 0.1 –0.1 0.0 0.0 0.0

Fleet at end of year 315.2 323.9 335.0 348.1 361.2 375.7
% change from previous year-end +1.9 +2.8 +3.4 +3.9 +3.8 +4.0
source: Clarksons (historical data) & BSA 2021 forecasts *BSA forecast

DCi by Richard Scott, Bulk Shipping Analysis, Tel: +44 (0)12 7722 5784; Fax: +44 (0)12 7722 5784; e-mail: [email protected]

2
TRADE & COMMODITIES

Soaring energy costs fuel

fertilizer prices in 2021/22

Maria Cappuccio

The global economic recovery according to

GLOBAL FERTILIZER USE
the IMF is continuing and projected to
grow by 5.9% in 2021 and 4.9% in 2022. 1961-2025/26 mt nutrients
This is lower than previously forecast, Year Nitrogen Phosphate Potash Total
partly due to supply disruptions in 1961/2 11.6 10.9 8.7 31.2
advanced economies and for low-income 1970/1 31.8 21.1 16.4 69.3
developing countries, worsening pandemic 1980/1 60.8 31.7 24.2 116.7
dynamics. The rapid spread of Delta and 1990/1 77.6 36.0 24.6 137.8
the threat of new variants have increased 2000/1 81.2 32.5 21.9 135.6
uncertainty in several countries, raising 2001/2 82.9 33.4 23.0 139.3
concerns about how quickly the pandemic 2002/3 85.1 34.1 24.7 143.9
can be overcome. 2003/4 87.1 35.2 25.5 147.8
Grain and oilseed markets look to be 2004/5 90.2 37.5 25.6 154.7
well supplied with large crops of cereals 2005/6 93.2 37.0 26.3 156.5
www.drycargomag.com

(wheat, rice, coarse grains) and oilseeds 2006/7 97.4 38.1 26.9 162.4
projected at a record 3.4bn/t in 2021/22. 2007/8 100.5 38.4 28.9 167.9
International prices of most food crops, 2008/9 97.7 33.7 23.4 154.8
with the exception of rice are already at 2009/10 102.2 37.6 23.7 163.5
multi-year highs reflecting supply shortfalls, 2010/11 104.1 40.6 27.5 172.3
rising input costs (coal, natural gas and 2011/12 107.9 41.4 28.0 177.2
fertilizers) and strong demand for food, 2012/13 108.6 41.4 29.2 179.1
feed and biofuels. The effects of higher 2013/14 109.9 40.5 30.4 180.7
energy costs will be felt throughout the 2014/15 110.3 41.1 32.0 183.4
agricultural sector. 2015/16 108.0 41.0 32.0 181.0
2016/17 107.7 46.0 35.3 189.1
2017/18 107.9 46.7 36.9 191.5
WORLD FOOD DAY - “OUR ACTIONS ARE
NOVEMBER 2021

2018/19 e 104.1 45.5 37.5 187.1

OUR FUTURE”
2019/20 f 105.7 46.3 36.3 188.3
The UN’s Food and Agricultural
2020/21 f 110.0 49.6 38.5 198.2
Organization (FAO) Director-General QU
2021/22 f 110.8 50.0 39.1 199.9
Dongyu opening remarks underlined that
2025/26 f 114.5 52.5 41.2 208.3
this year’s World Food Day finds the world
at a critical time. The way we produce, Source: FAO, IFA
DCi

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TRADE & COMMODITIES

consume and waste food is putting FERTILIZER PRICES $ PER TONNE FOB 2015–2019
pressure on our natural resources, climate
and natural environment, yet 811 million 2017 2018 2019 2020 2021
people still go hungry due to conflicts, Oct Wk2 Oct Wk2 Oct Wk2 Oct Wk2 Oct Wk2
climate extremes and economic
$ $ $ $ $
downturns. World Food Forum a new
Urea
initiative of the FAO’s Youth Committee,
Baltic 270 260 237.8 245 418.8
seeks to harness the energy and creativity
Persian Gulf 215-275 320 255-257 270 800
of young people to shape a better future
US Gulf 265 350-296 230.5 240 700
for our food and was launched in Rome
Ammonia
shortly before the UN’s COP26 summit
Yuzhny 210-215 320-322 225-230 220 700
held in Glasgow (UK), which brought
Tampa CFR 245 330 255 228 558
parties together to accelerate
Middle East — 359–369 — — —
commitments to the goals of the Paris
Ammonium sulphate — — — — —
Agreement and the UN Framework
FSU — 118 — — —
Convention on Climate Change.
Asia — 142.50 114 126 —
Di-ammonium phosphate
IFA FORECAST A MORE MODEST RISE
North Africa 360–365 409 — — —
FERTILIZER USE IN 2021/22
US Gulf 345 421.50 271–280 360 727
Fertilizer companies have witnessed a
China 360 414 310—316 357 —
dramatic rise in prices for all types of
Baltic — 426 304 340 —
chemical fertilizers this year. Driven by a
Triple super phosphate
combination of factors including, a sharp
North Africa — 358 313 — —
increase in energy costs (coal and natural
US Gulf — 346 270 290 618
gas), strong demand, production
Muriate of Potash
curtailments, trade restrictions and adverse
Baltic — 290 190 220*
weather.
Vancouver — 215.5 265.5 245 230*
Looking ahead, the International
US Gulf 220–228 268 280 202 740
Fertilizer Association (IFA) forecast a more
modest rise of almost 1.7mt (million Source: Bloomberg, Farm Futures, Fertilizer Week, Fertilizer Market Bulletin, Profercy. *Contract prices
tonnes) N to almost 200mt Nutrients in
2021/22. This follows the huge rise of 10mt projects, a reflection of technology scaling- disruptions due to high natural gas costs in
N in global fertilizer use of nitrogen, up. Among existing ammonia producers, Europe, which rocketed from €19MWh to
phosphates, potash last year. The IFA there are new pilot projects at existing €95MWh. This led to production cutbacks
expects global fertilizer demand to grow at sites, as well as plans for longer term and plant closures in Europe, while,
a slow pace over the next five years, decarbonization of entire units. Green escalating coal prices in China led to a
reaching 208mt Nutrients by 2025/26. ammonia projects are also being developed rationing of electricity use in some
with potash to be slightly higher than by companies that do not have existing provinces and forced fertilizer factories to
phosphate and nitrogen. ammonia production, and several of these cut production. Urea prices were lifted by
projects align with governmental goals to a temporary suspension of Chinese
HIGH COST OF NATURAL GAS SHUTS DOWN include green hydrogen as part of their exports; since then, China imposed a ban
PLANTS IN EUROPE energy transition in the future. on urea exports from December ’21 until
Natural gas accounts for anywhere June ’22. In the US, the impact of
between 70% to 90% of the operating costs RECORD HIGH GAS AND COAL THREATENS Hurricane Ida led several large producers
of fertilizers and with natural gas prices at CROP YIELDS to declare force majeure as the category 4
www.drycargomag.com

historic highs, Yara, Borealis and CF The high cost of natural gas in Europe and hurricane shuttered nitrogen plants along
Industries have shuttered ammonia coal in China, prompted concerns about the US Gulf Coast that cut output by a
production at facilities across Europe. CF further supply disruptions in the current major nitrogen producer and prevented
Industries’ Billingham Complex in the UK season and the effect this will have on, crop product movement.
will continue operating until the end of yields, food inflation, longer term the
January 2022, following agreements made extension of environmental policies SURGING PRICES UNDERLINE SHORTAGE
with firms to purchase the CO2 a by- restricting fertilizer use. The World Bank In the US nitrogen fertilizer prices quoted
product of its ammonia production. expects, as demand eases and supply in the landed New Orleans, Louisiana,
Ongoing concerns include supply improves in 2022, that natural gas and coal market, the main entry point for fertilizer
disruptions and an intensification of costs will decline; although in the near —a year ago urea barges were about
environmental policies restricting fertilizer term, with very low inventories and $180/t in the Gulf of Mexico, this year on
use. persistent supply bottlenecks price spikes 29 Oct, a urea barge for Feb ’22 was
NOVEMBER 2021

may continue to occur. $735/t. The US retail price of anhydrous

SCRAMBLE FOR GREEN AMMONIA ammonia set a new record of over $1100/t
There has been a significant increase in the PLANT CLOSURES, SANCTIONS, ADVERSE in early November. Josh Linville, director of
number of green ammonia projects WEATHER CUT OUTPUT fertilizer for Stone X Financial Inc. based in
announced in the last year with larger Nitrogen (urea) prices surged in 2021 to Kansas City, Missouri said: “… prices were
DCi capacity planned than for previous pilot over $700/t, largely reflecting supply higher in 2008, but the 2021 issue is an

6
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TRADE & COMMODITIES

GLOBAL CEREALS & OILSEEDS-PRODUCTION, USE & STOCKS 2020/21–2021/22MT

Prod Prod Use Use Trade Trade Stocks Stocks

20/21 21/22 20/21 21/22 20/21 21/22 20/21 21/22
Wheat 775 775 782 787 198 205 288 276
Coarse grains 1,430 1,499 1,446 1,491 234 239 321 330
Total Wheat and Coarse grains 2,205 2,274 2,228 2,278 432 444 610 606
Rice 507 512 502 511 49 49 187 188
Total Cereals 2,712 2,786 2,730 2,789 481 493 797 794
Oilseeds 603 628 341* 350* 191 196 114 115
Source: USDA-mainly harvested Jul-Dec/ *oilseed meal — excl. fish meal

unprecedented global shortage. This is projected expansions in wheat and soy food/industry is strong, as is the need for
vastly different. Because it doesn’t matter acres come as global food prices led by better quality wheat in some countries.
what you’re willing to pay, you can’t get the cereals and vegetable oils are at ten-year The prospect of a Russian wheat export
product.” highs according to the UN’s FAO. Chicago quota for 5mt being introduced 15 Feb to
Board of Trade (CBOT) wheat futures 30 Jun ’22, to curb food inflation, lent
DAP PRICES REMAIN HIGH ON TIGHT climbed over $8/bu, the highest in almost further support to wheat values and
SUPPLY nine years, due to tightening global supplies sharply increased demand for wheat from
Diammonium phosphate (DAP) prices of milling wheat; while soy oil futures have consuming countries including Egypt.
continued to rise in 2021, supported by cooled since June, values are higher this
strong demand for corn and soybean crops season, due to global demand for vegetable SUBSTANTIAL COARSE GRAIN HARVEST IN
in Brazil and the US. Countervailing duties oils and for soy-based biofuels. US 2021/22
imposed by the US on DAP imports from plantings of corn, which require more Record coarse grain harvest is projected at
Morocco and Russia came into effect in fertilizer than soybeans, could be limited by 1,499mt in 2021/22, an increase of over
April and lifted prices. China’s decision to the higher cost of inputs in 2022. 70mt mainly due to a significant rise in corn
suspend phosphate exports earlier in the output offsetting a smaller barley crop.
year, before imposing a ban to take effect WHEAT STOCKS AT A NINE-YEAR LOW Corn output is projected to reach a new
from Dec ‘21 until Jun ’22, had an The global wheat harvest is estimated at record of 1.2bn/t following upward
immediate impact on DAP values. China 775mt similar to last year, with better crops revisions in output for the US 383mt, China
accounts for 30% of the global export trade in the EU, Ukraine and UK. Increased 273mt, Ukraine 38mt; Brazil’s farmers are
in DAP. Higher DAP costs are expected to wheat use will outpace production in highly dependent on imported fertilizers;
rise further in 2022 on tight supply, unless 2021/22. Wheat stocks excluding China their availability and cost will be key to
the ban on exports is relaxed. (141mt) are cut to 135mt, with major output, especially for the upcoming safrinha
exporters stocks of over 53mt the lowest corn crop — where acreage is expected to
MOP PRICES TO SURGE IN 2022 level since 2012/13. Global demand for increase to 39m/acres for planting in
Muriate of Potash (MOP) Prices have been
supported by sanctions on Belarus — the CEREAL EXPORT PRICES US $ FOB PER TONNE 2016–2020
world’s second largest producer —
imposed by the EU in June and by the UK,
2017 2018 2019 2020 2021
US and Canada in August. A spike in barge
Oct Oct Oct Oct Oct
shipping costs has led to near record-high
Wk2 Wk2 Wk3 Wk3 Wk3
potash spot prices for delivery to Brazil in
$ $ $ $ $
early October. Recent contracts in India
US
www.drycargomag.com

were closed at higher prices than those

Wheat No 2 HRW 217 237 213 279 363
agreed in April. Potash prices (Vancouver
Corn No 3 Yellow (Gulf) 157 167 174 230 267
FOB contract) are expected to increase
Sorghum (Nola) 191 191 188 293 297*
substantially in 2022, well above contract Soybean No 2 (Gulf) 375 324 364 456 502
prices negotiated earlier in the year-in the Brazil (Paranagua)
US Corn belt MOP FOB granular spot Soybean 386 416 380 500 521
prices-$730/t; Brazil CFR granular $825/t Corn (feed) — — — 233 274
(Nov 4 ’21). Argentina (up river)
Wheat — 232 228 283 300
WHAT TO PLANT IN 2022? Corn (feed) 148 164 174 228 250
Tight supplies, higher fertilizer and fuel Soybean 372 397 356 456 545
costs, pose a dilemma for farmers of what Thailand
NOVEMBER 2021

crops to plant in 2022? In USDA’s Rice White 5% broken 383 390 397 449 381
preliminary assessments, US farmers are Vietnam
projected to increase wheat plantings on Rice White 5% broken 400 407 353 477 428
49m/acres above last year; reduce plantings India
of corn to 92.3m/acres while expanding Rice White 25% broken 366 340 330 342 361
DCi seedings of soybeans to 87.5m/acres. The Source: FAO IGC USDA—*Monthly average — Sept; Rice prices based on indicative quote.

8
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TRADE & COMMODITIES

Jan/Feb ’22 with a record 118mt crop

anticipated in Brazil and 55mt in Argentina.

STRONG DEMAND FOR

FEED/FOOD/ETHANOL
Strong demand for coarse grains for
feed/food/ethanol use is expected to
increase by 45mt to 1,491mt. USDA
forecast an increase in trade by 5mt to
239mt. Larger corn imports into Brazil,
Canada, EU, Egypt, Mexico, Turkey and
other countries offset lower corn imports
into China down 2mt to 26mt. Global
coarse grain stocks are expected to rise to
330mt (excl. China 211mt) and are higher
at 119mt in 2021/22.

RECORD OILSEED OUTPUT IN PROSPECT IN

2021/22
Large oilseed output projected at 628mt
with a record global soyabean placed at
384mt, with larger crops of copra, oilseeds (with the exception of rice) are support grain and oilseed imports.
cottonseed, palm kernel, ground nut, already at multi-year highs. Global To meet increased demand each year,
sunflower seed and lower output of agriculture market fundamentals remain grain and oilseed supply, is expected to
rapeseed. US soy harvest is c.120mt and in attractive. With oil prices above $75 per grow as a result of higher yields on
South America, soy planting is well barrel, increased demand for biofuels and increased corn and soybean acreage
underway. In Asia expanded demand for renewable diesel are expected to push although there does not seem to be
soyabean meal and oil products are seen grain and oilseed demand higher, with a enough carry-over to raise year-end stock-
pushing up total use to a new peak. Trade number of countries announcing plans to to-use ratios to historical averages. With
in oilseeds is predicted at 196mt primarily increase output as part of efforts to meet exportable supplies insufficient to buffer
on bigger shipments to Asia. Stocks of climate change targets. China continues to weather or input induced shortfalls, prices
oilseeds (excl. China 37mt) are marginally be a large contributor to global demand for are likely to remain elevated into 2022.
higher at 115mt in 2021/22. grain and oilseeds, buying record amounts
of agricultural products to meet its STRONG DEMAND, TIGHT SUPPLY DRIVE
WHEAT, CORN AND SOYBEAN VALUES AT domestic needs. Further upscaling of its NITROGEN VALUES
MULTI-YEAR HIGHS livestock industry to larger enterprises and A combination of low global inventories,
International prices of most cereals and continuing to use ethanol in fuel, strong demand and tight supplies led to
is expected to much higher nitrogen prices this year and
continue to expected to continue in 2022. Looking
GLOBAL NITROGEN SUPPLY/DEMAND
2019-2025/26 MT N
GLOBAL UREA SUPPLY/DEMAND
Fertilizer 2019/20 2020/21 2021/22 2025/26 2019-2025/26 MT UREA PRODUCT
Nitrogen capacity 182.0 181.5 186.3 195.2
Nitrogen supply* 152.6 155.0 164.9 166.7 Fertilizer 2019/20 2020/21 2021/22 2025/26
Nitrogen demand 143.3 140.0 150.6 156.3
www.drycargomag.com

Urea capacity 209.0 212.0 225.0 235.0

Fertilizer use 105.7 110.0 110.8 114.5 Urea supply 186.2 190.3 196.7 205.0
Other 36.5 32.6 39.8 41.8 Urea demand all uses 178.3 181.3 185.4 192.8
Nitrogen balance 9.3 15.0 14.3 10.4 Urea balance 7.9 9.0 11.3 12.2
Source: FAO/ IFA-data N/t basis * effective capacity derived by capacity x by the Source: FAO/ IFA-Data mt Urea basis
highest achievable operating rate

GLOBAL POTASH SUPPLY/DEMAND GLOBAL PHOSPHORIC ACID SUPPLY/DEMAND

2019–2025/26 MT K2O 2019–2025/26 MT P2O5

Fertilizer 2019/20 2020/21 2021/22 2025/6 Fertilizer 2019/20 2020/21 2021/22 2025/26
Potash capacity 59.8 62.5 64.1 68.9 Phosphoric acid capacity 58.6 59.1 60.2 62.0
NOVEMBER 2021

Potash supply 47.6 48.4 50.1 54.7 Phosphoric acid supply 50.0 50.7 51.2 54.3
Potash demand 41.6 42.1 42.9 44.8 Phosphoric acid demand 47.1 48.8 49.8 53.0
Fertilizer 36.3 38.5 39.1 41.2 Fertilizer 46.3 48.3 49.3 52.5
Potash balance 6.0 6.3 7.2 9.9 Phosphoric acid balance 2.9 1.9 1.4 1.3
Source: IFA-Data K2O basis Source: FAO/IFA-Data P205 tonnes basis
DCi

10
 TRADE & COMMODITIES
ahead, the IFA forecast a 14mt N increase $1,000/t FOB for second half December PHOSPHORIC ACID CAPACITY FORECAST TO
in capacity by 2025/26, with lower loading in Malaysia will be shipped to a GROW BY 3.6 MT P205
production growth relative to the growth nearby market, most likely South Korea. The bulk of phosphoric acid expansions
in consumption. The increase in capacity forecast to start up between 2021 and
involves 20 new projects in three POTASH CONTRACT AND MARKET PRICES 2025 are located in Africa and the EECA
countries-Russia and Nigeria where the DIVERGE region. Phosphate expansions in Africa are,
projects are likely to increase urea exports MOP (muriate of potash, or potassium mostly expected to start up from 2023
and in India where government-funded chloride) prices increased by 6% in the fall, onwards. In the next two to three years,
investment in new capacity is designed to supported by sanctions on Belarus, the capacity expansions are limited to EECA,
reduce dependence on imports. world’s second largest producer. Potash Tunisia and Brazil. In China,1.3mt P205
supply is tight and prices have increased phosphoric acid capacity is forecast to
SOARING NATURAL GAS PRICES LED TO significantly in all key spot markets. start-up, partially offset by some closures.
SHUT-DOWNS Nutrien expects a surge to an annualized In the next five years, a larger volume of
Ammonia prices increased in the Baltic and run rate of 17mt during the fourth quarter capacity is forecast to be commissioned,
other regions due to rising natural gas of ’21 and is on pace for record production totalling 3.6mt P205 resulting from
prices and lower production capacity. With and sales. Grain and oilseed prices are well expansions in several regions but
gas prices continuing to escalate, Yara above the historic average and food concentrated in Africa and East Asia.
curtailed around 40% of ammonia capacity security remains a top global priority.
(includes both scheduled maintenance and Fertilizer markets will remain tight in 2022 STRONG DEMAND SUPPORTS DAP PRICES
market-driven curtailments) at several of due to the significant supply related outages Mosaic sees strength extending well into
its European facilities. Over the next five and constraints. 2022. Based on limited global grain stocks
years the IFA forecast ammonia capacity to and elevated corn and soybean demand
grow by 16 Mt N by 2025/26. RUSSIA AND BELARUS DOMINATE POTASH driven in part by Chinese demand and rising
GROWTH global biofuel demand. Resulting agricultural
TIGHT MARKET SITUATION IN 2022 The EECA region dominated potash commodity prices remaining high and
The global nitrogen outlook remains capacity growth with new mines starting up farmer income above historic norms. Given
strong, driven by strong demand in Russia and Belarus. These countries its depleted inventories, India is expected to
fundamentals, low global inventories and added 2.3mt of new capacity in 2020. return to the market in 2022. In Southeast
limited pre-buying so far this season. Going forward Russia has the largest Asia, fertilizer demand is benefiting from the
Industry consultant projections show number of individual projects in IFA’s strength in palm oil prices and China is
increased nitrogen capacity growth in 2022, capacity forecast, with three projects in the incentivizing its farmers to maximize yields
but Yara expects actual production growth country forecast to start from 2023 through subsidized crop prices.
to be lower, below historical trend onwards. The trend of shifting P205 to Lithium iron
consumption growth. Sustained nitrogen SOP expansions continue to make phosphate batteries (LFP) is expected to
curtailments in Europe over the winter progress, with two Australian projects profoundly change the phosphate industry in
likely to lead to a tighter market situation in expected to start this year. These projects, China-with around 300,000/t of purified
2022. along with smaller expansions, are forecast phos acid already shifted to LFP, equivalent
Urea prices show no signs so far of to add 4.6mt K2O of primary potash to 0.5mt of DAP. Tesla is working with other
abating. The sale for a 6,000t cargo at between 2021 and 2025. parties to build-up LFP factories in the US. DCi

www.drycargomag.com
NOVEMBER 2021

DCi

11
NEWS
Shedding light on port tariffs
ry bulk vessels frequently call at new traditionally an administrative-heavy Cost Estimator that in seconds and in just

D & unfamiliar ports. Harbor Lab is

helping vessel operations teams
evaluate their port agency and cost options
function that leaves in its wake complex
calculations and communications trails
through paperwork, phone-calls and
one click calculates the cost for port
expenses at a specific vessel’s port call. As
a cloud-based technology, all users can
more easily than ever before, writes Antonis emails. access the tool on a web-browser, making
SHIPPING & TRANSPORT

Malaxianakis, CEO and founder, Harbor Harbor Lab’s Disbursement Accounting it extremely simple to use on-the-go.
Lab. Tool brings together shipowners and Crucially, these tools are designed to
How many different ports does a tramp agents through a port directory and save ship operators time, money and
dry bulk vessel call at every year and delivers visibility and efficiency to the reduce their back-office paperwork as all
therefore how many relationships with entire process of selecting, nominating or correspondence and quotes are held in the
port agents does a typical dry bulk appointing an agent, evaluating rates and system and bring transparency to port
operator need to manage? The simple checking port costs. Shipowners and costs. From the agent’s side it creates a
answer is that every year a typical dry bulk operators can see the costs associated level playing field as small agents can
vessel will call at a handful of ports at with each vessel call and can make choices present their fees and capabilities alongside
which it has never or rarely called at based on this information: this can result in larger or more established businesses.
before and need to work with new significant savings. Already our platform has attracted 1200
counterparts to ensure an efficient, safe Streamlining processes ensure agents and vendors since it went live in
and cost-effective turn-around. transparency across the board and makes March last year.
There are currently over 1,700 dry bulk all players accountable for what they do. The information available through
cargo handling ports globally, out of a total Technology is now being incorporated Harbor Lab’s platform is valuable for
of around 4,300 ports which are capable of across the supply chain to create more operators, no matter whether their vessel
handling 10,000dwt plus sized vessels. A simplified and transparent procedures. is heading for a regularly-called at or a one-
typical versatile handysize vessel might Since 2019, data exchange between the off port. For those ports which the
undertake 15-20 voyages per year and a port and ship is required in an electronic operator knows well, Harbor Lab’s
voyage might involve more than two port format as mandated by the International platform gives them visibility of the official
calls. Not all port calls involve cargo being Maritime Organization’s (IMO) updated tariffs and expenses they should expect to
loaded and discharged: there will also be Facilitation of International Maritime Traffic pay and is an opportunity to negotiate on
port calls for bunkers to be taken on or (FAL Convention). At its most recent price and service. If it’s an unfamiliar port
repairs undertaken. Shipbroker Clarksons meeting in June, the committee also made to the operator, then it provides accurate
Research estimates that in 2018 the it mandatory for public authorities to port data so that there are no surprises
world’s top 20 ports accounted for 22% of establish and maintain a ‘single window’ for when finalizing fees with the agent.
all dry bulk vessel calls. Depending on the electronic exchange of information for the At the same time, we have put the ship
size of the shipping company, a vessel stay, arrival and departure of ships in ports. operator back in control, as they can
operations team might have a core of The digitalization of disbursements oversee their expenses in house through
perhaps 10-20 ports which it knows accounting is therefore a logical next step their own disbursement accounting teams,
intimately and at which its vessels call at in an increasingly tech-heavy shipping or outsource the disbursements to Harbor
regularly. In these ports the team members environment. Lab’s team of experienced analysts.
will know the right people, have long- With Harbor Lab’s solution, data and I believe that ship’s agents will continue
standing relationships with good port calculation methods are gathered and to work alongside every type of ship in the
agents and will probably be able to secure validated directly from ports around the years to come. The shipping industry’s
better rates for everything that the port globe by our team of port analysts. These general shift towards digitalization and the
call involves. But what happens at one of are then digitalized through the online desire for more transparency and
the other ports where the vessel might platform that is built on dynamic accountability will, however, inevitably
www.drycargomag.com

only call a couple of times in its life? Is the programming techniques and sophisticated result in more streamlined processes. And
ship operator confident that it is really formulae. through Harbor Lab’s tools, port
working with the right partners? The cloud-based software is further disbursements accounting is one area that
This is the problem which Harbor Lab supported by our recently-launched Port is ready to be transformed.
was created to address and something
which I saw during my time as a member of Antonis Malaxianakis, CEO and
the Thenamaris and Product Shipping & founder, Harbor Lab.
Trading disbursement accounting teams.
The software we have developed brings
transparency to the shipowner and
supports their decision making at ports
where they are less familiar. It is also there
NOVEMBER 2021

to help improve the agent/owner

relationship. This relationship is a critical
dynamic which we are seeking to support
and particularly important in the area of
disbursement accounts.
DCi Disbursement accounting is

12
 NEWS
BIO-UV Group adds 3D scanning to turnkey bio-sea BWTS retrofit service
France-based BIO-UV Group has scanning we can support complete ballast “The GPS Data is simply the registration
strengthened its position in the global water treatment projects end-to-end. This in the log of the system of the vessel GPS
ballast water treatment system (BWTS) is a significant benefit for shipowners position when a ballasting operation is
market with the addition of 3D laser looking at ways of installing a ballast water performed. By crossing with all other input
scanning and modelling to its BIO-SEA treatment system without taking the vessel data, various analyses will be possible,

SHIPPING & TRANSPORT

engineering and design services. The new out of service.” although at first this addition aims to
service follows increased shipowner Due to the current spike in freight rates, anticipate a possible IMO regulation update
demand for turnkey BWTS retrofit BIO-UV Group is fielding more enquiries for that respect localization and tracking of
solutions capable of reducing or negating for in-service installations using dedicated ballasting operations.”
BWTS installation time in drydock. BIO-SEA ‘flying squads’. BIO-UV Group will be exhibiting its
The digital scanning of a ship’s “Of course, this adds more to the total recently launched medium flow rate M-
compartment generates a 3D image from cost,” said Dedeurwaerder, “but at least the Series BIO-SEA at Booth 4202 of the
which BIO-UV Group engineers can find ship remains in service, earning money. This Europort 2021 trade show, which takes
the optimum site for its BIO-SEA system is a real hot topic at the moment.” place at Rotterdam’s Ahoy Centre between
and develop more detailed engineering to According to Dedeurwaerder, there is a 2nd and 5th November.
expedite class approvals and installation. noticeable trend for shipowners looking to
Florian Cortes, Technical Director - work with “a limited number of business ABOUT BIO-UV GROUP
BIO-SEA, BIO-UV Group, said: “By partners during a retrofit project, and to be For almost 20 years, BIO-UV Group has
providing a complete BIO-SEA BWTS fully supported along that process”. been designing, manufacturing and
retrofit package that includes everything Coinciding with the introduction of marketing ultraviolet light (UV-C) water
from 3D scanning, and modelling to digital modelling services, BIO-UV Group treatment technologies for a multitude of
detailed design and commissioning, has also updated all versions of its UV industrial applications. In 2011, it added the
shipowners need only deal with one or two technology-based BIO-SEA systems to treatment of ship ballast water to its range.
suppliers rather than several.” ensure compatibility with GPS data The company’s product range is designed
Maxime Dedeurwaerder, Business acquisition. and produced at its own purpose-built
Director – BIO-SEA, BIO-UV Group, “This is a new feature we are providing facility in Lunel, France, allowing the
added: “By offering a free-of-charge in anticipation of possible future regulatory company to quickly respond to its
feasibility audit and competitively priced 3D requirements,” Dedeurwaerder said. customer’s specific requirements.
NEWS
Britannia Loss Prevention Insight, Issue no. 2, November 2021:
Carriage of grain and oilseed cargoes, an overview for the maritime sector
INTRODUCTION source of wet damage claims. Owners should pay close attention to the condition
The global trade of bulk grains and oilseeds should also regularly check to ensure that of the grain or oilseeds during loading.They
has undergone continued expansion the bilges are free from obstruction and should record the colour and odour of the
SHIPPING & TRANSPORT

recently. Soya beans in particular have draining efficiently. cargo throughout loading and record the
increased significantly partly due to the Vessels loading grains or oilseeds in the cargo temperature at regular intervals
increasing demand in China for vegetable USA will usually undergo a stowage using a calibrated temperature probe. In
oil and animal feed. The major grains examination by United States Department terms of soya beans, the most helpful
shipped internationally include maize, of Agriculture (USDA) Federal Grain information to obtain at loading is cargo
wheat and rice, while the most shipped Inspection Service (FGIS) to ensure the moisture content and temperature. The
oilseeds are soya beans. Other oilseeds cargo space is clean. The purpose of the reason for measuring the cargo
shipped in large quantity include rapeseeds, examination is defined by USDA as: ‘A temperature is to assess whether there is
sesame and shea kernels. stowage examination is a service variation between lots which may indicate
The largest grain and soya bean performed by official personnel or licensed if some lots are already deteriorating and
exporters are Brazil and the USA. In terms co-operators who visually inspect an to obtain an average cargo temperature
of soya beans, these two countries account identified carrier or container and which can be used to assess whether to
for approximately 80% of the global export determine if the stowage areas are clean; ventilate the cargo during the voyage.
market, with China being the largest dry; free of infestation, rodents, toxic Clear photographs of the cargo and
importer. substances and foreign odor, and otherwise loading operations are also invaluable.
There have been a relatively large be suitable to store or carry bulk or These should include an overview of how
number of soya bean claims this year, partly sacked grain, rice, beans, peas, lentils or the cargo was loaded, the cargo in the
related to the bumper 2020/21 soya bean processed commodities’. holds during loading and, where possible,
harvest in Brazil. Claims for damage to In major South American exporting close-up photographs of the cargo itself.
Brazilian soya beans have been made in countries such as Brazil, hold cleanliness Additionally, a Letter of Protest (LOP)
Europe, the Middle East and most certificates or reports usually list the last should be issued to all concerned parties if
frequently in China. The high number of three cargoes carried on board the vessel any deteriorated/mouldy/wet cargo is
claims in the latter are primarily due to the and typically state that the holds were identified. The master has the right to
large quantity of beans carried from Brazil found ‘empty, dry, clean and in suitable reject the cargo for loading if it is of poor
to China. condition to carry the cargo’ or similar. condition. In such circumstances, it is also
The following (shortened) report The definitions and strictness to which recommended that the cargo is
provides some guidance on the main the cleanliness grades are applied vary representatively sampled according to the
precautions to be considered when from country to country, but it is sampling methods of the governing body
carrying bulk grains and oilseeds, points to important that the crew maintain their specified in the commercial contract, i.e.
consider in the event of damage being high cleaning standards to prevent delays the Federation of Oil, Seeds and Fats
found at the destination and concludes or contamination events. Failure to comply Associations (FOSFA) for oilseeds such as
with a brief case study covering various with cleanliness requirements can result in soya beans. Analysis of representative
issues relating to soya bean claims in China. the rejection of the vessel for loading by samples from the load port may become
The full report can be found on the the shipper which can lead to costly delays. crucial evidence in the event of a claim.
Britannia P&I website, under Publications. Alternatively, claims may be made at Since grains and oilseeds are heat-
discharge if the holds are incorrectly sensitive cargo, the master and chief
PRECAUTIONS accepted and the cargo is found to be engineer should consider the location of
PRELOADING contaminated with rust or previous cargo heated Fuel Oil Tanks (FOTs) prior to
www.drycargomag.com

The first point to consider prior to loading residue. loading and, if possible, stow cargo away
a bulk grain or oilseed cargo is whether from heated FOTs. Damage to soya bean
the holds are clean and in suitable LOADING cargoes from heat transfer from fuel tanks
condition to load the grains or oilseeds. Bulk grain and soya beans loaded in large is particularly problematic because as well
The holds should be cleaned after quantities are assembled from a wide as direct heat damage to the beans, self-
discharge of the previous cargo. geographic area and often from multiple heating can also be initiated which leads to
Charterparties for most grains and oilseed lots from different storage locations. quite severe discolouration in the beans
cargoes, including soya beans, will usually Consequently, there can be significant next to the fuel tanks.
indicate that the holds must be at ‘grain variation in cargo quality between different
clean’ standard prior to the lots even though the whole cargo may FUMIGATION
commencement of loading. meet the contractual specification. This Grain and oilseed cargoes are usually
It is recommended that owners appoint variation in cargo quality can be fumigated in-transit, after the completion
NOVEMBER 2021

a local surveyor prior to loading. The interpreted by consignees at discharge as of loading. Masters should familiarize
surveyor can take part in inspections, damage which has occurred during a themselves with the IMSBC Code
where particular attention should be paid voyage. It is therefore important that a Supplement MSC.1/Circ.1264 (27 May
to hold cleanliness and the bilge boxes and cargo surveyor and/or the crew monitor 2008) as amended by MSC.1/Circ.1396
ballast tank manhole covers, ensuring they the cargo loading closely. Recommendations on the Safe Use of
DCi are clean and dry, as these are a frequent A cargo surveyor and/or the crew Pesticides in Ships Applicable to the

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 NEWS
All images reproduced with kind permission of CWA.
fumigation instructions to ensure that any
remaining fumigant gas is dispersed. This
typically takes place just before
commencement of discharge.

VOYAGE
The only active method of cargo care

SHIPPING & TRANSPORT

available during carriage of grains and
Fig 1: Mould residue on the hatch coaming Fig 2: Cargo of wheat contaminated with a oilseeds is ventilation. The purpose of
from condensation wetting in a cargo of localized area of foreign material comprised of ventilation is to reduce the risk of
maize. Black, mould-damaged grains can be sand and stones. It is difficult to assess such condensation during a voyage. To
seen rolling down the cargo slope from beneath contamination during loading due to the levels demonstrate cargo monitoring, hold
the deck areas where moisture condensed and of dust and colour of foreign material. temperatures can also be measured via the
wet the cargo. Cargo compaction/caking in the hold sounding pipes. This will provide a
centre was due to prolonged stowage on board general oversight of whether cargo
during a delayed voyage. temperatures may be changing within the
holds, but is also influenced by the ambient
conditions and should not be considered
as a direct measurement of cargo
temperature. Condensation can result in a
localized increase in the cargo moisture
content. This places the affected cargo at
risk of accelerated decomposition and
mould growth with an associated rise in
temperature.
Fig 3: Small column of caked soya beans positioned Fig 4: Column/area of wet damaged cargo When ventilating bulk hygroscopic
directly below a hatch cover ventilation window. positioned beneath the hatch cover joint. cargoes such as grains and oilseeds, it is
recommended that the Three Degree Rule
is followed. The rule prescribes that
ventilation should occur when the outside
ambient temperature is more than 3°C
below the temperature of the cargo at
loading and the weather conditions are
suitable.
The crew should assess conditions
Fig 5: Partially discharged cargo of soya beans. Fig 6: Partially discharged stow of soya beans throughout the voyage to check whether
The caking well below the cargo surface is with characteristic mouldy crust on the surface ventilation is required. Ideally, the crew
indicative of mould growth between the beans due to self-heating within the pile. The dark should check the ambient temperature and
causing them to stick together. The soya beans black discolouration is a drip line due to compare to the average cargo temperature
are only slightly discoloured at this stage. condensation dripping from the interior steelwork. at loading on each watch, particularly on
voyage routes which might experience a
Fumigation of Cargo Holds. of the fumigant residue before discharge. large daily temperature differential. A
The fumigator should provide the The crew should document the fumigant ventilation log should be maintained which
master with documentation describing the application from a safe distance and ensure records the rule followed: when, why and
type of fumigant, the method of application, that the fumigators are applying the how long ventilation was performed. It www.drycargomag.com
dosage and duration of exposure. The fumigant to the method stated on the should also include any reason why
quantity of fumigant should be calculated fumigation documentation. ventilation was not performed, which
based on the total volume of the hold and The most frequently seen fumigation might include rough seas and poor weather
not the quantity of the cargo. exposure period for bulk grains and soya conditions. Ventilation is often required
In addition to this information, beans is ten days. In some instances, the overnight since this is when the ambient
appropriate safety equipment and master may be advised not to ventilate the temperature is likely to be cooler
instructions should be provided to the holds for significantly longer and compared to the cargo loading
master relating to crew safety during occasionally for the entire voyage. If this is temperature. However, vessels often do
fumigation. This should include the the case, owners are recommended to not ventilate overnight due to the more
ventilation requirements to ensure the contact their charterer immediately, as a limited availability of crew and potential
holds are gas-free prior to discharge. long fumigation exposure period does not risks of sudden changes in weather and or
The most common fumigant used for take into account changes in environmental sea conditions. Where possible, the cargo
NOVEMBER 2021

bulk grain and oilseed cargoes is aluminium conditions that might result in should be ventilated according to the
phosphide. When exposed to air, condensation issues relating to a lack of Three Degree Rule on a 24-hour basis. If
aluminium phosphide reacts with moisture ventilation. ventilation is not performed overnight, this
to produce phosphine gas. The fumigant is Following the completion of the should be recorded with the reason why
applied in tablet or pellet form. It may be exposure period, the holds should be clearly stated.
applied in packaging to allow easy removal ventilated in accordance with the DCi

Page 2 of 4
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NEWS
with large quantities of sand, concrete
debris, plastic and fabric bags. Due to
loading methods which raise large amounts
of dust, it is often only at discharge that
localized accumulations of such foreign
material contamination are found. Other
sources of contamination are previous
SHIPPING & TRANSPORT

Figure 7: A close up of surface mould crust cargo residues and rust flakes from the
associated with self-heating within the stow of Figure 8: Soya beans caking well below the interior hold surfaces. The holds should
soya beans. Moisture condenses in the relatively cargo surface in the lower part of a cargo hold. always be inspected and confirmed suitable
cooler upper layer of cargo leading to mould The caking indicates mould growth between for receiving grain/oilseed cargo before
growth which often forms a white layer of mould. the beans. loading.

DISCHARGE ambient temperature cools the steelwork. WATER INGRESS

In most circumstances, discharge of bulk Warm air has an increased capacity to Another issue which can occur during
grains and oilseeds proceeds without hold more water vapour than cooler air. As voyages is the ingress of water through
incident. In the event of damage at the temperature within the headspace leaking hatch covers. When this occurs it
discharge, it is important that the position cools, the air reaches saturation point and commonly presents in the form of obvious
of damage in the hold(s) is accurately begins to release moisture. This moisture columns of mould damage and caked pillars
recorded – for instance the location, condenses on the cooled steel work. The of cargo where the water has leaked
depth/height above the tank top and the condensation will then drip onto the cargo directly down towards the tank top from
area. This will assist in determining the surface and/or run down the frames of the the point of entry (see Figures 3 and 4).
cause of damage. The crew should closely hold. This damage is characterized by The only preventative measure is to
monitor discharge and any segregation wetting and associated mould damage ensure that all hatch covers, and manholes
activities. A local surveyor should be visible as a regularly repeating pattern on deck, are inspected and maintained on a
appointed to document cargo condition, across the surface of the cargo reflecting regular basis to ensure weather tightness.
inspect the damage and, where relevant, the frames or features of the hatch covers The condition of the steel compression
obtain a cargo temperature profile directly above. bars and rubber hatch cover seals should
throughout discharge. Repeated wetting due to the prolonged be regularly checked and maintained
A Grain and Feed Trade Association formation of ship’s sweat can result in accordingly. The crew should ensure that a
(GAFTA) or FOSFA approved damage extending deeper into the stow. Hatch Cover Test is performed prior to
superintendent should also be appointed The main source of moisture in the hold is the voyage and that a certificate or report
to take representative samples of the cargo the cargo itself where it is present in a is produced.
during discharge in accordance with significant quantity. The formation of ship’s Wetting of cargo can also occur if hatch
GAFTA Sampling Rules no. 124 or FOSFA sweat can be influenced by the cargo covers are left open when it is raining or
sampling guidelines. Ideally, the sampling moisture content itself through moisture there is spray during loading or discharge.
should be performed on a joint basis with migration and respiration of the If this occurs at loading, the wetted cargo
other interested parties. The grains/oilseeds. When moisture reaches must be discharged. Failure to discharge
representative samples obtained should the relatively cooler steel structure it wetted cargo at the load port is likely to
represent the cargo as a whole and any condenses and then drips onto the cargo lead to cargo claims at disport due to
segregated categories (i.e. additional causing localized damage. visible mould growth. Furthermore,
representative samples should be obtained Cargo sweat, conversely, forms when wetting prior to the voyage is likely to
for cargo considered sound and damaged). the cargo temperature is lower than the result in deterioration that affects other
dew point of the air in the headspace. This areas of the stow, thereby increasing the
COMMON RISKS/CLAIMS EXPERIENCED normally occurs in situations where cold quantum of potential damage. To prevent
www.drycargomag.com

WITH CARRIAGE OF GRAINS AND OILSEEDS or relatively cooler cargo is loaded and these issues, the master and crew should
SHIP’S SWEAT AND CARGO SWEAT warmer air is subsequently introduced into pay close attention to the weather and be
Ship’s Sweat and Cargo Sweat are types of the headspace by incorrect ventilation ready to close hatch covers in advance if
condensation that form due to differences during a voyage or when a cold cargo is required.
between conditions in the hold and the discharged in a significantly warmer Additionally, severe weather conditions
external environmental conditions. destination. In this case, the condensation during the voyage resulting in water on
Condensation can result in a localized forms directly on the surface of the cargo deck can also lead to water ingress to the
increase in the cargo moisture content. itself. This damage would be characterized cargo holds.. In the event that such adverse
This places the affected cargo at risk of by mould growth at the surface of the stow weather conditions are experienced, a Sea
accelerated decomposition and mould without the distinctive grid pattern seen Protest detailing the weather event may
growth with an associated rise in with ship’s sweat. also assist in the defence of a claim.
temperature as discussed above (see Mould and wet damage found at the
NOVEMBER 2021

Voyage section). CARGO CONTAMINATION lower part of the hold is often attributed
Ship’s sweat forms when the steelwork The crew should closely monitor the cargo to overflowing and poorly maintained
of the vessel is cooler than the dew point during loading to ensure it is not bilges. A surveyor or crew member should
of the air within the headspace. This excessively contaminated with foreign closely inspect the condition of the bilges
typically occurs when a vessel sails to a materials. There have been cases where prior to loading the cargo to ensure that
DCi cooler climate and the lower external cargoes of grain are loaded co-mingled waste water can be easily removed.

Page 3 of 4
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 NEWS
SELF-HEATING to understand that there are a range of alleviate any hotspots which may develop.
Grain and oilseed cargoes carried in bulk mitigation strategies that can be employed Another method used to mitigate the
will undergo biological reactions during to help reduce the scale and severity of effects of self-heating damage to soya
storage. The grains and oilseeds continue damage. Broadly, these can be split into beans, although this also applies to
to slowly respire, consuming oxygen and activities performed during and after damaged grain cargoes, is to blend the
generating carbon dioxide, water and heat. discharge. affected beans with beans of a better
Due to the large quantity of cargo within During discharge, if a claim is quality, often from another vessel. The

SHIPPING & TRANSPORT

the holds and the high insulation capacity anticipated or damage is found, it is practice of blending is commonplace at
of such cargoes, the grain/oilseed recommended that representative samples large processing facilities or grain terminals
temperature can increase over time. are obtained throughout discharge. With with enough reserves of suitable grains or
The degree to which self-heating will soya beans, the samples must be obtained soya beans that can be blended.
manifest itself within a cargo is influenced in accordance with the latest FOFSA When attempting to quantify or
by the moisture content and temperature sampling method. The same applies for validate a potential claim that arises
of the cargo at loading and the length of grain cargoes and samples should be taken following mitigation by blending, it is
the voyage. In some cases, pockets of cargo according to GAFTA Sampling Rules no. important to obtain relevant documents
with a higher moisture content will begin 124. Once representative samples are and data, such as the blending ratios and
to develop mould, further heating the obtained, they can be retained and analysed quantities, and the quality parameters and
cargo. If the entire cargo has an inherently to investigate a number of factors, such as results for each lot that is blended with the
high moisture content, the risk of mould quality grading and biochemical affected cargo.
growth and self-heating increases parameters. It is important to stress that a
significantly. spot sample (i.e. a sample that is not CONCLUSIONS
Carriage of cargoes with a high oil comprised from multiple incremental There are a range of considerations for the
content, or processed feed products with samples taken throughout discharge) crew to consider prior to and during the
residual oil content, have an additional risk cannot be considered representative of the carriage of grain and oilseed cargoes. It is
of self-heating due to the breakdown of cargo. Ideally, a FOSFA or GAFTA most important for the crew to document
the oil. As a result, there is a greater risk of accredited superintendent should be cargo loading and monitor cargo during
soya beans and seed cake cargoes self- appointed to undertake representative the voyage to ensure that sufficient useful
heating in comparison to cereal grain sampling, either on a unilateral or joint information is retained to helpfully defend
cargoes. basis. any potential claims at the destination. An
There are several other potential Additionally, it is important that an understanding of the common issues
sources which can initiate or exacerbate effective segregation operation is put in experienced during the carriage of these
the self-heating process. A common source place. This is usually the responsibility of cargoes and ways to avoid these issues may
of heating is insect infestation. Insects, like the receiver, though owners should well assist in minimizing and preventing
other living organisms, generate heat as a monitor their plans and assist when cargo damage and claims. Therefore,
by-product of their metabolic processes. A possible. If damaged cargo is in a discrete Members should contact the Club if
significant insect infestation can lead to location, as is often the case with water requiring specific advice on particular
rapid increase in temperature and damage ingress through the hatch covers, it is matters relating to the carriage of soya
to cargo. suitable and effective to segregate damaged beans or grain cargoes.
Other external heat sources include cargo by hand. For more widespread
lights left on within the hold, improperly damage, typically seen with heavy ABOUT BRITANNIA LOSS PREVENTION’S
fitted fumigant recirculation fans inside the sweat/condensation related damage on the PARTNER: CWA FOOD & AGRICULTURAL
hold, and heated FOTs adjacent to the surface, it may be more appropriate and COMMODITIES DEPARTMENT
holds. These external heat sources practical to remove by ‘skimming’ with a The CWA Food & Agricultural
generate localized heating which can grab or small payloaders. In every instance, Commodities department provides expert
initiate the self-heating process and, in care should be taken to ensure that the advice on a range of food, feed and other www.drycargomag.com
some cases, cause combustion. most effective and practical segregation dry agricultural commodities, across the
In the event of self-heating, there is little method is undertaken. The segregated entire supply chain from field to consumer
that can be done to stop the continued cargo should also be representatively and especially relating to the shipment of
increase in temperature. Ventilation only sampled. these commodities as bulk, break-bulk,
serves to remove water vapour from the Once the cargo has been discharged by bagged, bottled, drummed, refrigerated,
headspace atmosphere and does not affect the vessel there are several steps that are frozen and containerized cargoes.
the temperature of cargo within the body commonly utilized to help mitigate The department applies scientific and
of the stow. potential cargo claims. For example, with commercial expertise to quality
The only truly effective method to stop soya beans which are self-heating and at management in the international trade of
self-heating is to discharge the cargo as high temperature at discharge, it is useful food, feed and other agricultural
soon as possible. Self-heating may continue to attempt to dissipate this heat. This can commodities, with particular regard to
post-discharge if the cargo is stored in be achieved by spreading the affected cargo damage causation, quantum, food safety
NOVEMBER 2021

large piles with little ventilation. in a flatbed warehouse to help reduce the and loss prevention. The department also
temperature of the beans. Care should be assists in loss mitigation by applying its
MITIGATION taken to avoid piling the cargo in high piles. scientific, operational and commercial
The common forms of damage described Storage in silos allows the rotation of the experience to advice on cargo utilization,
above, among others, often give rise to cargo, whether grain or oilseeds, between salvage and disposal.
claims from various parties. It is important silos and the use of forced ventilation to DCi

Page 4 of 4
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 SHIPPING & TRANSPORT
Freight market boost for
Handymax bulk carriers

Ultramax vessel Kobayashi Maru.

Richard Scott, Bulk Shipping Analysis

In the global freight market for Handymax Shipowners’ confidence in ongoing ships within the size group, the Supramax
bulk carriers a remarkable transformation employment prospects, coupled with and Ultramax vessels,.
unfolded during the first ten months of potential for replacing existing ships with By contrast, bigger capacity units,
2021. Shipowners and charterers tonnage of greater efficiency, helped to Panamax, Kamsarmax and Capesize bulk www.drycargomag.com
experienced rapidly rising freight rates sustain investment in Handymax bulk carriers usually are ‘gearless’ (no installed
which more than tripled. An improved carrier newbuildings. Sub-categories within cargo-handling equipment on board) and
balance between the demand for, and the Handymax size group are the therefore are totally dependent on loading
supply of these vessels emerged. Although Supramax and Ultramax sizes, which and discharging equipment at ports. A
it is not certain that all of this improvement successively gained most attention. Their frequent advantage of being geared is that
will be maintained over the twelve months adaptability, coupled with cautious this equipment allows efficient operation in
ahead, some added support seems likely to optimism about longer-term future growth trades where shore-based facilities are
persist. in the relevant global trades, has been either unavailable, or inadequate for the
A wide range of commodity trades is reflected in the popularity of these vessels. purpose required. Handymax gear also
embraced by Handymax bulk carriers — often assists handling cargo from or into
medium-size dry cargo vessels with a A VERSATILE WORKHORSE barges moored alongside, at an offshore
carrying capacity from 40,000 deadweight Specific design features partly explain the anchorage or river berth.
NOVEMBER 2021

tonnes up to 70,000dwt. Extensive as well inherent appeal of Handymaxes. A typical Another benefit is the Handymax
as varied employment on many routes is ship of this type is a ‘geared’ vessel (cargo- dimensions — length, beam and draught —
ensured. Fleet expansion in this segment of handling gear installed on board), equipped suitable for many ports around the world,
3–4% annually in recent years reflected with cranes and grabs for loading and on most trade routes. The carrying
actual or expected growth in the trades discharging cargo. This feature is included capacity offers some economies of scale.
where Handymaxes are employed. in the distinctive sub-categories of larger Consequently, widely varied employment DCi

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SHIPPING & TRANSPORT

TABLE 1

HANDYMAX (40-69,999 DWT) BULK CARRIER FLEET (MILLION DEADWEIGHT TONNES)

2016 2017 2018 2019 2020 2021
Newbuilding deliveries 13.2 10.8 5.6 8.2 9.2 7.0
Scrapping (sales) 4.3 3.1 0.7 0.8 1.8 0.8
Losses 0.0 0.1 0.1 0.1 0.0 0.1
Plus/minus adjustments –0.2 –0.2 0.2 0.0 –0.1 0.0
Fleet at end of year 187.4 194.7 199.7 207.0 214.3 220.5
% change from previous year-end +4.9 +3.9 +2.5 +3.7 +3.5 +2.9
source: Clarksons (historical data) & BSA 2021 forecasts *forecast

patterns often result. Involvement world fell to the lowest level since eleven SLOWING FLEET EXPANSION
frequently occurs in the coal, and grain and years earlier in 2018, following which there It seems likely that slowing fleet growth will
soya, trades. Numerous cargoes in the has been a revival to 9.2m dwt in 2020. persist through 2022 based on available
minor bulk commodity trades are a These volumes were offset to varying indications. Table 2 sets out the global
prominent feature: steel products, ores and degrees by scrapping of mainly older orderbook for new Handymax bulk
minerals such as nickel ore, other industrial vessels. Scrapping rose to 1.8m dwt last carriers, showing the schedule for the next
commodity cargoes, fertilizers and various year, from well under 1m dwt annually in twelve months and further ahead,
agricultural commodities including oilseeds the previous two years. suggesting that deliveries will decrease next
and meals. Changing fleet composition within the year.
The preferences of shipowners in new Handymax segment is a notable trend. Higher scrapping is also a distinct
vessels for employment within these Large differences between the average size possibility, after the current low volume,
trades, in recent years, firmly shifted of newbuildings delivered into the fleet, and resulting in a net deadweight capacity
towards higher-capacity Ultramax the average size of old ships sold for addition in 2022 of well below this year’s
60–65,000dwt bulk carrier designs at the demolition is a feature. In 2020 total. Both inflows and outflows will be
top end of the Handymax size range. newbuildings averaged 62,600dwt, affected by evolving freight market
Previously the Supramax, typically confirming the popularity of Ultramaxes patterns, and by changing market sentiment
52–57,000dwt, was the preferred unit, towards the top end of the Handymax size and views, so perceptions may change.
taking over from smaller Handymaxes range. By contrast, ships sold for scrapping One aspect is that newbuilding
below 50,000dwt. averaged 45,000dwt, with an average 26.7 orderbooks at shipyards, as reported,
years demolition age, representing an provide only a rough guide to the amount
HANDYMAX FLEET GROWS MODERATELY earlier era when the original Handymax of future fleet capacity likely to be added
Over the past few years, the world fleet of bulk carrier of 40–50,000dwt size was within any given period. Orderbook
Handymax bulk carriers has grown at a most popular. slippage and postponements, difficult to
moderate pace. Deadweight capacity in the Looking at newbuilding Handymax predict, often occur while more orders
40–69,999dwt size group increased by an deliveries during 2021, the total in the year could emerge.
average 3.2% annually in the three years as a whole seems set to fall well below last The entire current Handymax
from 2018 to 2020, including 3.5% in 2020 year’s deadweight volume. This estimate is orderbook for all future delivery years now
as shown in table 1. In 2021 as a whole a based upon the pace so far, coupled with totals about 12m dwt, equivalent to 5% of
similar rate of around 3% is foreseen, expectations for the remaining months. the existing world fleet in this size group, a
probably decelerating next year based on The scrapping volume has been limited relatively low percentage. Four-fifths of the
partly speculative assumptions. because of much higher freight rates deadweight capacity on order consists of
Handymax fleet capacity reached 214.3 obtainable, and the annual total could be Ultramax vessels, emphasizing how these
www.drycargomag.com

million deadweight tonnes at the end of below 1m dwt. Although the end of 2021 ships have become the dominant
2020 according to Clarksons Research is approaching, it is still difficult to estimate investment focus.
data. Vessels in the size group numbered these elements precisely because there is Ideas about the outlook for the freight
3,819. Within the entire 912.2m dwt world potential for unexpected changes. market and profitability, for the bulk carrier
bulk carrier fleet of all vessel sizes, this total sector as a whole and for Handymaxes,
comprised under one-quarter. On a longer
period comparison, over ten years TABLE 2
Handymax capacity almost doubled,
increasing by 92%. HANDYMAX (40-69,999 DWT) BULK CARRIER ORDERBOOK (MILLION
In the 2021 first nine months the DEADWEIGHT TONNES)
Handymax fleet has been augmented by scheduled orderbook deliveries, not forecasts of actual deliveries
more than 2%, boosting the total to 3,897 4q2021* 2022 2023/later total
NOVEMBER 2021

ships amounting to 219.2m dwt at end- 40–49,999dwt 0.2 0.6 0.1 0.9
September. The newbuilding deliveries 50–59,999dwt Supramax 0.3 0.6 0.9 1.8
trend has slackened, while scrapping has 60–64,999dwt Ultramax 1.1 5.9 2.2 9.2
diminished. Total 1.6 7.1 3.2 11.9
Newbuilding Handymax deliveries to source: Clarksons Research *fourth quarter of year
DCi owners by shipbuilding yards around the

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affect incentives to invest in new ships.

Although orders for Handymax bulk
carriers picked up last year after a lower
volume in the previous twelve months, this
year has seen only a limited response to
higher freight rates and improved
expectations for the future market trend.
Despite recovering freight rates this
year buoying sentiment, shipowners’ views
of longer term market prospects have
become more cautious, reflected in
reluctance to order new ships. There is
heightened uncertainty about the effects of
tightening regulation of shipowning
activities and, in particular, the intensified
focus on cutting ships’ emissions. The
technology which will be required for
alternative fuels facilitating decarbonization,
suitable for the entire lifetime of a typical
ship is unclear. Until more clarification is
available, fleet growth may remain
restrained.
Another imponderable for fleet growth
predictions is variations in the pace of
scrapping (recycling). How this influence
evolves is always difficult to foresee both in
the immediate future and further ahead.
Potential for scrapping old tonnage is
apparent, but the Handymax fleet’s
relatively young age is a limitation. Only 8%
(about 18m dwt) is 20 or more years old,
an age group where recycling is more likely,
mostly in the 40–50,000 dwt size sub- remaining category of utilization, especially visible change, accompanied by
group. However, tightening regulations and contributing over half of the total, is the reduced imports into many other
compliance costs could encourage extra extensive and diverse minor bulk countries.
sales to demolition yards. commodity trades. Frequently changing grain and soya
cargo volumes imported and exported by
VARIED TRADING PATTERNS NUMEROUS COMMODITIES various countries, and varying geographical
Observation of global trading patterns for One of the most prominent segments, trade patterns, requires flexible sea
Handymax bulk carriers confirms that a global trade in grain and soya, provides transport services. Rises or falls from year
high proportion of dry bulk commodity many cargoes for Handymax bulk carriers. to year, in volumes of grain or soya available
trades is accessible, with only a few A characteristic of this market segment is a in exporting countries, and quantities
limitations. The dimensions and cargo- continuously changing pattern of trade required in importing countries, often
handling capability of typical ships routes and quantities which is highly reflect harvest output fluctuations. These
promotes their employment carrying variable in both the short and longer term, production changes are typically caused by
www.drycargomag.com

numerous commodities in most and tends to be largely unpredictable. weather variations, often unpredicted.
geographical areas. World trade in wheat and coarse grains, Coupled with port and storage limitations
Nevertheless, large parts of global long- together with soyabeans and meal, saw in many countries, this feature enhances
haul iron ore and coal movements do not strong overall expansion during the past employment opportunities for the
normally employ Handymaxes. On many of two crop years. But the current 2021/22 adaptable Handymax bulk carrier.
these routes bigger panamax, kamsarmax, year could see a decrease, according to Prospects for wheat and coarse grains
capesize and even larger bulk carriers can tentative indications. trade in the current 2021/22 period suggest
be accommodated. Where higher-capacity Based on International Grains Council that the upwards trend may not continue.
units are involved this usually reflects the calculations, world trade in wheat plus corn Positive influences have receded. Some
greater economies of scale derived, and other coarse grains during crop year signs point to a fall in China’s imports,
providing cheaper transport. 2020/21 ending June was 31mt (million which the IGC estimates as 12mt or 19%,
According to approximate calculations tonnes) or 8% higher, compared with the from 60mt in the previous twelve months
NOVEMBER 2021

of the significance of various trades, for previous twelve months, at 427mt. Global to 49mt. Increases in other importing
Handymax 40–70,000dwt size bulker soyabeans and meal trade was 2mt (1%) countries such as in the Middle East area
employment, the iron ore and coal trades higher in marketing year 2020/21 ending may not be fully offsetting, resulting in an
each contribute up to one-tenth of total September, at 230mt, according to US overall 6mt (2%) global trade decrease to
employment. Grain and soya trade Department of Agriculture estimates. 421mt. In the soya category China’s
DCi contribute about one-fifth, while the Increased grain imports into China was an imports could continue strengthening.

22
 SHIPPING & TRANSPORT
These were marginally higher in the past
photo: Panama
twelve months, and another rise is
Canal Authority.
estimated by USDA to contribute to a 7mt
(3%) increase in global soya trade to 236mt
in 2021/22.
Handymax bulk carriers are extensively
employed carrying cargoes within the
‘minor dry bulk trade’ category. Some
individual elements of this group are not
actually minor but large, amounting to
massive annual volumes. The commodity
range is broad and in recent years the
overall total has been around 2000mt. Last
year there was a reduction of about 2%
when some elements were affected by the
pandemic-related weakening of global
economic activity.
Among minor bulk commodities the
two biggest trade components are steel
products (coil, sheet, plate and other
items), and forest products, although not all
quantities are carried by bulk carriers.
Other big volumes are contributed by the
bauxite/alumina (aluminium raw materials),
fertilizer raw materials and semi-finished
fertilizers, and cement trades, accompanied
by large quantities of ores and minerals other industries), and coking coal (used in range. A spectacular rise then ensued,
such as nickel and manganese ore. the steel industry). Steam coal comprises taking the index upwards more than
One of the largest individual trades is almost four-fifths. threefold to 3624 on 21 October 2021,
exports of steel products from China, Exports from Indonesia, mainly steam after which there was a sharp setback in
which frequently employs Handymaxes. coal, is one coal trade element utilizing the final part of that month and into early
These shipments totalled 51.4mt in 2020, Handymaxes extensively. Indonesia is the November.
about 19% lower than seen in the world’s top supplier of this coal type, with How much of this year’s upturn in
preceding year. Another prominent a vast total estimated at over 400mt Handymax freight rates will be preserved
individual trade is bauxite exports from (including low-grade lignite) last year. through the year ahead? Among supporting
Guinea which continue expanding and Shipments to China are a feature, limiting influences, prospects for lower newbuilding
totalled about 66mt last year, 8% higher, demand for bulk carriers because of the deliveries and higher scrapping imply
although many cargoes are carried by short voyage length which restricts vessel slowing fleet expansion. But some of the
bigger ships. employment duration for each cargo load. productivity deterioration now apparent
In the coal segment, especially on because of port congestion and delays, and
specific trade routes, Handymax size AN ELEVATED HANDYMAX FREIGHT diversions for crew changes, which has
cargoes amount to large volumes, but MARKET been instrumental in tightening the market,
numerous routes chiefly employ panamax Amid reviving global dry bulk trade this may unwind. Also, any pick up in average
and capesize ships. Global seaborne coal year, charter earnings of Handymax bulk speed related to improved freight rates
trade is the second largest commodity carriers in the freight market have been obtainable could also contribute to www.drycargomag.com
trade employing bulk carriers, after iron much higher than seen in the previous enlarging effective transport capacity.
ore, and amounted to 1,165mt in 2020, twelve months, and well above those seen The outlook for a number of
according to Clarksons Research data. in recent years. The world fleet of these commodity trades in which Handymax bulk
Coal still exceeds one-fifth of all global dry ships has continued growing, but carriers participate seems positive for
bulk cargo movements, despite the longer deadweight cargo capacity added has been 2022. An assumption is that global
term downwards pressures on outpaced by additional cargo volumes. economic recovery continues — assisting
consumption. Several influences diminished fleet the industries which generate import
Last year coal trade fell by 9% after productivity, restraining the supply of demand for commodities carried by
growing by 2% in the previous twelve tonnage when demand was expanding bulkers — and China’s imports in particular
months. The principal adverse influence Towards the end of last year the remain strong. Future world trade growth
during 2020 was the coronavirus pandemic, Handymax freight market strengthened in commodities relevant to the Handymax
resulting in a downturn in energy further. The Baltic Supramax Index segment may be slower than seen in the
NOVEMBER 2021

consumption in many countries, coupled calculated by the Baltic Exchange is a useful rebound of the past twelve months,
with reduced activity in industries indicator. In late November 2020 this however. Together with the expectations
consuming coal. A continued shift towards index exceeded 1,000 points for the first for fleet carrying capacity, a tentative
cleaner energy sources also persisted. time since early November 2019, having conclusion is that a substantial part of this
Seaborne movements comprise steam coal been as low as 383 in April 2020. At the year’s freight market strengthening may
(used chiefly in power stations, also in beginning of 2021 it was in the 1020-1030 persist. DCi

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SHIPPING & TRANSPORT

NORDEN moves into port logistics

A cargo of 30,000 tonnes of salt
being offloaded from a NORDEN
Handysize vessel, part of a whole-
service operation in which
NORDEN is managing the entire
logistics process.

Through a complex operation to offload that NORDEN will make for Chilean salt when the ship arrives at the berth for
bulk salt, NORDEN is optimizing the supply miner Empremar. While NORDEN has discharge,” explains Mark LaFrankie, head
chain for its customer Empremar. been shipping salt to the US for Empremar of NORDEN’s Vancouver office.
At a chemical plant in California, 30,000 for 20 years, this is the first time it is “For Empremar we are handling all the
tonnes of salt is being offloaded from a bulk managing the entire logistics operation of port logistics too. This involves an intricate
carrier onto a private terminal. The salt will moving the salt from ship to shore. barging, heavy equipment, and labour
be taken directly to the plant and used to “Usually our contracts for carrying bulk operation, and timing it all to consistently
make chlorine. commodities are simple ‘Free in / Free out’ meet the arrival of the ship coming from
This shipment is one of eight per year — which means our responsibilities end Chile. There’s a great deal of specialist
www.drycargomag.com
NOVEMBER 2021

DCi

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 SHIPPING & TRANSPORT
knowledge involved.” operators have also been contracted to service to our customers,” says Adam
With no space at the terminal to bring complete the offloading operation in about Nielsen, head of Industrial Bulk. “We’re
in heavy equipment, NORDEN has four or five days, working 12-hour shifts looking at new ways to optimize and
partnered with a local barge company to night and day. decarbonize our customers’ supply chains;
carry bulldozers, clamshell buckets, re-fuel Such port logistics and cargo handling and we are actively looking for business
tanks and gangways alongside the vessel to services represent a critical new business where integrated solutions are required.
offload the salt. area for NORDEN. “Our ambition is to be We see it as an exciting new growth
A team of private heavy equipment much more than just a standard freight opportunity for NORDEN.”

www.drycargomag.com
NOVEMBER 2021

DCi

25
SHIPPING & TRANSPORT

PEINER ship grabs - cost-efficient in procurement and operation

For 70 years PEINER grabs have been
present on the market and are today
distributed by PEINER SMAG Lifting
Technologies GmbH, a global player among
the suppliers of bulk handling equipment.
Common is their dual scoop grabs suitable
for the maritime sector. In addition to the
universally applicable rope grabs for general
cargo cranes, the company offers electro-
hydraulic motor grabs, which are used for
single rope cranes and require a power
supply from the crane. The most widely
used motor grab is the MZG/L series. High
handling quantities per loading cycle is the
outstanding feature of this type of grab. By
means of power-controlled hydraulic
pumps, the electrical power supply is very
efficiently converted into handling power.
The motor grab achieves an optimum filling
degree through high closing forces. No
matter if light, medium or heavy bulk
materials — with its customized dual scoop
design the grab copes with different
materials to be handled. One key
advantage is that the grab control can be
integrated into the control of the crane and
operated from the crane cabin.
Among the rope grabs, the radio-
controlled single-rope grab (EGF), is the
predestined ship grab. Many bulk carrier
operators use this proven and continuously
developed rope grab in the tough cargo
handling business, for good reason: using
this model allows any shipboard or
container crane to handle bulk material in
the shortest possible time without
www.drycargomag.com
NOVEMBER 2021

DCi

26
 SHIPPING & TRANSPORT
www.drycargomag.com

additional equipment. Their major robust handheld remote control. It enables extra tools.
NOVEMBER 2021

advantage: they can work without power reliable, interference-free radio

supply from the crane — the operator just communication up to 500m. High- MATURE TECHNOLOGY FOR BULK
has to charge the batteries and the grab is performance accumulators of the remote HANDLING WORLDWIDE
ready for operation. The PEINER radio- control guarantee continuous operation PEINER grabs can be found in almost every
controlled single-rope grab can be precisely for up to 24 hours and can be easily port of the world and are a respected and
controlled wirelessly with the portable, changed within a few minutes without any popular brand for the loading and DCi

27
SHIPPING & TRANSPORT

unloading of bulk carriers.

The product portfolio
ranges from mechanical
four-rope grabs, electro-
hydraulic motor grabs,
radio-controlled single-rope
grabs, hydraulic grabs,
slewing units (rotators) to
special lifting accessories.
With regard to the specific
demands in the shipping
industry PEINER dual scoop
grabs enable cost-effective
loading and unloading of a
broad range of cargo, such
as coal, ore, minerals, grain,
fertilizers etc. Scoops and
lips are always adapted to
the respective cargo. In
addition, various sealing
systems can be supplied to
prevent spillage and dust
emission. The application
areas of various dual scoop
grabs are as versatile as the bulk material: IN-HOUSE R&D AND MANUFACTURING decentralized spare parts warehouses, e.g.
ports, cargo terminals, bulk carriers, Thanks to the global SMAG group in Singapore.
industrial enterprises. PEINER motor and structure with its own plants in Germany, PEINER SMAG Lifting Technologies,
rope grabs are suitable for the use in rough China and India, PSLT can supply complete stands for sophisticated, reliable technology
bulk handling environments and can be grabs from all locations. Customers benefit that provides a quick and economical
operated in every climate. All components from a fast and flexible after-sales service solution for any handling task in demanding
are resistant to water. network in over 70 countries with work environments. DCi
www.drycargomag.com
NOVEMBER 2021

DCi

28
 SHIPPING & TRANSPORT
The role of OFTs
RT Genova is one of
Rocktree’s two flagship
in driving efficiencies and
self-loading and self-
unloading bulk carriers sustainability within the supply chain
and floating terminals.
The second is RT Leo
(inset).

www.drycargomag.com

The logistics and wider shipping industry is

scrutinizing all areas of the supply chain to
maximize operational efficiencies as a
means of improving revenues and
sustainability and meeting the demands of
charterers, shippers, institutions and
regulators, writes Francesca Bonsignore,
Corporate Development Manager, Rocktree.
Optimizing vessels through technology and
digitalization has significantly ramped up in
recent years. However, it is the first and diversified fleet of specialized Offshore geared vessels that have been converted
NOVEMBER 2021

last mile of the supply chain — in ports — Floating Terminals (OFTs) and with specialist handling systems to deliver
where there is latent efficiency to be seized multipurpose vessels, as well as a number highly efficient operations that also address
and a real opportunity to improve of tugs and barges. Innovation is the key in the technical and regulatory challenges that
sustainability. delivering a high performance, flexible and can impact a project’s success.
As a major logistics solutions provider, sustainable logistics solution, and this is RT Leo (2011) and RT Genova (2012) are
Rocktree owns and operates a highly exemplified in two of Rocktree’s standard Rocktree’s flagship self-loading and self- DCi

29
 RT Leo.
SHIPPING & TRANSPORT

unloading bulk carrier and floating

terminals. With their LOA of 194m and a
DWT of 53,690 MTs RT Leo and RT Genova
mix the flexibility and sailing capabilities of
standard Supramax vessels, with a powerful
cargo handling system and superior
manoeuvring performances.
They are specifically designed for
smooth and continuous handling of dry
bulk cargo, including fertilizer, coal, iron ore,
sand, aggregate, limestone and bauxite.
They are capable of loading vessels up to
the largest Capesize and have 53,000
tonnes of buffer storage to prevent any
discontinuities in the supply chain.
Both vessels were upgraded as recently up to the largest Capesize, safely, efficiently controllable pitch main propellor and an
as 2019 to maximize efficiencies and and with minimal shifting. For self- enhanced rudder.
performance and are now equipped with unloading, the boom can deliver cargo to a The vessels are also equipped with
four side-mounted heavy-duty cranes, with shore stockpile or hopper, or into barges. metal detectors and a metal catcher to
40t SWL and 26m outreach, which enables Critically, both RT Leo and RT Genova mitigate against the contamination of tramp
double the reach compared to standard have an average loading and unloading rate metal to the cargo. The conveyor system
geared vessels. This ensures reliability for of 2,700tph (metric tonnes per hour), with onboard is fitted with monitor devices to
cargo reclaiming from the shore or to a peak capacity of 4,000tph, which is four continually ensure the right temperature
offload two barges simultaneously. times faster than conventional geared and moisture percentage of the cargo
For OGV loading, they have a 37m vessels. And they have superior handled. Thanks to the variable-speed
outreach travelling shiploader equipped manoeuvring capabilities due to the conveyors, the different cargo grades can
with a discharge chute and can load vessels installation of twin bow thrusters, a be handled separately and, when required,
homogenously blended through an
advanced cargo handling system. All this
ensures the integrity and quality of the
commodity for the end user throughout
the transshipment and logistics process.
With environmental responsibility at the
top of the industry agenda, both RT Leo and
RT Genova are designed and operated to
minimize sea and air pollution. Within the
cargo handling systems, the hoppers are
designed to prevent spillage and utilize spill
plates and wind breakers, the enclosed
conveyor belts have fully sealed transfer
RT Leo points, and incorporate a travelling,
self-unloading lowerable shiploader with a trimming
to a hopper on chute. The vessels also include an oily
shore. water separator, as well as bilge water
separation and filtering tanks.
www.drycargomag.com

To ensure efficiencies in fuel

consumption and therefore lower
emissions, Rocktree has developed power
management initiatives and processes,
including integrating technological
capabilities on the vessels to optimize power
management, reduce fuel consumption and
ensure that the engines and generators are
used as efficiently as possible.
While developments need to be made
within global port infrastructure, it is clear
that state-of-the-art OFTs have an
NOVEMBER 2021

important role to play in driving efficiencies

and sustainability within the first and last
mile of the supply chain to the benefit of
the local port community, the dry bulk
market, as well as the wider shipping
DCi industry. DCi

30
 NEWS
CSL and Viterra set grain load record at Port of Thunder Bay
Canada Steamship Lines reached a historic the most of favourable conditions.”
milestone at the Viterra terminal in the CSL Welland is part of CSL’s biodiesel
Port of Thunder Bay in early November, testing programme — the longest ongoing
when it loaded a record-setting 31,362 trials of pure B100 biodiesel on vessels in
metric tonnes of grain on CSL Welland, Canada. Over the course of the tests this

PORTS & TERMINALS

breaking the previous record of 31,143 year, which were conducted on half of
metric tonnes. The cargo of wheat will be CSL’s Great Lakes fleet, CSL Welland was
discharged in Montreal, destined for able to achieve a lifecycle reduction of
international markets.
The 36,364dwt Trillium Class bulk
carrier is currently running on second
generation biodiesel made from non-food
biomass, adding to the significance of this
remarkable accomplishment.
“I commend Captain Rowe and his
crew, the Viterra team, the Port of Thunder
Bay, as well as our CSL teams on the
ground who contributed to this
achievement,” said Louis Martel, CSL
President and CEO. 6,800 tonnes of CO2 compared to marine programme has accumulated the most
“Safely maximizing cargo load on a ship gasoil (MGO). running hours on B100 with marine
depends on many factors such as load Across the entire Canada Steamship engines worldwide.
sequencing and distribution, draught Lines fleet, the CSL biodiesel programme Replacing fossil fuel with biodiesel on
restrictions, vessel weight, water level and has to date resulted in a 22% lifecyle vessels requires no modification of existing
weather. In collaboration with the Viterra reduction of CO2 compared to MGO. equipment and provides a viable carbon
team, we were able to plan for and make Introduced in 2018, CSL’s biodiesel neutral fuel source over its lifecycle.

Castellón to introduce further anti-dust screens

In Spain, Castellón Port Authority has
announced it is to increase the number of
dust collection screens deployed in the
port, which has significant dry bulk traffic.
It has issued a tender worth in the region
of €317,276 for a new anti-dust system to
be erected in the southern harbour. The
screen will consist of 20, five-metre high
modules, which will equate to a wall some
100 total metres in length, with an overall www.drycargomag.com
height of 11 metres.
PortCastelló already has three similar
screens in place: two of these are to be
found in the North Harbour, at the
Cerámica quay and on the Transversal
Exterior quay, and a third in the South
Harbour. These were set up at a cost of
€650,000 and are currently monitored and
evaluated by the Institute of Ceramic
Technology.
The decision to install anti-dust screens forms part of an 18 point environmental protection plan instigated by the port
authority as a means of reducing particle emissions. Nowadays, data collected from pollution monitoring is made available to the
NOVEMBER 2021

public via the port’s internet page. Data is drawn from five monitoring stations that give coverage of the entire perimeter. This
allows the authorities to know in real time whether anomalies occur and for action to be taken to ensure these are not repeated,
overall leading to better air quality.
The port authority has also approved a Code of Good Environmental Practices, which aims to regulate all dry bulk handling
operations carried out in the port area. Barry Cross
DCi

31
NEWS

Record fertilizer volumes arrive at

ABP Ipswich
PORTS & TERMINALS

Amid the current shortage of nitrogen fertilizer to Ipswich. We’d like to thank Our distribution hubs are located
fertilizer, ABP’s Port of Ipswich is bucking the ABP stevedoring team for their strategically around the UK, with help
the trend and seeing record amounts attention to detail in discharging our from ports such as ABP, to ensure the
arrive at its shores. vessel in good time and with great care. farmer gets what they need, when they
In October alone, seven vessels (four “Being able to ship such quantities need it.”
www.drycargomag.com

dry bulk and three tankers) carrying helps all involved in providing a Paul Ager Divisional Port Manager
59,450 metric tonnes of fertilizer safely competitive and essential fertilizer for East Coast said: “I am pleased that the
came through the port; up from 5,452 the UK farming community.” Port of Ipswich is playing an integral role
metric tonnes in October 2020. Last Andrew Butler – Commercial in the supply of fertilizer to our farmers.
month also saw the port’s largest single Director, South at OMEX Agriculture We are ideally located to support
fertilizer cargo received to date. said: “Market conditions this year have Britain’s breadbasket and I hope this
The year 2021 has born witness to been particularly difficult for fertilizer goes some way of returning confidence
strong demand for fertilizer and low suppliers; however, OMEX are for a strong spring yield.”
supply. The situation was made worse in committed to UK agriculture and our The Port of Ipswich is typically better
September when Britain’s two nitrogen team are working tirelessly to ensure we known as the UK’s foremost grain
fertilizer plants closed. have high quality product available for export port but recently fertilizer
Dave Blackmore, Director at our customers throughout Spring imports have taken over as the main
NOVEMBER 2021

Ameropa, the global experts in season. Our latest record deliveries into activities onsite. British supply is slowly
agricultural business practices ABP Ipswich mark a number of record returning but ABP ports will no doubt
commented: “Ameropa are delighted to achievements for OMEX, as the UK’s continue to handle large volumes of
work with our contract partners in largest ever vessel of liquid fertilizer fertilizer for the foreseeable future and
bringing a record-breaking cargo of arrived at ABP Immingham in September. support the British farming industry.
DCi

32
KEEPING
ABP’s 21 ports are at
the heart of the UK’s
green recovery:
Connecting the nations’
importers and exporters

BRITAIN
to global markets
Building sustainable
supply chains
Partnering in the growth
of renewables and the

TRADING
o昀shore wind sector
Handling £150 billion of
UK trade annually
Generating £7.5 billion
for the UK economy
Supporting 119,000 jobs

1
2

4
5

6
7
8
9
22 10

14 11
15
16 17 18

12

13
19 20

21

1. Troon 7. Goole 13. Ipswich

2. Ayr 8. Hull 14. Swansea
19. Plymouth
3. Silloth 9. Immingham 15. Port Talbot
20. Teignmouth
4. Barrow 10. Grimsby 16. Barry
21. Southampton
5. Fleetwood 11. King’s Lynn 17. Cardiff
22. Hams Hall Rail www.abports.co.uk
6. Garston 12. Lowestoft 18. Newport Freight Terminal [email protected]
NEWS
Port of Hamburg: good seaborne cargo handling
result for first nine months
PORTS & TERMINALS

In the first nine months of the year, at Hamburg accordingly further strengthened volatile for the rest of the year. “Delayed
95.8mt (million tonnes), the Port of its position as Europe’s largest rail port. ships’ arrivals plus the related delivery
Hamburg achieved a 2.9% increase in postponements also hit the ports. The
seaborne cargo throughput. Bulk cargo PORT OF HAMBURG SEABORNE CARGO problems of supply chains meanwhile out
throughput advanced especially strongly, THROUGHPUT IN THE FIRST NINE MONTHS of synch will continue to be apparent at the
being 6.1% ahead at 29.7mt. Totalling OF 2021 land/sea transport interface. Despite
66.1mt, in the first three quarters general Throughput of containerized general cargo providing 24/7 service, for the terminals a
cargo throughput was a modest 1.6% in the first three quarters of 2021 totalled fraught situation will persist on vessel
ahead. The upward trend was also 65.2mt, representing a gain of 1.5%. At clearance,” said Mattern.
www.drycargomag.com

maintained on container handling. A total 908,000 tonnes, conventional general cargo “Partly since the beginning of the year,
of 6.5 million TEU — 20-ft standard was up by an emphatic 5.2%. In the large sections of industry have suffered
containers — were hoisted across the quay container throughput sector, exports, 2.9% bottlenecks on deliveries. Despite full
walls of Hamburg’s container terminals, a up at 3.2 million TEU, outperformed order books, this can hamper production,”
2.4% gain. imports, just 1.9% higher at 3.3 million TEU. added Egloff.
Despite this positive throughput trend, Growth in bulk cargo throughput is The ifo Institut puts German industry’s
the Port of Hamburg was not yet able to primarily attributable to the strong trend in forfeited added value on account of
fully overhaul last year’s downturn caused the grab cargo segment. Ore and coal delivery bottlenecks at almost 40 million.
by Covid-19. Axel Mattern and Ingo Egloff, imports led to growth there of 17.8% to Having previously put fourth-quarter
HHM – Port of Hamburg Marketing’s Joint 16.3mt (million tonnes). Up 0.9% at 8.7mt, growth at 1.3%, the institute now reckons
CEOs, are therefore especially pleased that liquid cargo throughput was stable. In the with just 0.5%.
pre- and post-voyage railborne container suction cargo segment, at 4.7mt, or –15.1% Despite the current situation, the Port
NOVEMBER 2021

transport set a new record at 2.1 million lower, throughput of grain and oleaginous of Hamburg’s marketing organization
TEU. “That represents an 8.3% advance,” fruits was below the previous year’s strong reckons on continuation of the slight
stressed Egloff. “At 709,000 TEU, the Port total. upward trend in seaborne cargo
of Hamburg posted the highest quarterly throughput during the fourth quarter.
total in its history for containers FURTHER OUTLOOK FOR 2021 For the Port of Hamburg, total
DCi transported,” added Mattern. The Port of Worldwide transport chains will remain throughput of around 130mt and 8.7

34
 NEWS
Riga now a major centre of forestry products
Three-quarter figures released by the Port Viesturs Zeps, Chairman of the Freeport of
of Riga indicate that it handled 15.2mt Riga Board, shippers overseas choose the
(million tonnes) of cargo up to the end of port because of its tariffs, cargo handling
September. Indeed, this final month efficiency, inland connections, geographical
registered growth of 8% compared to the location, infrastructure, as well as for the

PORTS & TERMINALS

same month last year. range and quality of services it offers.
Nowadays, the port has become a major The port also points to its cargo quality
portal for the handling of forestry inspection service as one of the major pull
products, reporting throughput in this factors for dry bulk cargo. Inspectors,over
commodity of 4.6mt, equivalent to a rise of the years, have tested more than 300mt of
10% compared to the same period in 2020. various commodities, including coal, solid
In addition, 2mt of total volume handled of the grain cargo handled by the port biofuels, manganese and ore, ferrous alloys,
was generated by grain and grain products, came from other countries, most notably as well as grain, oilseed and bean crops.
also up 10% on last year. Significantly, 32% Lithuania, Russia and Estonia. According to BC

TransContainer to move coal by container

Delo Group company PJSC products via border crossing points at quality and reliable service and to ensure
TransContainer and JSC Siberian Coal Zamyn-Uud (in Mongolia) and at the development of export transport
Energy Company (SUEK) have signed an Grodekovo (in Primorsky Kray). from Russia to China.
agreement to develop ways of exporting TransContainer president Aleksandr “We are confident that the signing of
coal in containers. Consignments, which Isurin noted, “The transport of coal in this agreement will allow us to find the
will be shipped via the Zabaykalsk border containers will make it possible to optimum transport solutions for our
crossing point to China, could amount to optimize the use of [existing] infras- business […] and have a positive impact
more than one million tonnes annually. tructure capacity.” on the development of SUEK’s products
For its part,TransContainer will also look This, he stresses, will allow the by rail,” said SUEK CEO Stepan
into the possibility of dispatching SUEK’s company to offer its partner a high- Solzhenitsyn. BC

Rail now accounts for half of São Francisco do Sul’s grain movements
The growing importance of rail to ship grain
can be seen at the Brazilian Port of São
Francisco do Sul. Each year, the port handles
around 700 block trains, most of which
transport consignments of soya or corn. On
average, this amounts to three million tonnes,
which is half of all export grain volume
accounted for by the port annually. Remaining www.drycargomag.com
shipments are undertaken by the road haulage
industry.
The majority of grain being handled comes
from the surrounding states of Santa Catarina,
Paraná and Mato Grosso do Sul and arrives at
the port via the 170km rail link from Mafra, in
the North Plateau of Santa Catarina.
At Corupá, some 80 kilometres from the
port, the transshipment and distribution of
wagons bound for São Francisco do Sul is
carried out. Average block train speeds are
modest, with most running at 25–30
NOVEMBER 2021

kilometres per hour, meaning that this journey

takes about two and a half hours. Most trains load to 80 wagons, each holding around 50 tonnes.
On a normal year, around 57,000 wagons enter the port. These are then unloaded at one of three locations: at the grain terminal
which is managed by the port authority, or at two privately managed terminals, run by Terlogs and Bunge respectively.
However, rail infrastructure oversight within the port remains the responsibility of the port authority. According to port president
Cleverton Vieira, the main investment has been primarily in optimizing train unloading to increase handling efficiency. BC DCi

35
 REGIONAL REPORT
A ship from Norway unloads 38,267 tonnes of
crushed stone on the Quay of Saint-Wandrille
for the company Stema.

Belgium & France

Regional Focus

Jay Venter

Regular investments keep HAROPA PORT | Rouen competitive

On 30 June 2021, dry bulk traffic was down represented 75,000 tonnes at the end of Canteleu-Croisset terminal. Soufflet
in Rouen. This is largely due to the decline June 2021, against 80,000 last year. On the Négoce’s investment amounted to €10
in cereal exports, which have fallen by 39%. whole of the Seine axis, coal traffic million, with the installation of a new
The low French production recorded in amounted to 127,000 tonnes at the end of loading gantry and the adaptation of
2020 and the comparison with a record June 2021, a result that is clearly down. handling equipment, and came in addition
2019–2020 cereal season explain this drop, These products will continue to decline in to the work carried out by the Port of
despite the good quality of the cereals. tonnage due to the energy transition. Rouen for an amount of €7.8 million in
However, over the first six months of 2021, Conversely, biomass traffic (wood energy) order to bring the terminal up to the level
the port of Rouen still exported 3.4mt is continuing to position itself on the Seine of the new channel draught.
(million tonnes) of cereals, a result that is axis. The development of this sector is Simarex has completed its programme
within the ten-year average recorded by based on the needs of the industry and to renovate the storage domes scheduled
the port establishment. Soft wheat urban heating systems, which have for the last three seasons (€5.3 million)
represents the bulk of exports, and barley switched to this product. and has invested in automated tools to
is on the increase with 30% of the total Exports of wood chips to Sweden guarantee the superior quality of the
tonnage. continued with 12,000 tonnes during the cereals loaded and to comply with HACCP
A strong presence from China was first six months of the year. Snow removal regulations.
noted, for both soft wheat and barley salts totalled 42,000 tonnes in imports. Finally, the port operators Sea Invest
exports (brewing and feed). Attapulgite (clay) traffic remains stable with and Surveyfert have built new warehouses
The port of Rouen is characterized by a 25,000 tonnes. The same trend applies to for the storage of dry bulk goods,
great diversity of agricultural products peat (vegetable earth). representing 16,000m2 of additional
(malt, cocoa beans, oilseeds, pitch, beans, storage space. In Grand-Couronne, Sea www.drycargomag.com
oilcake, pulp, etc.). Also in the first half of PORT EXPANSIONS Invest is investing €10m in its terminal with
2021, rapeseed imports are increasing in HAROPA PORT: Rouen has carried out the construction of a 6,700m² warehouse
order to meet the demand of biofuel works on the Quai de Petit-Couronne that will be operational from June 2021
manufacturers. where Surveyfert (fertilizers), Groupe BZ (€5m). The facility is intended for the
At the end of June, the flow of (cereals) and GDE (scrap metal) are storage of dry bulk goods, including wood
aggregates transiting through HAROPA located. The works have made it possible pellets. Sea Invest will also build a 9,000m²
PORT’s river and sea terminals to lengthen the berthing front, which now warehouse on the quayside in Grand-
represented 1.15mt, i.e. an increase of offers an additional 30 metres of linear Couronne by 2022 (€5m) for wood
+39.1%. The sector is benefiting from the space on the quayside. Two new dolphins pellets, biomass and solid fertilizer.
Greater Paris works and the launch of were installed to facilitate ship
construction sites for the Paris 2024 manoeuvres. As an extension to this THE HAROPA ADVANTAGE
Olympic Games facilities. project, the Rouen territorial management The competitiveness of HAROPA PORT |
Solid fertilizers are down. The has scheduled work to deepen the quay Rouen is the result of the know-how and
AUGUST 2021

production stoppage for maintenance at downstream for 2022. regular investments of the port’s
the Borealis plant in Grand-Quevilly for operators, who are capable of handling all
three months and high prices explain this DURING THIS FIRST SEMESTER, THE CEREAL types of goods and packaging. The
unfavourable situation. OPERATORS CONTINUED THEIR INVESTMENTS: completion of the improvement works on
In Rouen, coal and petroleum coke Soufflet-Socomac modernized its the maritime accesses to the port of DCi

37
REGIONAL REPORT

Rouen, effective in the summer of 2019, has

significantly improved the competitiveness
of the port of Rouen with the gain of one
metre of draught. Panamax vessels, the
most commonly used for grain transport,
can now load up to 55,000 tonnes in
Rouen, compared with 45,000 tonnes
previously.
HAROPA PORT is continuing to install
electrical terminals on the quays to supply
the river units. Equipment has been
operational in Paris, Rouen and Le Havre
since 2018 and new bollards are being
installed. The next stage in this programme
to electrify port terminals will concern
maritime cruise ships. Studies have been
launched to equip the quays and terminals
dedicated to the handling of dry bulk For several years, coal imports have been on a
downward trend as a result of the energy transition.
cargo.
HAROPA PORT is investing and acting
in order to develop bulk flows, in particular This objective is taking shape with Delta terminals by waterway represents 27% of
by setting up an incentive system for Rail, which has launched a shuttle between the final tonnage. Voies Navigables de
shippers to turn to rail or waterway Le Havre and Chalon-sur-Saône to make France (VNF) has started the
transport. The objective is to consolidate the Saône river port a hub between the modernization of its infrastructure in the
and develop the share of rail and river Channel and the Mediterranean. For its Seine basin. Locks and other structures
transport on the Seine axis. part, the combined transport operator, are being modernized in order to make the
Indeed, the massive modes currently Naviland Cargo, has increased the transport of goods by river more fluid. The
represent about 15% of HAROPA PORT’s frequency of its connections between Le rail mode’s share of pre-routing is
modal share, including 5% for rail and 10% Havre and Bordeaux. Rail rotations have stagnating, but the commissioning of the
for waterways. The long-term objective is been increased from six to seven per SNCF Serqueux-Gisors line should
to reach the threshold of 20% of massified week. increase the number of train paths and
modes. Pre-routing of cereals to the Rouen thus the offer available to operators.

Two turnkey industrial facilities on port land

Le Havre’s Grand Canal and Eco- Photo: André Wipff / Zeppeline.fr.
Normandie Business Park have been
awarded an official label by the government
and are now ready to welcome new
industrial and logistics activities within
shorter timeframes.
“This government label not only throws
a spotlight, but also provides a marvellous
boost, because setting up a new industrial
operation or a logistics platform can take a
www.drycargomag.com

great deal of time. By getting ahead of the

official procedures and technical studies,
we are in a position to offer investors
two sites ideally located for the potential
development of new activities on our
land, in addition to new jobs,” explains
Edouard Philippe, Chairman of the Le
Havre Seine Métropole urban and district
authority. Early completion of the site diagnostics and an area of approximately 30 hectares in the
“The label awarded to Le Havre’s Grand our commitment to the development of a industrial/port area with many utilities
Canal reflects the major ability of our local high level of services are key to success in already in place (potable and industrial
area to mobilize and constantly reinvent setting up a large-scale project,” explains water, electricity, gas, steam).
itself. Indeed, HAROPA PORT, with the HAROPA PORT CEO Stéphane Raison. The Eco-Normandie Business Park in
AUGUST 2021

support of its local partners, has proved Saint-Romain-de-Colbosc is ideally placed

itself capable of making this former cement OVER 50 HECTARES AVAILABLE FOR NEW right next to the A29 motorway and the
production facility a site that is ready for ACTIVITIES industrial areas of Le Havre and Port-
the setting up of a new type of activity The Grand Canal land in Le Havre, which is Jérôme with 22 hectares available for
DCi within a unique industry/port ecosystem. under HAROPA PORT ownership, offers setting up new activities.

38
 REGIONAL REPORT
Port of Antwerp records growth in all segments
After nine months, Port of Antwerp conventional breakbulk segment and even SUSTAINED GROWTH FIGURES FOR REEFERS
records a total throughput of 179.1 million the best month since June 2011. RoRo is The number of reefer containers grew by
tonnes, a rise of 4.8% compared to last up 18.2% compared to the same period in 3.6% compared with the same period last
year and the same level as 2019. Despite 2020. In addition to the increased handling year. Reefer containers contain fresh
the still persevering operational challenges, of commercial vehicles, wood and building products including fruit, vegetables, meat
all goods flows are recording growth. materials are also notable risers. and fish, pharmaceutical products and
“This year, we are reaffirming and Container traffic continues to enjoy chemicals. Last year, the port already
strengthening our market position. The continuous growth, increasing 2.3% in exceeded the worldwide growth in the
growth figures, for all segments, are proof tonnes (105.4 million tonnes) and 2.8% in reefer market with a total volume of one
that our resilience allows us to turn TEUs (9,100,620 TEUs) after nine months million TEU of reefer containers. This
challenges into opportunities,” says Jacques compared to 2020. trend is clearly continuing, and with it the
Vandermeiren, CEO, Port of Antwerp. Annick De Ridder, port alderwoman port of Antwerp is consolidating its role as
said, “Despite continuing operational an important player in the reefer segment.
GROWTH IN ALL SEGMENTS challenges such as disrupted container
Dry bulk throughput is up by 9.3%. The liner shipping, pressure on the terminals
growth in fertilizers (+25%) and scrap due to the pandemic and delays, we
(+13.5%) play a significant role in this continue to record growth in all segments.
regard. Despite a sharp drop in the What is more, September was an
handling of crude oil (–68.5%), the handling exceptionally good month for breakbulk,
of liquid bulk increased by 2.2% thanks to reflecting the hard work of all employees.
the strong performance in the chemicals These figures once again confirm the
segment, which grew by 9.8% and of oil resilience of our port and the flexibility of
derivatives which did 4% better than the everyone who ensures that our port
previous year, mainly due to an increase in continues to operate.”
non-fuel related derivatives and energy
gases. SEAGOING VESSELS
Conventional breakbulk has grown by In the period January–September, 10,608
62.7%, primarily due to the strong growth seagoing vessels called at Antwerp,
in steel trade (+65.9%). September was representing a rise of 3.6% compared to
the best month of the year for the the same period in 2020.

Yara and Geldof reunites for quay belt renewal

www.drycargomag.com

A few years after its successful ABOUT GELDOF builder of high quality equipment for the
collaboration, Yara has chosen Geldof for Geldof is an engineering fabricator/ storage and handling of bulk materials,
the renewal of 190m of quay belt, contractor and full scope solution provider combined with its innovative process
where Yara wants to increase transport for the storage, handling and processing of knowhow and proven technologies.
capacity but also improve safety and bulk solids, liquids and gasses. Geldof teams up with its customers to
cleanliness. find the best solutions and to apply the
This quay belt transports nitrate DRY BULK STORAGE & HANDLING best practices, be they mechanical
granules from the tower to the shiploader Geldof offers turnkey solutions for the constructions, civil engineering works,
by means of tripper car that can move over conceptualization, the engineering and the electrical and instrumentation, integrations
the full length. realization of custommade projects in of machinery or other challenges. Using
AUGUST 2021

The installation is built completely in materials handling. It is a reputable and this open and full scope approach, the
stainless steel and this within a very tight reliable partner for all projects that it company develops pioneering devices
time schedule for engineering, production undertakes. The company is confident in which it modulates into new and
and assembly. this claim, which it confidently bases on its independent installations with proven
long-standing track record as a respected technology. DCi

39
REGIONAL REPORT

ArcelorMittal Ghent takes the next step towards producing zero carbon-
emissions steel by replacing fossil coal with Perpetual Next’s bio-coal
ArcelorMittal Ghent has taken an
important step in its decarbonization
journey by choosing to use high-quality
bio-coal as a raw material for its steel
production process. Until now, fossil coal
was mainly used in steel production to
extract iron from iron ore, among other
things.
ArcelorMittal Ghent is starting a pilot
project to use bio-coal as a high-quality
partial replacement for fossil coal. The bio-
coal is being responsibly sourced from
Dutch company Perpetual Next, which
produces the bio-coal using its patented
high temperature torrefaction technology.
The partnership with ArcelorMittal in
Ghent starts with an initial delivery of
30,000 tonnes of bio-coal to the Ghent
blast furnace, which can be scaled up to will do this step by step in a responsible sites in Ghent, Liège, Genk and Geel,
350,000 tonnes of bio-coal on an annual way, and today’s announcement is one such employs 5,000 people. The total direct and
basis. step – partially replacing fossil carbon with indirect employment is estimated at 30,000
bio-coal. Perpetual Next’s torrefaction jobs.
NEED FOR CHANGE technology is a perfect fit with our XCarb® The company produces high-quality
Global steel production was 1.86 billion program which brings together all of steel for the most diverse applications in
tonnes for the year 2020, 70% of which ArcelorMittal’s reduced, low and zero- the automotive sector and other industrial
was produced in blast furnaces using fossil carbon products and steelmaking activities, sectors such as the green energy sector,
coal. Steel demand is expected to double as well as wider initiatives and green construction, white goods, packaging, etc.
from current levels by 2050, which could innovation projects, into a single effort The company’s goal is to help build a
lead to a doubling of CO2 emissions with focused on achieving demonstrable better world with smarter steels. Steels
unchanged policies. This underlines the progress towards net-zero steel.” made using innovative processes which use
need for change: compared to using fossil Martijn van Rheenen, CEO, Perpetual less energy, emit significantly less carbon
coal, 2.5 tonnes of CO2 are saved per Next, adds, “With the application of our and reduce costs. Steels that are cleaner,
tonne of bio-coal. technology for ArcelorMittal in Ghent, we stronger and reusable. Steels for electric
are opening up a new industry to help vehicles and renewable energy
TORREFACTION make it more sustainable. The bio-coal has infrastructure that will support societies as
Perpetual Next’s torrefaction technology such high-quality properties that it offers a they transform through this century.
converts biomass produced from Forest partial replacement for fossil coal in
Steward Council (FSC) certified forests applications such as the steel industry’s ABOUT PERPETUAL NEXT
into bio-coal with the same properties as production process. In addition to The mission of Perpetual Next is to
fossil coal. With this technology, the raw reducing ArcelorMittal’s own CO2 prevent further climate change by reducing
materials are converted into bio-coal emissions, this step gives ArcelorMittal’s CO2 emissions and capturing and storing
www.drycargomag.com

through a thermal refining process. This clients the opportunity to reduce their so- CO2 for its customers. Perpetual Next
creates a relatively affordable renewable called scope 3 emissions, in line with the achieves this by preventing waste and
raw material with high energy density. The EU Fit for 55 programme presented by upgrading organic waste streams to high-
patented technology is owned by Perpetual Frans Timmermans, European quality raw materials and products with
Next, which supplies high-quality coal from Commissioner and Vice-President of the the use of leading technology. The
its own production facilities, as well as the European Commission, on 14 July.” company is organized into three divisions:
technology, including the torrefaction Trading, Conversions and Technologies.
reactors. ABOUT ARCELORMITTAL & For the storage of CO2, Perpetual Next
“ArcelorMittal Belgium has the ARCELORMITTAL BELGIUM pursues an active reforestation policy. In
ambition to decarbonize its steel ArcelorMittal is a prominent global steel 2021, in the countries where Perpetual
production faster and deeper than and mining company, with a presence in 60 Next is active, at least one million trees will
required by the Paris Agreement.,” says countries and primary steelmaking facilities be planted in favour of reforestation.
Manfred Van Vlierberghe, CEO, in 17 countries. In 2020, ArcelorMittal had With its activities, Perpetual Next
AUGUST 2021

ArcelorMittal Belgium. He continues “We revenues of $53.3 billion and crude steel generates carbon credits, which are a
do not only want to reduce our carbon production of 71.5mt (million metric fundamental part of its business model.
footprint, but also our waste footprint — tonnes), while iron ore production reached Perpetual Next has linked its mission to
our steel company has a roadmap towards 58.0mt. the UN Sustainability Development goals,
DCi zero carbon emissions and zero waste. We ArcelorMittal Belgium, with production the ESG criteria and the EU Green Deal.

40
Thermal solar power plant for sustainable malting at Boortmalt, Issoudun

REGIONAL REPORT
Sustainable energy: the Boortmalt malting years to come. step towards more sustainable production
plant at Issoudun, Kyotherm and ADEME in is a further step towards meeting the
September 2021 officially announce the SUSTAINABLE DEVELOPMENT: A PILLAR OF expectations of our customers, and
commissioning of the site’s solar thermal THE AXEREAL COOPERATIVE MODEL ultimately of consumers,” says Paul-Yves
power plant, the largest facility of its kind “The Issoudun malting plant, the historical L’Anthoën, Axereal Group CEO.
supplying an industrial site in France. processing site for the cooperative’s malt
First there was cogeneration and activities, has played an essential role in our MAKING THE REDUCTION OF THE CARBON
biomass, and now the Boortmalt malting industrial development. Over the years, it FOOTPRINT A PRIORITY www.drycargomag.com
plant in Issoudun can draw on solar has been able to keep pace with changing Producing malt in a sustainable way
thermal power for its heating needs. On times and incorporate cutting-edge requires a daily commitment to continuous
20 September 2021, the site inaugurated a technology for increasingly sustainable malt improvement. Reducing energy
solar thermal power plant covering an area production. Today, it perfectly embodies the consumption and emissions is one of
of 14,252m2, third-party financed by dynamics of our forward momentum, as we Boortmalt’s four main objectives for
Kyotherm with the support of ADEME. aim to accelerate agricultural and food sustainable development, along with water
The facility generates 8.5GWh of transition,” declares Jean-François Loiseau, conservation, sustainable agriculture, and
sustainable, low-carbon heat per year, Chairman of the Axereal Group. This large- health and safety issues. “Our goal is to
representing around 10% of the site’s scale facility is representative of the Axereal reduce CO2 emissions by at least 50% by
needs. Group’s overall sustainable development 2030 across Boortmalt’s activities
This facility will make it possible to strategy. “We aim to increase our worldwide, in line with the Paris climate
avoid the annual discharge of 2,100 tonnes profitability, in particular by focusing on the agreements,” states Yvan Schaepman,
of CO2 into the atmosphere, or the annual structuring of our channels. Boortmalt CEO (malting subsidiary of the
AUGUST 2021

equivalent of the emissions from 1,050 Environmentally friendly-production, high Axereal group). For several years,
cars. Thanks to this new facility, 50% of the environmental value, low-carbon channels Boortmalt has been investing in alternative
heat needed to run the malting plant now and new generation grain storage are all energy sources to reduce its carbon
comes from sustainable sources. This topics in which we are assuming a leading emissions and limit its consumption of
proportion is destined to increase in the role, as well as in many other areas. Each fossil fuels. DCi

41
REGIONAL REPORT

Scrubber overboard pipe repairs in the Netherlands

Corroded scrubber pipes on bulker. The affected area was ground out. Inside of pipe coated with Ecospeed to prevent
further corrosion.
Hydrex was asked to assist with the three Hydrex welder installing reinforcement shell.
corroded scrubber overboard pipes of a
292-metre bulker. The ship was not
allowed to sail to drydock without a repair.
Hydrex immediately sent a dive team to
the bulker’s location in Ijmuiden, the
Netherlands for a temporary solution.
Exhaust scrubbers are systems that
filter out all harmful toxins from exhaust
gasses of marine diesel engines. These
can severely corrode the pipes of the
scrubber which can result in water ingress
if not handled quickly enough. For this
reason the classification society requires
regular thickness measurements to be
performed.
The latest inspection had revealed that
the three pipes were heavily corroded and
needed to be repaired. The ship was sailing
to drydock where the pipes would be
replaced, so a fast temporary solution was
required.

FAST MOBILIZATION
A team travelled to the bulker’s location in
Ijmuiden. After arriving at the ship they
first performed an inspection of the
damaged areas on both the waterside and
the onboard side of the hull.
Hydrex’s diver/welders then sealed off
the outlets of the overboard pipes with
www.drycargomag.com

custom cofferdams designed and

constructed at the company’s workshop.
This allowed for work inside the engine
room without water ingress.
The team ground away the affected area
before rebuilding it back to its original
thickness. To give extra protection during
the trip to drydock Hydrex’s men installed
reinforcement shells around the pipes. also be used to coat the replacement pipes permanent repair that can be done while
When the welding was complete the before they are installed in drydock. This the vessel stays afloat.
surface was cleaned and an MPI was will make sure that the owner will not have If a pipe is already starting to corrode a
carried out by an independent inspector. to call Hydrex again for the same problem. leak is just a matter of time. One does not
The inside of the pipes was then coated have to wait until it is fully corroded,
AUGUST 2021

with Ecospeed to keep them safe from PREVENTATIVE MAINTENANCE Hydrex can also replace pipes
further corrosion. In this case a drydock visit had already preemptively. By performing the
This product is produced by Hydrex been planned and a temporary repair was replacement before the leak occurs,
sister company Subsea Industries and is needed, but Hydrex’s teams can also Hydrex’ divers prevent a costly
DCi highly chemically resistant. Ecospeed will replace a corroded exhaust pipe. This is a unscheduled repair later. DCi

42
 NEWS
New Bedeshi project for ORANO Group
As part of a project to extend the PAD for heap leaching in Arlit on behalf of the
company SOMAIR (Niger) — a subsidiary of the ORANO group (France) —
Bedeschi is responsible for carrying out the engineering work and the mechanical
and electrical supply of all transport and stockpiling equipment.
The challenge of this project was to provide machinery which is compatible

ENGINEERING & EQUIPMENT

with the existing equipment.
The list of provided equipment is:
v fixed tripper car for the connection between the existing overland conveyor
and the new BEDESCHI overland conveyor, which is 980m long and 800mm
wide;
v an overland conveyor designed to load a mobile tripper car on wheels;
v a mobile bridge conveyor on pneumatic wheels for the connection between
the existing mobile tripper car and the 15 other existing mobile link
conveyors; and
v the entire electrical part (MV / LV transformation, cables, cable ducts).
Bedeschi also provides the technical assistance for the assembly and
commissioning phase.

The correct way to store conveyor belts CONVEYING

The on-site storage of conveyor belts is an important subject which is often neglected. Even ADVICE
large industrial conveyor belts can be damaged if they are not stored or handled correctly.
Fortunately, the ‘rules’ are quite straightforward. The first thing to take care with is the actual
off-loading of the belt rolls onto your premises. When off-loading rolls or drums of belting, always use skids or a crane. Never
allow the roll to be dropped or rolled off the transporter. The same applies when moving the belt to its final location where it
will be installed. In terms of the actual storage environment, the ideal place to store conveyor belts is preferably under covered
shelter such as a warehouse because there are a number of factors, as detailed below, that can have a detrimental effect on the
belting. However, it is appreciated that covered storage is not always possible or certainly available only on a limited basis.
v Position: unless damaged in transit, the belt should be stored in the manufacturer’s packing in an upright position until
required for use.
v Storage temperatures: the ideal ambient storage temperature falls within the range of 10–20ºC. Prolonged exposure to
temperatures below 0ºC (freezing point) or in excess of 30ºC should be avoided. www.drycargomag.com
v Exposure to ozone & ultraviolet light: it is
strongly recommended that the belt is kept
covered as much as possible. Retaining original
packaging materials such as wooden drums, hessian
and cardboard is a good idea because they provide
some protection against external influences.
Storage in motor-control rooms, welding shops,
and other places where ozone is generated should
be avoided.
v Humidity: belts should not be stored in excessively
wet, humid environments.
v Contamination: avoid storing belts in areas that
NOVEMBER 2021

also oils, gasoline, solvents, paint materials, acids,

and corrosive liquids.
Dunlop Conveyor Belting

DCi

43
NEWS

Cargotec and Konecranes announce planned high-level operating

model and leadership team for the Future Company
As announced earlier, Cargotec and global talent. The Future Company’s MARITIME BUSINESS
ENGINEERING & EQUIPMENT

Konecranes will merge to create a global designed high-level operating model Cargotec’s current MacGregor business
leader in sustainable material flow. The would be a customer-centric model as would continue to serve shipbuilders,
merger is expected to take place by the the planned four independent businesses shipowners and operators with a strong
end of H1/2022, and Cargotec. In early would each serve one clear customer portfolio of products, services and
November, Konecranes announced the segment: industrial, maritime, ports and solutions.
planned high-level operating model and roads.
leadership team of the Future Company. After the completion of the merger, PORTS BUSINESS
“The planned high-level operating the Future Company is planned to The Future Company plans to create a
model of the Future Company is the consist of the following businesses, with new business by combining Cargotec’s
result of months of integration planning their leaders being members of the Kalmar and Konecranes’ Port Solutions
work and the benchmarking of best Future Company leadership team and to be a true lifecycle partner for port
practices across various industries, and reporting to the Future Company and terminal customers, capturing
the selection of the planned leadership President and CEO Mika Vehviläinen. technology, innovation and scale benefits
team is the result of a rigorous selection The naming and branding of the to deliver end-to-end material handling
process. Today marks a major step planned businesses is part of the solutions including equipment, software
forward on the road to creating a global integration planning work and is and services.
leader in sustainable material flow, and currently ongoing.
I’m confident we will have the right ROADS BUSINESS
leaders to unlock that potential,” said INDUSTRIAL BUSINESS Cargotec’s current Hiab business would
selected Future Company President and The Future Company plans to combine continue as a world’s leading provider of
CEO Mika Vehviläinen. Konecranes’ Service and Industrial on-road load handling equipment,
The Future Company aims to be a Equipment Business Areas to strengthen intelligent services and smart and
customer-centric organization of top the position as a global lifting leader. connected solutions.

Kinder Australia’s K-SkirtSupport System for conveyors

The K-SkirtSupport System from Kinder The K-SkirtSupport System mounting kit is support, this innovative system engineered
Australia has been engineered to supplied in a flat pack for more economical by the team at Kinder Australia is the
specifically accommodate Kinder’s shipping. When it comes to giving sufficient perfect fit — adaptable, precise, efficient.
comprehensive internal and
external conveyor skirting
solutions range. It is an ideal
perfect addition to ensure that
adequate support is provided
for all bulk material handling
industries.
A galvanized bolt-in system
www.drycargomag.com

that requires no welding

during installation, the
K-SkirtSupport System is
supplied with fixtures and bolt
hole drillings for accurate, easy
and fast installation.
A variety of options are
available depending on the
application needs.
The K-SkirtSupport
System:
v is suitable for the addition
NOVEMBER 2021

of K-AllShelter® Capotex
conveyor covers;
v is available in a range of
belt widths; and
v is available as stainless steel
DCi or painted options.

44
NEWS
4B releases ATEX-version of Milli-Temp 4-20 mA bearing temperature sensor
4B has just launched an ATEX version of its lubrication of the bearing without the need 4B Milli-Temp sensor.
popular Milli-Temp, a loop-powered to remove the sensor.
analogue sensor with a 4-20 mA linear The sensors are supplied with a 3m
output that is scaled across a temperature cable. The connections are not polarity
range for continuous temperature sensitive therefore special connection
ENGINEERING & EQUIPMENT

monitoring. requirements are eliminated, and the cable

The Milli-Temp series can be used on can be extended in the field.
any application where bearing temperature ABOUT 4B GROUP
monitoring is needed. PRODUCT HIGHLIGHTS A subsidiary of The Braime Group, 4B
The sensor has been designed to allow v One Body Design — provides a GROUP has been an industry leader in
the depth of the probe to be adjustable 4–20 mA output provided directly from developing high quality, innovative, and
depending on the application. the sensor, eliminating the need for an dependable material handling components
This adjustability allows the tip of the external transmitter; for the agricultural and industrial sectors.
probe to be placed in the optimal position v rated to –40°; Its product line ranges from elevator
for monitoring bearing temperature and v small probe diameter allows easy grease buckets, elevator bolts and drop forged
also enables verification using the 4B ADB flow; conveyor chain to level monitors, speed
Tester. v probe lengths 50mm, 75mm, 100mm, switches and hazard monitoring systems.
The sensor screws directly into the 150mm, 200mm; With offices in North America, Europe,
bearing housing using the threads of the v approved for explosive atmospheres: Asia, Africa and Australia along with a
existing grease zerk. The body of the ATEX and IECEx Zones 20, 21 & 22 for worldwide network of distributors, 4B can
Milli-Temp has an integrated zerk, allowing dust provide practical solutions in any location.

Phoenix Lighting reports multiple North

American crane lighting projects won this year
Phoenix Lighting continues to supply by ZPMC and fully equipped with
lighting for the North American ship-to- Phoenix’s LED lighting. The lighting
shore and yard crane lighting market as systems on these cranes include
the company reports multiple projects customized EcoMod® 2 floodlights and
won this year. Cube-Light and HDL fixtures for
Ports America Chesapeake walkway and engine room lighting.
welcomed four super-post Panamax As more North American ports look
cranes for Port of Baltimore’s Seagirt to improve their infrastructure and
Marine Terminal this year, manufactured achieve greener operations, they
by ZPMC and fully equipped with continue to look to Phoenix Lighting to
Phoenix’s LED lighting. The new ship-to- accelerate these initiatives with proven
shore cranes are capable of handling two LED lighting engineered specifically for
14,000 TEU vessels simultaneously. The Konecranes and completely fitted with ports and terminals.
LED lighting system on the massive Phoenix’s LED lighting. Georgia Ports While these contracts all relate to
cranes include Phoenix’s EcoMod® 2 Authority and Phoenix Lighting have a container shipping, Phoenix Lighting’s
www.drycargomag.com

floodlights and Wayfinder™ walkway strong history, dating back to 1996 when solutions can equally be applied in dry
lights. Port of Baltimore is also awaiting its first cranes arrived with Phoenix cargo handling operations where
delivery of eight new RTGs lights. Now both ship-to-shore and RTG effective lighting systems are required.
manufactured by Kalmar that are fully cranes use Phoenix LEDs including the
fitted with Phoenix’s LED fixtures. With EcoMod® 2 for floodlighting and ABOUT PHOENIX LIGHTING
100% energy-efficient LED lighting on Wayfinder™, HDL and ReadiLED™ Phoenix Lighting is the trusted authority
the cranes, Ports America Chesapeake fixtures for engine room and walkway in LED lighting for container handling
strengthens its commitment to lighting. cranes, container yards and cargo
environmentally sustainable operations Other crane lighting projects facilities that want to achieve safe and
and a safer work environment. awarded to Phoenix this year include efficient nighttime operations. Cranes
Georgia Ports Authority has Port of Houston Authority, the Gulf’s fitted with its durable floodlights
expanded its Port of Savannah to better largest container port that has had a eliminate costly maintenance disruptions
NOVEMBER 2021

accommodate increased volumes and record year for the volume of containers while increasing productivity and safety.
demand for their services. As part of the handled. Port Houston has looked to Phoenix’s full-service solution for yard
expansion this year, Savannah purchased improve its infrastructure at Bayport lighting maximizes security and safety
eight new ship-to-shore cranes and 18 container terminal and purchased three with superior fixtures and advanced
RTG cranes, manufactured by new ship-to-shore cranes manufactured wireless lighting controls.
DCi

46
 NEWS
Game-changing electric cranes
ordered for ABP Port of Ipswich

ENGINEERING & EQUIPMENT

Existing cranes at
ABP Ipswich.

Associated British Ports (ABP) has further reduce energy. This model will “At ABP, we have firm plans to
announced that its blue cranes at the replace the diesel-powered version and decarbonize our ports. We know
Port of Ipswich will soon be turning will improve ABP’s cargo handling greener operations are important to our
green. A new supply contract with service to its customers. customers too and we are listening.”
Cooper Specialised Handling has been The port already has some 4,000 Speaking on behalf of Cooper www.drycargomag.com
agreed which will deliver some of the solar panels installed onsite which could Specialised Handling, Executive Director,
first fully mains electric-powered power the two new cranes. ABP have David Cooper commented: “This is truly
hydraulic cranes in the UK to the port. also invested in an electricity sub-station a landmark supply and hope this is the
This £4 million investment is another infrastructure that is future-proofed to first of many. We congratulate ABP on
step in ABP’s companywide policy to accommodate up to four electric their foresight and vision in opting for
reduce CO2 emissions and energy powered cranes working concurrently electric power. We have noticed a
consumption. The company expects all on the same quay. significant increase in interest in both
cargo handling operations at the Port of Commenting on behalf of ABP Paul direct electric power and Mantsinen’s
Ipswich to be fully electrified within the Ager Divisional Port Manager East Coast dual power (electric and diesel in one
next five years. said: “This investment shows that going machine) however, infrastructure costs
The Mantsinen model 95ER is green does not cost the earth. In become a barrier that often thwarts
destined for use at the Port of Ipswich. addition to reducing our CO2 footprint, further investment. ABP have tackled
NOVEMBER 2021

It has been configured around the we estimate that these electric cranes this head-on and will yield the cost and
specific workings of the port operation. will save in excess of 40% in energy environmental benefits in the years
To enhance efficiencies, each machine costs. The electrification of our cranes ahead.”
will be ready supplied with innovative will also significantly reduce noise The new units are expected to enter
insight reporting systems that can emissions. service in spring 2022.
DCi

47
NEWS

Bühler builds state-of-the-art oat mill

for Suomen Viljava in Finland
ENGINEERING & EQUIPMENT

DRIVING INNOVATION FOR A based food and high-quality oats is processes to increase efficiency and
SUSTAINABLE WORLD strengthened by, among other things, traceability. Bühler digital solutions also
Suomen Viljava has chosen Swiss Bühler increased purchasing power, better level play a key role in improving productivity
Group to build its new oat mill in of education and increase in general and reducing operating costs. Service
Finland. With Bühler’s strong health awareness of consumers. modules such as Yield Management
technological capacities and ability to Products based on oats have a significant System (YMS), Error and Downtime
www.drycargomag.com

craft individual solutions and Viljava’s role in reducing climate warming, with a Analysis (EDA), Overall Equipment
expertise in oats and its global network, relatively low carbon footprint. “Viljava Effectiveness (OEE) and Bühler Insights
the new state-of-the-art mill is planned has been planning an oat mill to Rauma Replay will be fully integrated in the high-
to go into operation in 2023 as Oat Mill for a long time and we are convinced tech oat mill.
Finland Oy. that the cooperation with Bühler in this “This project offers us a unique
The mill will be installed in a strategic ambitious project will support us to opportunity to craft a customized and
area in the port of Rauma on the west reach our business goals,” says Pasi highly efficient solution to Viljava’s new
coast of Finland, a deep-sea container Lähdetie, CEO of Suomen Viljava. plant while implementing the mill in an
port with good connections to the world, Bühler will deliver a package of fully already existing building, taking
with exports by ship and as direct railway engineered solutions to Suomen Viljava, advantage of the infrastructure already
connections to the east to China. In which includes the cleaning, dehulling, available. We save resources while
addition of groats and flakes, the mill will kilning, cutting, and flaking, bagging, and offering the most technological and
NOVEMBER 2021

produce oat hulls pellets for the Baltic load out. The entire line will be advanced solutions in the area,” says
rim countries’ feed and biofuel markets. controlled by the Mercury Mathias Hannsbauer, Head of Business
The global consumption of oat Manufacturing Execution System (MES), Segment Oat at Bühler Group.
products has been growing by 3.5% Bühler’s full factory automation system The installation of the new oat mill
annually. Demand for healthier plant- that integrates plant control and will start in September 2022.
DCi

48
 NEWS
RHI Magnesita orders six chain bucket elevators for large project from AUMUND Brazil
Global producer and
supplier of fireproof
products and systems,
RHI Magnesita, is
investing € 30 million in a

ENGINEERING & EQUIPMENT

new rotary kiln line for
its mine in Brumado in
the State of Bahia, Brazil,
where magnesite, one of
the raw materials for
fireproof products, is
mined. To convey the Bucket elevator head and bucket elevator boot ready for
raw material between dispatch to RHI Magnesita (photos AUMUND).
the magnesite mine and
the production facility in
Brumado, RHI Magnesita has ordered from ABOUT THE AUMUND GROUP (Gelsenkirchen, Germany), SAMSON
AUMUND Ltda six bucket elevators with The AUMUND Group is active worldwide. Materials Handling Ltd. (Ely, Great Britain),
central chain. The conveying and storage specialist has TILEMANN GmbH Chains & Components
The AUMUND bucket elevators with special expertise at its disposal when (Essen, Germany) as well as AUMUND
central chain, with heights of 15, 30, 33 and dealing with bulk materials. With their high Group Field Service GmbH and AUMUND
45m, were ordered by RHI Magnesita at the degree of individuality, both its technically Logistic GmbH (Rheinberg, Germany) are
end of 2020 and supplied this year. They sophisticated as well as innovative products consolidated under the umbrella of the
will operate in the Pedra Preta magnesite have contributed to the AUMUND Group AUMUND Group. The global conveying
mine in Brumado, where the rotary kiln is today being a market leader in many areas and storage technology business is
designed for processing 140,000 tonnes of of conveying and storage technology. The spearheaded through a total of 19 locations
magnesite per annum. The new line will manufacturing companies AUMUND in Asia, Europe, North and South America
bring an increase in production of around Fördertechnik GmbH (Rheinberg, and a total of five warehouses in Germany,
30%. Germany), SCHADE Lagertechnik GmbH USA, Brazil, Hong Kong and Saudi Arabia.

PFS4-0D-CSRR
High Precision Fully
Suspended Belt Weigher
RELIABLE INTERNATIONAL TRADE
- OIML CLASS 0.2 (+/- 0.1%)
Features
High precision fully suspended weigh frame
Direct force measurement
(no lever arms, pivots or bearings)
Strong rigid beams
Low deflection design
4 load cells
3 or more idler weigh length
Extended Idler Spacing for improved performance
Close Spaced Roller Rack (CSRR) for reduced belt sag and
reduced belt dynamic effects (Protected by International Patents)

E: [email protected] + Subscribe to Newsletter

T: +61 1 300 784 449 + Book a Zoom meeting with a CST expert

controlsystems.com.au + Brochures: RCS, IntelliRoll

NEWS
Liebherr’s Biggleswade HQ just got bigger
LGB development site Biggleswade October 2021.
ENGINEERING & EQUIPMENT

Following some unavoidable Covid-19- resources and capacity to support a period continue to provide industry leading
related delays, ground has been broken as of sustained growth in the UK. service to our customers.”
the expansion of Liebherr-Great Britain The initial phase of construction works
Limited headquarters in Biggleswade are expected to take up to 6 months, with ABOUT LIEBHERR
officially gets underway. Within the 15-acre a projected completion pencilled in for end The Liebherr Group is a family-run
site, there are plans to house the of Q1 2022. Liebherr has handed technology company with a highly
machinery giant’s state-of-the-art new responsibility for the works to PJ Hegarty diversified product portfolio. The company
facility which will include preparation and will work closely alongside them to is one of the largest construction
workshops for earthmoving, mobile crane ensure the project runs to time. Liebherr equipment manufacturers in the world. It
and concrete divisions, a customer centre construction machinery will, be in evidence also provides high-quality and user-oriented
as well as welfare for engineering teams. in the early stages of the build. products and services in a wide range of
The facility will adjoin its existing nine-acre The Managing Directors of Liebherr GB, other areas. The Liebherr Group includes
complex in its Bedfordshire home. The commented: “Even during these over 140 companies across all continents.
initial capital investment of £8 million will unprecedented times, we are delighted the In 2020, it employed around 48,000 staff
ensure that the company has both the development is under way, this ensures we and achieved combined revenues of over
€10.3 billion.
TPH machines at work on the LGB Liebherr was founded in
development at Biggleswade in October 2021. Kirchdorf an der Iller in Southern
www.drycargomag.com

Germany in 1949. Since then, the

employees have been pursuing the
goal of achieving continuous
technological innovation and
bringing industry-leading solutions
to its customers.
Liebherr-Great Britain’s head
office is in Biggleswade,
Bedfordshire and the company
currently employs over 400
people who operate from the
eight sales and service centres
NOVEMBER 2021

across the UK and Ireland.

Liebherr-GB supplies the
complete Liebherr construction
equipment portfolio to the UK
and Ireland, backed up by a
DCi comprehensive after-sales service.

50
 Challenge your
material limits

Nothing should stand in the way of your productivity – least of all the materials you
move. With our compact Hägglunds direct drive systems, you can adapt easily to the
job at hand, taking advantage of full torque at an infinite range of speeds. And should
an overload try to stop you, the drives’ low moment of inertia and quick response will
keep your machines protected. We’ll support you too, with an agile global network
and smart connectivity to bring you peace of mind. Driven to the core.

www.hagglunds.com
NEWS
Martin Engineering continues programme to support Susan G. Komen® Foundation
ENGINEERING & EQUIPMENT

A global expert in bulk material handling the firm supplemented its regular annual breast cancer,” Orlandi added. “We chose
technologies and training has announced donation with $8,950 from the fundraising the Komen Foundation so that the funds
the completion of this year’s annual campaign. we raise will directly support breakthrough
programme to support breast cancer “October is National Breast Cancer research and provide help for the women
education, screening, treatment and Awareness Month in the U.S.,” she and men facing breast cancer. Whether it’s
research around the world. Martin continued. “As a family-owned company of emotional support via the helpline, financial
Engineering continued the effort rolled out four generations with over 900 employees support through the treatment assistance
in 2017, contributing a portion of its sales making up our extended family, Martin program, or help navigating their care
www.drycargomag.com

revenue from the company’s popular air Engineering is acutely familiar with the journey, we know the organization will be
cannons and truck vibrators during the impact breast cancer has on individuals, there for them.”
month of October to support the Susan G. families, friends, colleagues and According to the National Breast
Komen® organization, inviting customers to communities. This disease affects such a Cancer Foundation®, about one in every
“go pink” and honour all those affected by large number of people that just about all eight women will be diagnosed with breast
the disease. The company donated $50 for of us have been touched by it in some way.” cancer in her lifetime, along with thousands
every Martin truck vibrator and $100 for In addition to its donations, Martin of men. At this point, doctors don’t know
each 70-litre air cannon, with the units’ Engineering also created a team to the exact causes, and it’s rarely possible to
traditional paint scheme replaced by the participate in the 2021 Komen Peoria determine why one person develops the
iconic pink colour adopted by the MORE THAN PINK WALK® on 2 October disease and another doesn’t. But research
organization. to raise awareness and encourage has identified a number of risk factors,
“We’re excited to get this programme contributions to this worthy cause. along with early detection techniques and
NOVEMBER 2021

back on track after the Covid year in 2020,” Orlandi led a group of cancer survivors at advanced treatments.
said Vibration Business Development the event and took part in the opening The Susan G. Komen Foundation was
Manager Susie Orlandi. “Every ceremony, representing Martin Engineering created in 1982, launching its famous ‘Race
contribution is a small step that supports as an Action Pillar Sponsor. for the Cure®’ shortly thereafter. The
those in need today, while the researchers “Support from efforts like this helps us organization has contributed to a number
DCi continue their work for a cure.” This year get one step closer to a world without of advancements, including the

52
 NEWS
identification of genetic
links, less-invasive
surgical techniques and
advanced drug
therapies, as well as
advocating for more
federal funding of

ENGINEERING &
additional research and
early detection
programmes.
The foundation has
invested over $3 billion
in more than 60
countries since it was
formed — helping to
reduce breast cancer-
related deaths by an
estimated 40% — with
an emphasis on
supporting those with
the fewest resources.
With treatment options, community
outreach, advocacy and other programs
around the world, the organization has
played a critical role in virtually every major
advance to combat breast cancer —
transforming how the world talks about
and treats the disease and helping millions
of breast cancer patients become cancer
survivors.
“Programmes like this generate media
exposure and get people talking,” Orlandi
added. “Many of our customers agreed to
join us in this fight, placing orders at this
critical time to contribute to its success.”
Martin Engineering has been a global
innovator in bulk material handling
applications for more than 75 years, with its
industrial vibrators and air cannons both
improving safety and productivity in mining,
coal handling, cement manufacturing and a
broad array of other industries. The firm
specializes in advanced technologies for
improving the performance of conveying
systems, high-temperature processing,
storage and transport of bulk materials.
The company has a legacy of support for
the Susan G. Komen foundation over the
years, thanks to a similar family history.
“The Komen family has roots in the Peoria
area, much like our own,” added Martin
Engineering Chairman Ed Peterson. “So,
we’ve always felt a special connection to
the cause.”
Martin Engineering is a global innovator
in the bulk material handling industry,
developing new solutions to common
problems and participating in industry
organizations to improve safety and
productivity. Headquartered in the USA,
Martin Engineering products, sales, service
and training are available from factory-
owned business units on six continents.
NEWS

AXIS Tech installs 42m telescopic conveyor at

ENGINEERING & EQUIPMENT

Energy production solutions and steel

processing company AXIS Tech has installed
a telescopic belt conveyor at the AB
Dolomitas quarry, which operates in the
Pakruojis district of Lithuania. The
maximum length of the telescopic conveyor
is up to 42 metres. This is the third
telescopic conveyor installed in this
dolomite quarry.
“While the Covid pandemic has become
a challenge for manufacturing sectors
around the world, the companies that have
automated their production process have
been the least affected by quarantine
restrictions. The solutions we develop for
more efficient business operations also
contribute to process automation,” says
www.drycargomag.com

Paulius Arštikys, CEO of AXIS Tech.

The company manufactured the
conveyor installed in the AB Dolomitas
quarry according to an individual order
within four months. The capacity of this
conveyor is up to 600tph (tonnes per
hour), and the belt width is 0.8m.
Transporting this giant conveyor from
the factory to the workplace posed several
challenges. The product was delivered to
the quarry partially assembled, due to the
difficulties of the transportation process —
NOVEMBER 2021

caused by the fact that the cargo being

transported was 26m long.
According to Arštikys, among the most
important requirements for the customer
was the high quality of the equipment,
DCi because the quarry operates 24 hours a

54
 NEWS
the Dolomitas quarry in Lithuania
day, seven days a week. The to various facilities in Portugal,
company's activities range from the Germany, Spain and Latvia.
mining of dolomite to its processing AXIS Tech designs and
and delivery to customers. manufactures various types of

ENGINEERING & EQUIPMENT

“This is one of the few conveyor stationary and mobile belt
production orders in our home conveyors, belt, screw and scraper
market. We are happy to contribute conveyor systems. High quality
to the development of advanced systems in production help to ensure
Lithuanian companies,” says Arštikys. the safety of workers, work efficiency
AB Dolomitas produces the highest and the quality of the transported
quality products from dolomite and material.
granite which are used in road In September of this year, AXIS
construction, building and agriculture. Tech launched a new slogan
In recent years, AXIS Tech has been contract with partners from Germany to ‘Handling. Heavy. Heat’. This slogan
supplying most of its conveyors and supply a transportation system to a new encompasses the company’s diversified
transportation systems to foreign sugar processing plant in Dhaka, business model and briefly identifies other
countries. A few months ago, the company Bangladesh. industry players in the area in which the
installed a new bulk cargo transportation Having started offering transportation company specializes. The ‘Handling’ part
system with a main 180m-long conveyor equipment manufacturing services in early introduces lifting and handling equipment,
and a conveyor gallery for the specialized 2020, AXIS Tech since signed deals worth the ‘Heavy’ part includes a custom steel
SIA Riga Bulk Terminal. €6 million to date. The company has processing function, and the ‘Heat’ part is
The company also signed another supplied custom-made conveyor systems for biomass energy equipment.

AUMUND USA supplies SCHADE Stacker to PEMEX

Refinery at Dos Bocas in Mexico
At the Port of Dos Bocas in Paraíso,
in the Tabasco region of South-
Eastern Mexico, the state-owned oil
and gas company PEMEX (Petróleos
Mexicanos) is building the largest oil
refinery of its kind in the country,
due for completion by the end of
next year. ICA Fluor, the Mexican SCHADE portal
EPC partner on the project, has reclaimer for Dos
ordered from AUMUND Bocas, Mexico
Corporation, Atlanta USA, via the (SCHADE
Fluor subsidiary Virta Inc., a stacker drawing).
and a portal reclaimer made by www.drycargomag.com
SCHADE Lagertechnik GmbH of Gelsenkirchen, Germany.
Supply of the stacker and portal reclaimer from SCHADE Lagertechnik, a member of the AUMUND Group, is planned for
the first quarter of 2022. Both machines will operate in the petroleum coke stockyard at the Dos Bocas refinery. The stacker
with tripper car is designed for a capacity of 1,150tph (tonnes per hour), and the portal reclaimer for 700tph.
Virta Inc., based in California, is a Fluor Corporation company specializing in conveying technology and system engineering.
AUMUND Corporation and SCHADE Lagertechnik worked closely with the Virta team to support the project development
process. Virta Inc. will supply all belt conveyors and the complete engineering for this project.

ABOUT THE AUMUND GROUP

The AUMUND Group is active worldwide. The conveying and storage specialist has special expertise at its disposal when dealing
with bulk materials. With their high degree of individuality, both its technically sophisticated as well as innovative products have
contributed to the AUMUND Group today being a market leader in many areas of conveying and storage technology. The
NOVEMBER 2021

manufacturing companies AUMUND Fördertechnik GmbH (Rheinberg, Germany), SCHADE Lagertechnik GmbH
(Gelsenkirchen, Germany), SAMSON Materials Handling Ltd (Ely, England), TILEMANN GmbH Chains & Components (Essen,
Germany) as well as AUMUND Group Field Service GmbH and AUMUND Logistic GmbH (Rheinberg, Germany) are
consolidated under the umbrella of the AUMUND Group. The global conveying and storage technology business is spearheaded
through a total of 19 locations in Asia, Europe, North and South America and a total of five warehouses in Germany, USA, Brazil,
Hong Kong and Saudi Arabia. DCi

55
NEWS
The latest tippler trends in perspective
By Rainer Wirtz, Frank Severin & Michael Herzog, thyssenkrupp Industrial Solutions AG
Countries which experience rapid
economic growth and industrial output,
such as China and Brazil, and large
exporters of commodities, for example
ENGINEERING & EQUIPMENT

Australia and Russia, are required to

upgrade their port infrastructure on a
continuous basis to keep up with the
growing volume of global trade in bulk
materials. Rail transport is a key link in this
chain, for along with shipping, it tends to be
the most economical and environmentally Train loadout station around 1900 (Heckel). Travelling and slewing wagon tippler (Pohlig).
friendly mode of transport. In order to
handle the increased traffic by rail, existing place primarily in the mining regions of TIPPLER PLANTS
wagon dumper installations are extended Lorraine, the Saar and Ruhr where the Though tipplers are employed for various
and customers search for new ways to mining industry was a significant purposes, the most common application is
achieve higher wagon throughput rates. component of the local economy. found in the handling of bulk materials. The
This article offers an introduction to The significance of the railways for the raw material, which is generally mined at
rail car dumpers, giving the layman an transport of goods grew in step with the remote sites located in the hinterland,
overview of their technology and mode of expansion of the rail network. On the one must be transported to coastal ports from
operation. The discussion is structured hand, the greater reach and efficiency of where it is exported. At this point the
around a range of different tippler the installed rail infrastructure motivated transfer of the material takes place from
concepts, and their associated subsystems, the conversion from other modes of rail to the ship.
which are briefly described and placed in transport and stimulated the overall In essence, the typical tippler plant
broader context. The article then volume of trade. On the other, network consists of the dumper for tipping the
proceeds to discuss some examples of expansion was also driven by the necessity wagon as such, as well as the various
actual plants to illustrate the performance to establish an efficient link for supplying mechanisms that comprise the handling
that can be expected. raw materials from coal and iron ore mines system for moving the train. The crucial
to the rapidly developing steel industry. aspects that must be considered when
HISTORICAL DEVELOPMENT The time consuming and labor intensive developing the plant are the nature of the
The transport of raw materials has been a work involved in the manual unloading of material and its properties, the prevailing
critical challenge in the furtherance of wagons soon led to the development of climatic conditions and the range of
human development from the earliest systems that could facilitate and automate wagons that are to be encountered in the
times. The enormous public works this process. The design of the first particular application.
projects which were completed by the dumper systems was constrained by the The classification of wagon dumpers
Babylonian and Egyptian civilizations would construction of the wagons in operation according to their operating principle
not have been possible without viable and took the shape of tipplers that yields three general types: rotary dumpers,
solutions in this regard. discharged via the end of the wagon. side tipplers and miscellaneous special
Along with the development of steam Apart from the ubiquitous box wagons, constructions. The class of rotary dumpers
power, the transport of bulk materials with railway companies also commissioned the is subdivided into two further types with
wagons and their discharge through development of special wagons with closed and open end-shields respectively.
tipping, closely paralleled the bottom or side discharge . These units Another differentiating factor is found in
modernization of the mining industry. The were particularly suited for the transport the number of wagons that can be
www.drycargomag.com

use of wagons, initially hand drawn and of materials with good flow properties or discharged simultaneously by a given
running on tree trunks as rails, goes back which required to be enclosed during installation. Historically, tipplers were
to the infancy of industrial mining activities. transport. designed to handle only single wagons,
During the 19th century, the introduction For materials that do not flow easily or usually requiring the tipped unit to be
of ropes and chains and advances in the are of greater density, the use of open uncoupled. Efficiency requirements have
manufacture of steel helped further the wagons which are discharged through since led to the development and
development of handling systems with tipping provide the more effective and installation of double, triple and quadruple
wagon dumpers. This development took reliable solution. dumpers. At present, quadruple dumpers
NOVEMBER 2021

DCi
Layout of a tippler system (1 positioner, 2 tandem tippler, 3 pusher, 4 transfer car, 5 outward rail).
56 Page 1 of 5
 NEWS
have proven to be the largest units that are
economical, though the tipping of five
wagons is an issue that is under
investigation.

MULTI-CAR DUMPERS
Through the development of multi-car

ENGINEERING & EQUIPMENT

dumpers, a crucial step was taken in raising
performance of tippler systems. A further
increase in throughput can be achieved by
installing more than one of these units in
parallel; a number of such plants are now in Quintuple Tippler (thyssenkrupp).
operation. Multi-car dumpers were
traditionally composed of single units
which were arranged in series and
operated in unison. The latest development
has however been to construct tandem
dumpers as a unified structure that offers
greater rigidity than two linked units. This
form of construction also obviates the
need for synchronization in the tipping
operation of the units. Quadruple
dumpers are generally constructed as the
combination of two tandem dumpers
arranged in series. This layout, while
retaining the structural benefits of tandem
units, offers the advantage of redundancy
because the respective subunits can
continue with independent operation at Two parallel quadruple tipplers at Caofeidian (China).
lower throughput.

CONVEYOR SYSTEMS
The tippler plant is generally constructed
with a hopper or bunker below the tippler
to receive the discharged material. When
required, a grizzly with suitable opening
size may also be installed. This
arrangement can be equipped with a rock
breaker to deal with larger lumps. Apron
feeders are the preferred extraction
solution below hoppers, which ensure a
steady feed of material onto the belt
conveyor that links the tippler with the
stockyard facility of the plant.
In colder climates defrosting systems www.drycargomag.com
may be required to thaw the outer
surfaces of the material in the wagons and Hydraulically driven apron feeder below the tippler hopper.
facilitate its discharge during tipping.
Broadly speaking, the track layout
within a plant can be constructed as a loop
or, alternatively, consists of a set of parallel
incoming/outgoing rails. Because curved
track segments are subject to minimum
radii, extensive space is usually required to
accommodate a looped layout. Parallel
layouts tend to be more compact but
require the added complexity of a transfer
NOVEMBER 2021

car that shifts the wagons to the outgoing

rail after discharge.
The nature of the rolling stock that
must be handled is a decisive consideration
when laying out the tippler plant. It is
usually the case that multiple wagon types Example of a rail loop around the stockyard. DCi

Page 2 of 5 57
NEWS
and sizes must be accommodated. One multiple-wagon tipplers the relative available are designed for the discharge of
reason is that customers tend to use the movement must be catered for between single wagons, though tandem units are in
state-owned national railroad company appropriate segments. development.
which has an assortment of rolling stock in Trains have become longer over the A clamping mechanism secures the
its inventory. Another reason for potential years and are now typically composed of wagons during the tipping cycle. This
dimensional variance may occur when between 80 and 260 wagons. The physical system is usually either hydraulically
materials with different densities are constraint imposed by the maximum limit actuated or alternatively relies on gravity-
ENGINEERING & EQUIPMENT

handled by the same plant. Wagons on power transmission between wheel and based leverage. In applications where only
designed for the transport of low-density rail means that longer trains may require limited throughput is required, the wagons
materials, such as coal, will be constructed up to five locomotives. Of these can be manoeuvred onto the tippler
with a higher volume than those for high- locomotives, the leading units are often platform with small locomotives or
density materials such as iron ore. required to pass through the tippler. The vehicles that have been modified to
Maximum axle loads are usually prescribed tippler platform must be designed to operate on rails (for example certain
in national regulations and must be accommodate the additional load and UNIMOG variants). Where higher
considered. Clearly, wagons for the larger dimensions in these cases. The trains discharge rates are required, specially
transport of coal can be used for iron ore of extreme length which are encountered designed positioning systems are used.
if the loaded volume is suitably adjusted. in Australia and Brazil are provided with Longer cycle times are encountered
Locomotives and wagons of different additional locomotives located centrally in where side tipplers are used because of the
sizes must be able to pass through the the train. The train is split at this location constraints imposed by the operating
tippler structure. In this regard, the when the train reaches its destination principle of these systems. The wagon to
minimum clearance outline set down for prior to the commencement of unloading. be tipped must be uncoupled from the
the railway network, is of critical Plants are, in such cases, commonly train prior to the tipping operation. This
importance for ensuring compatibility arranged with tippler units operating in step limits system performance to
during tippler operation. This standard parallel which allows the simultaneous between ten and 15 wagons per hour.
defines both the boundaries which limit unloading of the subsegments.
the maximum size of the rolling stock and ROTARY TIPPLERS
the minimum clearance envelope that may TIPPLER TYPES Next to side tipplers, rotary tipplers are
not be encroached upon by stationary SIDE TIPPLERS the most common wagon tipping
structures. Within these prescribed limits, Side tipplers are suitable for lower installations. With these units, the platform
the wagons may vary in length, width and throughput applications or alternatively for is rotated through either 180° or 360°
height. special purposes such as discharging around its longitudinal axis (both angles
The coupling between wagons can be residual material from emptied wagons. It approximate and depending on design).
either of fixed or rotary design. Some may also be the preferable solution at Most common, currently, is the tandem
railway companies may also use mixed locations where the water table restricts arrangement which accommodates two
compositions where every second, third or civil works, for the underground wagons at a time. Quadruple arrange-
fourth unit is equipped with a rotary construction that accommodates the ments are also encountered, but these
coupling. In these cases, the compatibility of discharge hopper and extraction usually consist of two tandem tipplers
the tippler type and operational procedure arrangement of a side tippler is shallower arranged in series (older tandem tipplers
must be ensured, for it may be necessary to because these elements are not located consisted of two single tippler platforms in
uncouple the wagons manually. underneath the tippler. For discharge, the series). The wagons are secured during the
With good planning and management, it wagon is rotated through 150° with the tipping cycle through a hydraulic clamping
can be ensured that the location of the axis of rotation positioned alongside and mechanism, vertically or horizontally
rotary couplings in the train match the approximately 2.5m above the level of the mounted. The system is designed to limit
operational requirements of the tippler rail. This arrangement requires the lifting the wear and tear on the wagons and the
plant. Care must be taken with the of the full weight of the wagon and hydraulic pressure is regulated to relax the
www.drycargomag.com

composition of the train prior to loading therefore tends to require larger drives. wagon springs after discharge.
to avoid breakages and delays during The example shown is equipped with an The tippler geometry is largely
unloading. Single rotary tipplers require installed power of 315kW and can handle determined by the coupling design of the
rotary couplings between all wagons to 15 wagons per hour. wagons that must be accommodated. If
avoid manual disconnection, while for The side tipplers that are currently these are exclusively rotating couplings, it
NOVEMBER 2021

DCi Side tippler (thyssenkrupp). Rotary tippler during the discharge of wagons (thyssenkrupp).

58 Page 3 of 5
 NEWS
ENGINEERING & EQUIPMENT
Mechanism for manoeuvring the wagons (positioner, indexer, puller or side-arm charger). Container tippler.

Helix TipplerTM as a continuous side tippler (Kiruna Wagon, Sweden). Spiral guide structure for discharge (Kiruna Wagon, Sweden).
is unnecessary to uncouple the individual manoeuvre the wagons into and out of the financially viable.
wagons and the train can be handled as a tippler depends on their mode of The fact that the container must be
complete unit. In this case the axis of operation and function; terms such as hoisted, traversed and discharged into the
rotation of the tippler platform must positioner, indexer or side arm charger are hold of the ship is a significant constraint
coincide with the corresponding axis of encountered. Most commonly, these units on the cycle times that can be achieved.
the coupling. This places a geometric are mounted on a chassis and travel on a Such an installation can therefore not
constraint on the minimum diameter of set of rails. Travel drives utilize a rack and compete with more conventional handling
the platform, resulting in a larger platform pinion arrangement, where the rack is fixed plant in high capacity applications. The
structure and thus also a higher installed between the rails and the planetary drive containers are also limited in the volume of
power for the plant. The two drives that units with electric motors are vertically high density materials that can be handled.
rotate the platform structure, each with an mounted on the travelling platform. The overall logistic concept does however
installed power of approximately 200kW, Depending on the traction force required, give this type of system an advantage in
are located on either side of the end shield. the units are equipped with between four particular applications.
Power is transmitted via pinions to the and 12 drives. The length of the unit
circular rack mounted on the end shield. increases in proportion to the number of SPECIAL TIPPLER CONCEPTS: HELIX DUMPER
The two drives must be linked for the drives required, and in some cases spatial The Swedish company Kiruna Wagon AB
purposes of drive synchronization. The constraints make it necessary use an has recently developed an interesting
rotating platform is supported at the end arrangement with two parallel rack units. variation on the tippler theme.
shields on sets of equalized rollers that This more compact solution has the The Helix DumperTM relies on purpose-
allow it to rotate freely. drawback of reduced accessibility to built wagons that are unloaded through
Rotary tipplers may be constructed maintain and repair the drive units. mechanistic interaction with a specially
either with a full end-shield (O-type) or An alternative drive concept that may constructed discharge station. The load
with an opening to allow access for the be chosen is the rope winch system. The body of the wagon is shaped to facilitate
positioner (C-type). Because tipplers are unit is pulled by rope via a drum located the discharge of material and is connected
mostly housed under a roof structure or above the rails. The advantage of this by hinge to the one side of the rail chassis www.drycargomag.com
within a building, it is advantageous for the arrangement is that the drive is not located on which it is supported. The discharge
positioner to remove the empty and insert on the moving platform, and therefore station consists of the spiral guide whose
the next full wagons in a single movement. remains stationary during operation. The central axis is coincident with the
This can be achieved with the open end- wear and tear of the rope, its dynamic centreline of the hinges on the wagon. The
shield design. For applications where the oscillations and the requirement to guide wheel which is mounted on the load
wagons must be separated, the throughput provide intermediate support for the rope body wall opposite to the hinges is engaged
of the tippler system can be increased by over the long travel distance are challenges in the helix-shaped guide structure whilst
using two separate positioners for to be considered for this arrangement. the train is in forward motion. As the
removing the empty and inserting the full guidewheel moves along the constrained
wagons respectively. The positioner on the SPECIAL TIPPLER CONCEPTS: CONTAINER TIPPLER path, the load body is tilted towards the
input side pushes the loaded wagons onto One example of an unconventional side and the material is discharged into the
the platform, while the positioner on the concept is the container tippler that was hopper alongside the rail.
NOVEMBER 2021

output side operates on a parallel set of developed by thyssenkrupp in South Africa.

rails to pull the empty wagons out at the The advantage of this system is that ships INTEROPERATION BETWEEN POSITIONER
output side. can be loaded using slightly modified AND TRAIN
container cranes and containers at ports The optimization of the train unloading
POSITIONER where the installation of specialized cycle requires a better understanding of
The terminology used for systems that materials handling infrastructure is not the dynamic behaviour and interaction of DCi

Page 4 of 5 59
NEWS
Train consisting of 120 coal wagons.
ENGINEERING & EQUIPMENT

the elements which comprise the train. tipplers at Ust Luga, the largest harbour in autonomously from origin to destination;
The system can be modelled as a chain of Russia, each unit unloading coal at a rate of this type of development has already been
point masses connected with spring- 3,500 tonnes per hour. implemented by some operators. It may
damper elements. The load capacity of the Another example of an application of thus be expected that in future the entire
couplings between individual wagons this technology is the tandem tippler which process from mine to port will be largely
should not be exceeded and is the limiting thyssenkrupp delivered to Tata Steel at automated. Even today, tipplers are often
factor when considering the acceleration Kalinganagar. This tippler handles two 140 the most highly automated systems in the
of the train induced by the positioner. This tonne wagons at a rate of 25 cycles per materials handling plant.
process is now actively controlled to hour, achieving a discharge rate of 3,500
achieve minimum cycle times within the tonnes per hour. These tippler units Bibliography:
given constraints. As the mass of the train comply with the latest RDSO guidelines [1] Matthews, Volker.: Bahnbau. 4., neubearb. und
decreases during the unloading cycle, the and can handle all types of box wagons in erw. Auf!.. - Stuttgart; Leipzig: Teubner, 1998, ISBN
acceleration imposed on the wagons can current operation, as well as the proposed 978-3-519-30113-4
be ramped up steadily. DFC, which are to be introduced in the
[2] Iwnicki, Simon : Handbook of railway vehicle
There is unfortunately not much foreseeable future for the transport of iron
dynamics, 2006 by Taylor & Francis Group, LLC,
literature available on the dynamic ore and coal.
ISBN-13: 978-0-8493-3321-7
behaviour of trains at slow speeds and In the year 2016, a tippler plant was
[3] Reiplinger, Matthias : Entwicklung einer
stop/go operation. It was therefore installed by thyssenkrupp at Caofeidian in
betriebsoptimierten Alternative zum bestehenden
necessary for thyssenkrupp to conduct its China consisting of two tippler lines. Each
Seitenarmvorzieher eines Waggonkippers, 2007,
own research by collecting data from the line was furnished with two tandem
HTW-Saar,
large number of tippler plants that it has tipplers, arranged in series. The ability of
constructed. The results of this work were the combination to discharge four wagons The latest tippler trends in perspective

incorporated into software modules that simultaneously makes it the first [4] Bolsöy, Bengt.: Breakthrough performance with
allow a very good prediction of dynamic operational quadruple tippler globally. This the Helix Dumper system, International Heavy Haul
responses encountered in the train. It is innovation allows material to be unloaded Association (IHHA) conference in Narvik, 2019,
thus possible to simulate the forces in the at a rate of 8,600 tonnes per hour by each [5] Herzog, M., Severin, F., Wirtz, R., Developing the
coupling as a function of time and develop of these lines. high performance car dumper: Wagon dumper
the optimal operating characteristics for technology and its associated infrastructure,
the positioner. The effect of the plant PROSPECTS CEMENT INTERNATIONAL 3/2021, VOL. 19
layout in terms of rail gradients and curves In view of the growing demand for [5] Sakhardande, Y.; Badhe, R.: Speeding up wagon
(both convex and concave) are brought sustainability in the supply of raw materials, unloading. bulk-online.com 34 (2014) No. 6.
into consideration. tippler systems remain an economical and [6] Xin Ge, Kaiyun Wang, Lirong Guo, Min Yang,
environmentally friendly solution in future. Kaikai Lyu, Wanming Zhai.: Investigation on
SYSTEM PERFORMANCE The proportion of the overland transport Derailment of Empty Wagons of Long Freight Train
Tandem tipplers are employed extensively of bulk materials that is conducted by rail during Dynamic Braking, 2018, DOI:
where higher throughput rates are needed is expected to grow. Various 10.1155/2018/2862143,
www.drycargomag.com

to optimize the utilization of the rail improvements may also be expected with
[7] Pavol Šťastniak, Pavol Kurčík, Alfréd Pavlík :
infrastructure. At the coal export terminal regards to wagon technology to further
Design of a new railway wagon for intermodal
at Huanghua in China, for example, enhance the functioning of the rail logistics transport with the adaptable loading platform,
thyssenkrupp installed nine tandem tippler system. In this regard, particularly the MATEC Web of Conferences ,
units to achieve the required export digitalization of coupling systems may https://doi.org/10.1051/matecconf/20182 235 0
capacity of 80 million tonnes per year. unlock major benefits. Such couplings (2018)
The tipplers installed at this harbour could be developed to transmit higher
[8] Roker, Stephanie, Rio Tinto delivers iron ore via
are designed to unload two wagons loads and be controlled and disengaged
world’s first fully autonomous train, (2018) Dry Bulk,
simultaneously, each weighing a maximum automatically. The rapid advancement of
https://www.drybulkmagazine.com/rail-
of 98 tonnes, at a rate of 33 cycles per information technology has also opened a barge/13072018/rio-tinto- delivers-iron-ore-via-
hour. This amounts to an average rate of myriad of new possibilities regarding the worlds-first-fully-autonomous-train/
4,000 tonnes of coal per hour, with the management of the logistics system. Trains
NOVEMBER 2021

[9] Development of a concept for the EU-wide

peak capacity being 4,500 tonnes per hour. could be automatically constituted at the
migration to a digital automatic coupling system
In Brazil, at Porto Sudeste, two tandem point of origin and separated at the
(DAC) for rail freight transportation, Final Report,
tipplers are in operation which handle two destination. The network integration of
Federal Ministry of Transport and Digital
140 tonne wagons (gross weight) of iron the various processes such as the loading
Infrastructure (BMVI),
ore, achieving 40 discharge cycles per hour. and unloading of trains is inevitable. It is https://www.bmvi.de/SharedDocs/DE/Anlage/E/final-
DCi Thyssenkrupp also installed two tandem also envisioned that trains will travel report-dac- study.pdf?__blob=publicationFile

60 Page 5 of 5
 NEWS
RCT tech secures port operations
RCT, in partnership with Komatsu, integrated
the proven and interoperable
ControlMaster®
Portable

ENGINEERING & EQUIPMENT

Teleremote
solution with a
Komatsu
PC228 Excavator.

Smart technology specialist RCT and machine damage. demands for bulk handling operations at
equipment manufacturer Komatsu have “We really appreciate RCT’s support ports around the world.
delivered a bespoke technology project to for this pilot project which is a very good
safeguard bulk handling operations at a step forward in terms of innovation and ABOUT RCT
major port in New Caledonia. safety improvements onsite,” said Komatsu RCT is an innovative Smart Technology
The technology transforms the Technical Manager Jean Damour. company with the expertise to evolve
efficiency of operations by allowing local “This kind of professional relationship entire industries. It designs, manufactures
companies to quickly and effectively clear helps us improve our technical skills and and delivers technology and service
storage areas in bulk carrier ships while ability to adapt to changing site solutions to support clients around the
protecting port crews from hazardous requirements, while focusing on customer world in multiple sectors including mining,
working conditions within the ship’s hold. needs and supporting their activities.” industrial, agricultural and civil. With more
RCT, in partnership with Komatsu, RCT Account Manager Wayne than 49 years of success, RCT leverages
integrated the proven and interoperable Carrington said the project demonstrates knowledge and insight to provide clients
ControlMaster® Portable Teleremote how ControlMaster® can be applied to any the advantage of measurable value — www.drycargomag.com
solution with a Komatsu PC228 excavator. machine for use in a broad range of increased profitability, productivity,
RCT’s customer service team provided industries. efficiency and safety.
comprehensive remote support to “We empowered Komatsu with the Since the 1970s, RCT has traversed all
Komatsu staff based in New Caledonia to knowledge necessary to commission the corners of the globe. Its team has grown
efficiently commission the machine. equipment and deploy it to site with to 215+ committed people working with
The technology package enables the support from our international Customer clients in more than 71 countries
excavator operator to stand at a safe Service team,” he said. worldwide, from Australia to Africa, Asia,
vantage point while accessing the full range “Port staff are pleased with the easy-to- Russia, North America and Latin America.
of machine functions, as if they were in the use interface and signal strength which With its unique way of viewing the world,
excavator’s cab. enables them to work quickly and intelligent solutions and backed by
The solution includes a pitch and roll effectively.” exceptional support, service and training,
indicator which provides the operator with “We are very pleased to work with RCT is a global expert in smart Guidance,
NOVEMBER 2021

real-time information on the excavator’s Komatsu to deliver this project and we Teleremote and Remote Control
status and position within the ship hold. regard them as a competent and highly automation solutions for the mining
The pitch and roll indicator will enable professional company.” industry. It continues to listen, see, think,
the operator to make more informed “While ControlMaster® has a proven create and evolve solutions that lead to
decisions about the status of the machine history in mining, this project better profitability, productivity and safety
within the hold and prevent unnecessary demonstrates the technology can meet the for its clients DCi

61
 ENGINEERING & EQUIPMENT
Under scrutiny
latest developments in cement
handling and storage

Louise Dodds-Ely

Two new Siwertell road-mobile ship unloaders support US cement

handling operations
Bruks Siwertell will deliver two new unloader in less than an hour, and then The first unit will be delivered to the US
Siwertell road-mobile ship-unloaders for clear the quay in equal time once finished.” Midwest in summer 2022, with
dust-free cement handling operations in As with larger unloaders, Siwertell road- commissioning scheduled for winter 2022, www.drycargomag.com
North America. Destined for an mobile units use screw conveyors that are and the second unit, destined for the
undisclosed owner, these new 5000 S units fully enclosed, with a dust mitigation Southeast region, will be delivered in
will join the company’s other existing system, which limits any fugitive dust to an summer 2022, with commissioning by
Siwertell technology. absolute minimum. They also ensure than spring 2023.
They will provide a flexible, no dry bulk material is lost through
environmentally friendly solution for spillage. Road-mobile unloaders have a ABOUT BRUKS SIWERTELL
unloading cement at planned future sites, double-bellows discharge arrangement and Bruks Siwertell is a respected supplier of
and will enable better access to barges and can transfer material to waiting trucks or dry bulk handling and wood processing
port facilities. any other receiving system. systems. The company designs, produces
“Siwertell ship-unloaders are located Both unloaders will have a rated cement and delivers systems for loading, unloading,
across the world and have decades of handling capacity of 300tph (tonnes per conveying, storing, and stacking and
proven, dedicated service,” says Pedro hour) for vessels up to 5,000dwt. They are reclaiming dry bulk materials, alongside
NOVEMBER 2021

Alfaro, Project Development Engineer, the latest iteration of the 5000 S, and will equipment for chipping, screening, milling
Bruks Siwertell. “Road-mobile units are have electric as opposed to diesel-drives, and processing wood for the biofuel, board,
extremely flexible in their ability to serve further reducing environmental impact. sawmill, pulp and paper industries. All
operators at multiple ports, and are robust Other advanced features include equipment is designed to ensure
and easy to operate. In fact, a single technology for diagnostics and trouble- environmentally friendly and efficient
operative can unfold a road-mobile shooting. operations. DCi

63
 AUMUND: Successful implementation of PREMAS® 4.0 Predictive
ENGINEERING & EQUIPMENT

Maintenance at Jura-Cement
Since the beginning of 2021 Jura-Cement-
Fabriken AG Switzerland has been using the
newly launched PREMAS® 4.0 Predictive
Maintenance Solution on an AUMUND belt
bucket elevator at its cement plant in
Wildegg. PREMAS® 4.0 is an innovative
digital monitoring system offered by
AUMUND Fördertechnik GmbH,
Rheinberg, for predictive maintenance.
Ramona Keller is Head of Maintenance
at Jura-Cement-Fabriken AG, and after
several months her experience with
the Predictive Maintenance Solution has
been positive. “We are convinced that
predictive maintenance is the future. With
PREMAS® 4.0 we can better plan our spare Ramona Keller, Head of Maintenance at Jura-Cement-Fabriken AG, checking the IoT box
parts and maintenance, which has a positive which sends the collected data via a mobile connection to the PREMAS® Cloud. The
effect on resources and costs. The PREMAS® Portal visualizes and supplies all relevant data for complete online condition
PREMAS® Portal is easy to use and very monitoring with secure access 24/7 for authorized users on any mobile or desktop device.
clear. It allows us to recognize immediately
when we need to act, no matter where we the belt (which was installed in 2015), special expertise at its disposal when
are or what time of day or night it is.” machinery performance over the past 30 dealing with bulk materials. With their high
PREMAS® 4.0 informs the maintenance days, and/or some of the most important degree of individuality, both its technically
department online, in real-time, about the variables such as belt lengthening, motor sophisticated as well as innovative products
condition of the machine, provides a current, and temperatures measured at the have contributed to the AUMUND Group
prediction about the estimated lifespan of bucket elevator head and boot. The today being a market leader in many areas
critical components, and facilitates indicators allow the condition of the of conveying and storage technology.
proactive planning, timely action and AUMUND bucket elevator to be The manufacturing companies
prevention of possible problems. monitored continuously. AUMUND Fördertechnik GmbH
Jura-Cement has been able to At the beginning of 2020 Jura-Cement (Rheinberg, Germany), SCHADE
experience this since the beginning of 2021. was the recipient of the first prototype of Lagertechnik GmbH (Gelsenkirchen,
Thanks to PREMAS® 4.0, wear and ageing of the PREMAS® 4.0 System. Test runs were Germany), SAMSON Materials Handling
important machine components of the kiln- carried out to collect and evaluate data to Ltd. (Ely, Great Britain), TILEMANN GmbH
feed belt bucket elevator at the Wildegg be visualized in the first version of the Chains & Components (Essen, Germany) as
plant are flagged up at a very early stage. To PREMAS® Portal. The finalized PREMAS® well as AUMUND Group Field Service
make this possible PREMAS® 4.0 combines System was successfully installed in January GmbH and AUMUND Logistic GmbH
the latest sensor technologies with data 2021 and put into operation. During the (Rheinberg, Germany) are consolidated
collection and analysis. Jura-Cement has entire test phase Jura-Cement actively under the umbrella of the AUMUND
unlimited access to the condition of the provided feedback, making a significant Group.
AUMUND Bucket Elevator via the contribution to successful development, The global conveying and storage
PREMAS® Portal, and is informed and helping to bring the system to market. technology business is spearheaded
proactively by the abnormality recognition through a total of 19 locations in Asia,
www.drycargomag.com

function as soon as any action needs to be ABOUT THE AUMUND GROUP Europe, North and South America and a
taken. This can be triggered by various The AUMUND Group is active worldwide. total of five warehouses in Germany, USA,
indicators such as lifespan and workload of The conveying and storage specialist has Brazil, Hong Kong and Saudi Arabia.
NOVEMBER 2021

AUMUND IoT box and dashboard for

DCi real-time display of machine data (all
photos AUMUND).

64
ENGINEERING & EQUIPMENT

CNBM expertise in handling cement and other commodities

CNBM International Engineering &

Technology CO. is a member of CNBM
Group. CNBM Port specializes in offering
client solutions for port cargo handling. As
a reliable partner, its expertise and
knowledge helps minimize cost and
maximize profit. It has significant expertise
in cement handling equipment.
The company’s diverse portfolio
encompasses consultancy, design,
manufacturing, equipment delivery, site
installation, commissioning, training, and
spare parts supply from single equipment
to terminal turnkey project.
CNBM Bulk’s service stands out by
providing clients with a tailor-made design,
full set financing package, port operation
management research and consultation,
cargo handling technology and related
equipment, electromechanical and
automatic control system, equipment
maintenance and services.
www.drycargomag.com

CNBM Bulk is dedicated to providing

the domestic and overseas clients the
NOVEMBER 2021

DCi

66
 ENGINEERING & EQUIPMENT
well-rounded solution and professional services. And CNBM Bulk v Port of Ploce Bulk Handling facility Croatia: equipment
is extending the service which covers Asia, Europe and Africa. capacity of 2,000 tonnes/day.
Equipment manufactured by CNBM Bulk includes projects for v Transnet Port Terminal multiple shiploader in South Africa:
these customers: equipment capacity of 3,000 tonnes/day.
v Vietnam Hoang Cement JSC in Vietnam: equipment
capacity of 1,000 tonnes/day.
v Najran Cement Company (Phase I ) in Saudi Arabia:
equipment capacity of 6,000 tonnes/day.
v Najran Cement Company (Phase II ) in Saudi Arabia:
equipment capacity of 3,000 tonnes/day.
v North Region Cement Company (Phase I) in Saudi
Arabia: equipment capacity of 6,000 tonnes/day.
v North Region Cement Company (Phase II) in Saudi
Arabia: equipment capacity of 3,000 tonnes/day.
v ACC Cement Project in Saudi Arabia: equipment
capacity of 10,000 tonnes/day.
v Berber Cement Project in Sudan: equipment capacity
of 4,800 tonnes/day. www.drycargomag.com
v Atbara Cement Project in Sudan: equipment capacity
of 5,300 tonnes/day.
v Al Mafraq Cement Plant in Jordan: equipment
capacity of 6,000 tonnes/day
v Derba Midroc Cement Project in Ethiopia: equipment
capacity of 7,000 tonnes/day.
v United Cement Company in Yemen: equipment
capacity of 3,000 tonnes/day.
v Fezan Wadi Alshati Mahrug in Libya: equipment
capacity of 3,000 tonnes/day.
v Northern Jordan Cement Plant (Grinding Station) in
Jordan: equipment capacity of 3,000 tonnes/day.
NOVEMBER 2021

v Al-Douh Cement Plant in Iraq: equipment capacity of

3,500 tonnes/day.
v Al-Douh Grinding Plant in Iraq: equipment capacity of
3,500 tonnes/day.
v Oman Cement Company in Oman: equipment
capacity of 2,200 to 2,700 tonnes/day. DCi

67
 Cement handling sector places continued trust in TAKRAF technologies
ENGINEERING & EQUIPMENT

TAKRAF bridge reclaimer

similar to that which has
recently been awarded.

MAJOR INDIAN CEMENT PRODUCERS PLACE v 1 x luffing stacker; 1 x slewing stacker; 1 sizer technology from the cement
SIX MAJOR CONTRACTS FOR TAKRAF side scraper reclaimer; and modification sector); and stacking and reclaiming yard
MATERIALS HANDLING EQUIPMENT. to the existing bridge reclaimer, to conveyors in various capacities. The
Recent orders from major cement handle limestone, coal and additive. equipment will handle limestone,
suppliers in India highlight the continued v 1 x luffing stacker and 1 x bridge corrective, coal and petcoke.
demand for TAKRAF bulk material handling reclaimer to handle limestone.
technology from this sector. In March 2021 v 3 x luffing stackers with various Both these companies rank amongst the
alone, TAKRAF received six orders from capacities; 1 x bridge reclaimer; and 2 x world’s leading producers of both white
two prominent cement producers in the side scraper reclaimers, to handle and grey cement.
sub-continent and long-term customers of limestone, coal and additive. S.T. Rajesh, General Manager – Sales,
TAKRAF Group. v 1 x slewing stacker and 1 x side scraper TAKRAF India, had the following to say
These orders included stacking, reclaimer to handle slag, coal and upon conclusion of the recent awards,
reclaiming and yard conveying equipment, gypsum. “Such ongoing orders underline the high
with one also including a TAKRAF levels of customer satisfaction, both with
sizer, which is building a strong The remaining two orders comprise the our state-of-the-art technologies and the
reputation of high availability, maintainability following: service provided by our teams, right from
and value. v 1 x luffing stacker; 1 x bridge reclaimer; sales through engineering and
The scope of the orders covers and yard conveyors for the handling of manufacturing to project delivery. The
engineering, supply and supervision (ESS) limestone. entire TAKRAF team must be
and range in duration from four to 11 v 3 x luffing stackers (various capacities); 1 congratulated on winning such important
months. x bridge reclaimer; 2 x side scraper awards, which demonstrate the continued
www.drycargomag.com

The four orders placed by one of the reclaimers; 1 x TAKRAF sizer (indicative trust placed in TAKRAF Group by these
cement producer’s cover: of the growing demand for TAKRAF’s important repeat clients.”

TAKRAF India sees notable project wins despite challenging economic

conditions
A strong track record of superior Group’s cement works and two for the charger, a wagon shifter and a wagon
equipment performance and project Group’s greenfields site. pusher, with capacity for 25 wagon tips per
delivery, supported by competitive pricing, The order for the cement works, hour. The contract was awarded at the end
has seen TAKRAF India win a number of received in December 2020, comprises a of January 2020. In the third order,
awards over the past year from existing luffing stacker and bridge reclaimer for awarded in March 2020, a slewing stacker
NOVEMBER 2021

customers, as well as attracting new clients. handling limestone. and a side scraper reclaimer are being
A large Fortune 500 Indian multinational In the first of the two orders for the supplied.
conglomerate and a repeat client, awarded greenfields site, TAKRAF India is supplying A leading cement brand and the largest
three major Engineering, Supply and wagon-unloading equipment to handle producer of slag and speciality cement in
Supervision (ESS) contracts in 2020. These gypsum. This includes a 1,600tph (tonnes India, contracted TAKRAF India to supply a
DCi comprised one for a brownfields site at the per hour) wagon tippler with a side arm bridge reclaimer for handling limestone at

68
 ENGINEERING & EQUIPMENT
Process flow diagram for
material handling.

one of its works. This company is an cement conglomerate, contracted TAKRAF to our General Manager, Sales and his
existing client with the ESS contract for the India for the design, engineering, supply, site dedicated team, whose commitment and
brownfields site being placed in October erection supervision and commissioning of hard work resulted in these important
2020. a material handling system for a greenfield project awards during a highly challenging
A first time client also placed an order cement project. year and against stiff global competition.
for a 500 tonnes per hour slewing and The contract includes various luffing We are especially proud that we continue
luffing stacker for a large petrochemical stackers, a bridge reclaimer, side scraper to attract project awards from existing
plant for one of the largest petrochemical reclaimers, a wagon tippler, side arm clients as this is testimony not only to the
companies in India. The stacker was chargers, apron feeder, sizer and an quality of our product and service delivery,
ordered under an Engineering, assortment of various conveyors. but also to the exceptional and durable
Procurement and Construction (EPC) Gopal Kalyanakrishnan, Managing customer relationships we have built.
contract in September 2020. Director TAKRAF India, had this to say Attracting new clients in such tough times
Lastly, an important client for the past upon confirming the company’s order is also a noteworthy achievement for which
20 years and part of a large international intake for the past year: “Congratulations our sales team must also be commended.”

The world’s most powerful belt conveyor system!

Total installed drive power of 58 MW (up to 10,000 KW per single drive pulley)
Advanced gearless drive technology, 13 km belt conveyor system, ~1.2 km of vertical elevation change
A number of world firsts, including the first global application of the newly developed ST 10,000 premier steel cord belt
TAKRAF - a leading global technology brand for handling high capacities/complexities in mining and material handling

TAKRAF Corporate Headquarters

Innovation out of tradition - It pays to talk to a specialist!
To watch a video of this
impressive installation, Phone: +49 341 2423-500
click on the QR code. [email protected], www.takraf.com
ENGINEERING & EQUIPMENT

Fugitive material: a preventable problem in bulk conveying

Most conveyors suffer some amount of
material loss from spillage, leakage, dust and Leakage at skirt seal
carryback emissions, collectively called causing belt wear
fugitive materials, writes R. Todd Swinderman, (all photos:
CEO Emeritus/Martin Engineering. This can © Martin
happen when moving a wide variety of bulk Engineering 2021).
cargoes, including cement. The loss can
range from 3% of the cargo for poorly
operated and maintained systems to less
than 0.1% for world class operations. The
lost material manifests itself as degraded
component life, workers exposed to
hazards and reduced product quality. While
fugitive materials cannot be totally
eliminated from bulk material handling
conveyors, the problem can be managed.
The root causes are often obvious but
rarely addressed. Rather, the standard
approach is to treat the symptoms, which
can include: unplanned downtime, excessive
cleaning costs, regulatory actions, poor
public relations and safety incidents.
Addressing these symptoms with workable
long-term root cause solutions will
improve availability, housekeeping, safety
and improve the company cash flow.

TYPES OF FUGITIVE MATERIAL

Fugitive material problems from any particle sizes similar to the cargo. Piles of
conveyor are indicated by the location and spillage can accumulate quite rapidly and
particle sizes of the accumulations, can occur intermittently from plugged
generally categorized as spillage, leakage, chutes, overloaded belts and mistracking or
dust and/or carryback. continuously from poorly designed or
Spillage is cargo that escapes the belt, inadequately maintained transfer points.
accumulating on either side of the Inclined loading zones can also have
conveyor and characterized by a range of material roll backward, causing spillage out

Spillage causing slip, trip and fall hazard.

the back of the transfer point.

Leakage of bulk material can happen
from worn skirt board wear liners and seals
www.drycargomag.com

or gaps in chutes and hoppers. Leakage

tends to slowly accumulate in piles of small,
mostly uniform particles created by the
dimensions of the leak. Leakage frequently
falls from overhead and collects on top of
transfer points and equipment below, so its
source may not be obvious.
Dust is the fine particles created during
processing and the degrading action as the
bulk material moves through a conveyor
system. Fine airborne dust is emitted at
locations where the cargo becomes
NOVEMBER 2021

airborne and is released from open

inspection doors, missing covers, worn
skirtboard seals and transfer point exits.
Because dust particles are very small, when
Dust spillage dry they are easily dispersed by wind and
DCi containing silica. blanketing wide areas.

70
ENGINEERING & EQUIPMENT

Carryback build up on return

roller and ground.

Carryback is fine material that sticks to fugitive material control, it’s advisable to return on the investment over time.
the belt surface or becomes lodged in the derate the capacity to 80–90% of the Quite often existing conveyor systems
cracks and crevices of the carrying side of theoretical capacity and use slower belt are “upgraded” to increase capacity or
the belt. Carryback material collects on speeds. A common spillage problem is handle alternate bulk materials. A common
components that the carrying side of the created during rainy periods when the change is to increase the speed of the belt.
belt touches and eventually dries out, angle of incline is appropriate for dry cargo Fugitive material problems are roughly
dropping beneath the system along the but not for wet material. Loading at less proportional to the speed of the conveyor
return path. Accumulations tend to range than a 5° angle and reducing the angle of (or tonnage). So if the belt speed is
from pyramid shaped piles of dry dust incline will reduce flooding and material doubled, the fugitive material problem and
particles to puddles of muck. rollback at the tail. costs may also double. Quite often an
Designing a skirtboard enclosure that is upgrade results in less capacity rather than
ISSUES CREATED BY DESIGN longer and taller, with the proper number more because of changed material
Control of fugitive material requires and placement of dust curtains, will help trajectories resulting in chute plugging and
attention to detail in the design stage that control dust emissions. Designing access increased wear, both requiring increased
is often not considered because of the for cleaning and maintenance can shorten downtime or reduced throughput to keep
additional design time (capital cost) downtime for these activities by 33% and running.
required and the perception that fugitive significantly reduce exposure to hazards
material control costs are hard to quantify that can result in safety incidents. If future ISSUES CREATED BY FUGITIVE MATERIAL
and therefore it’s hard to justify design capacity increases are likely, they should be Because of the large number of variables in
improvements. planned for in the initial design. In most handling bulk materials — both in the bulk
In new projects, careful thought must be cases adding 10% to the design time of a materials themselves and in the condition
www.drycargomag.com

given to capacity calculations, angle of project will allow for these details to be of the conveyors — it is physically,
incline, transfer point design and access for designed into the project, with little impact financially and statistically impossible to
cleaning and maintenance. To improve on the overall equipment cost but a huge reduce fugitive emissions to zero over a
long period of time. Accumulations of
Transfer point designed for fugitive materials are often an indication of
fugitive material control, with an underlying culture of ‘production first’.
three dust curtains maintained In this environment, frequent cleaning is an
close to the cargo. accepted necessity to keep production
running.
Many safety incidents occur during
cleaning and many fatalities have occurred
trying to clean with the conveyor
NOVEMBER 2021

operating. Piles of spillage on walking

surfaces present slip trip and fall hazards.
Accumulations of carryback and build-up
that falls when cleaning a chute or spillage
of cargo from overhead conveyors can
DCi increase the risk of blunt trauma or

72
 Build-up causes belt
mistracking, which
leads to belt damage

ENGINEERING & EQUIPMENT

crushing hazards. Safety incidents range and potential safety
from minor first aid to lost-time cases. A incidents.
common lost-time event is a muscular
skeletal event manifested as a back or
shoulder injury. These sprains and strains
are often hard to diagnose and on average
result in a multiweek recovery. Control of
fugitive materials to the point where
cleaning is seen as a periodic housekeeping
task rather than a daily production-enabling
strategy should be the goal.
The need to clean to keep running is
one obvious cause of unplanned downtime.
Another less obvious productivity thief is
the large role fugitive materials play in
reducing equipment life, which leads to
more frequent outages for maintenance
than necessary. Idler bearings are worker productivity, in some studies as from low morale.
particularly susceptible to contamination much as 20%, if respirators must be worn. Fugitive materials are often a root cause
from dust. Material escaping under the The leading cause of death in industry is of catastrophic events. Many dusts present
wear liners and skirtboard seals leads to from disease, not accident. Respiratory fire and explosion risks in addition to
shorter belt life due to belt grooving under illness from exposure to even nuisance dust health and safety concerns. The destructive
the seals. The belt (because of its total often leads to workers being put on long- power of dust explosions is well
mass) and idlers (because of their numbers) term disability, increasing worker documented in industries such as cement
are expensive and time consuming to compensation costs. A dirty operation also manufacturing, coal mining, grain processing
replace. attracts the attention of regulators and and sugar production. Static discharge into
There are additional hidden costs that neighbours. A reputation as a dirty place to a dusty atmosphere is a common cause of
are often overlooked when justifying work reduces the pool of employees who many of these fires and explosions. What is
improvements to control fugitive materials. are willing to work in such an environment, often harder to detect is the chain of
Working in a dusty atmosphere reduces and those already employed often suffer events that led up to a conveyor belt fire.
ENGINEERING & EQUIPMENT

In many cases a frozen idler bearing is the

heat source that ignites the grease and in
turn causes the belt to catch fire. In other Damaged idler roll shell
cases, mistracking belts caused by spillage because bearings failed from
or carryback built up on pulleys creates fugitive materials penetrating
friction between the belt and structure that the bearing seal.
can actually cut steel beams in two or
create enough heat to become an ignition
source. Friction is another common root
cause of major incidents.

DETECTING AND MEASURING FUGITIVE

MATERIALS
Indirectly, safety switches and conveyor
parameter sensors create data outputs
from problems created by fugitive materials
and thus can provide some measurement Fibre optics are being used to detect heat workplace and dramatically reduce the cost
or indication of problems to come. In many rise in idler bearings. Many conveyor of operation.
operations, acceptable fugitive material components that were simply considered
control performance means keeping the ‘dumb’ brute force devices such as belt REFERENCES
emissions to a level that allows cleaning or cleaners are now being remotely i: Conveyor Equipment Manufacturers
maintenance during scheduled routine monitored and controlled to improve Association: Belt Conveyors for Bulk
production outages or maintenance time. cleaning effectiveness and provide Materials, 7th edition.
Through good design techniques, well indications of malfunction. ii: Swinderman, R. Todd; et al.: Foundations™:
trained operators and predictive The Practical Resource For Cleaner, Safer, More
maintenance practices, most conveyor CONCLUSION Productive Dust & Material Control, Fourth
systems can go weeks without a need to Because the problem of fugitive material Edition, p.552, Martin Engineering, Worzalla
shut down just for cleaning without causing has been around since conveyors first came Publishing Company, Stevens Point, WI,
a safety problem or significant production into use, in the minds of many operators, 2009.
loss. fugitive material is merely a sign that the iii: Hubbard, Douglas W.: How to Measure
The application of indicators such as plant is producing, i.e., “We’re making Anything, Finding the Value of Intangibles in
belt wander switches, zero speed switches money, so there’s dust and spillage.” Business, John Wiley & Sons, 2010.
and plugged chute detectors has been However, fugitive material leads to major iv: Foundations™, pp.492-504.
practiced for as long as there have been issues that can and should be addressed. v: Swinderman Scale of Fugitive Material
conveyors. These devices are often Managing fugitive material is a more Measurement: Coscione, Marco:
purposely defeated due to false trips or economically and operationally sound Measurement of Fugitive Material for Belt
other signals that interrupt production. choice than merely chalking it up as “the Cleaning Assessment, ENCOM.
The bulk material handling industry is cost of doing business.” The effect that
starting to adapt sensor technology to the spillage, dust and carryback have on an ABOUT MARTIN ENGINEERING
rigors of bulk material handling to better operation is a tangible reminder of Martin Engineering is a global innovator in
monitor conveyor performance and unnecessary inefficiency. By working with the bulk material handling industry,
provide proactive warnings of problems experts and installing modern solutions to developing new solutions to common
that are developing. For example, wireless age-old conveyor problems and practicing problems and participating in industry
technology can gather data from numerous state of the art maintenance, operators can organizations to improve safety and
sensors without the need for hard wiring. significantly improve safety in the productivity. The company’s series of
www.drycargomag.com

Foundations books is an internationally

recognized resource for safety,
Carryback accumulation can cause maintenance and operations training —
bearing failure, leading to a belt fire. with more than 20,000 print copies in
circulation around the world. The entire
500+ page volumes can also be
downloaded as free PDFs from the Martin
website.
Martin Engineering products, sales,
service and training are available from 19
factory-owned facilities worldwide, with
wholly-owned business units in Australia,
NOVEMBER 2021

Brazil, Chile, China, Colombia, France,

Germany, India, Indonesia, Italy, Japan,
Mexico, Peru, Russia, Spain, South Africa,
Turkey, the USA and UK. The firm employs
more than 1,000 people, approximately 400
DCi of whom hold advanced degrees.

74
ENGINEERING & EQUIPMENT

Conductix-Wampfler’s customized power and data-management

solutions are invaluable for the cement industry’s big hitters

Nowadays, the production, transportation, production. transmission solutions. It also offers a

storage and processing of cement is a topic Conductix-Wampfler is an ideal partner strong after-sales service from its
of particular interest. This is especially true for rugged and reliable power and data comprehensive sales and service network
when considering the challenges of this management systems for mobile machinery worldwide.
time when the market is booming again and equipment, providing the broadest This range of services perfectly fits to all
after the stagnation caused by the Covid-19 range of products and customized levels of the process chain from quarries
pandemic. solutions for a wide array of applications. and crushing to storage and transportation
Based on many years of experience and Conductix-Wampfler offers spring- and to transformation and beyond — and meet
extensive application knowledge, motor-driven cable and hose reels, cable the requirements of OEMs and end-users.
Conductix-Wampfler’s mission is to keep festoon systems, slip ring assemblies and Motor driven cable reeling system for
the vital business of its customers moving, rotary joints, conductor rail systems, radio reclaimers, stackers, tripper cars and grab
with the aim of sustainably increasing remote controls, energy storage and data cranes used in longitudinal stockyards is
www.drycargomag.com
NOVEMBER 2021

DCi

76
 ENGINEERING & EQUIPMENT
Conductix-Wampfler conductor rail solutions for
overhead cranes in use at a HOLCIM cement
facility in central Europe.

the perfect solution with proven their demands with added value. Highly ization of existing equipment where spare
technology by means of years of valued by the globally operating company parts or complete systems need to be
experience. groups such as Thyssenkrupp Industrial renewed or replaced.
Tomaso Giusti, Market Manager Mining Solutions AG, AUMUND Group, FLSmidth , Big cement companies like Lafarge,
& Bulk Material Handling in Europe, Beumer Maschinenfabrik (just to name a Holcim, CNBM or CEMEX are sensitive to
confirms the high preference and track of few), is the ability to manage projects on a reliability, availability and innovation and
this product among major OEM customers global scale.” have a need for customized solutions.
in this market. “We are in regular close Besides the engineering, manufacturing, It is for this reason that the company’s
contact with our customers and MAG installation and commissioning of new festoon systems (see picture on p76,
Drive System with its unique and reliable equipment, Conductix-Wampfler actively left) or vertical slipring used for stacker
features like the magnetic coupler, is supports the entire service life offering and reclaimer in circular storages (on the
mentioned as an ideal solution satisfying maintenance, refurbishment and modern- right, project for CILAS in Algeria) are

THE BEST BULK TRUCK

LOADER IN THE WO RLD

Deployed as the most

effective way to load
a truck with bulk goods.

www.dino.nl
ENGINEERING & EQUIPMENT

greatly appreciated.
Conductix-Wampfler is in the front line
with its conductor rail solutions for
overhead cranes (HOLCIM cement facility
in central Europe) and rotary kiln systems.
A rotary kiln (see picture below) is a
cylindrical furnace for continuous
processes in process engineering, which
rotates continuously around its own axis.
Combined with a slight inclination of the
axis of rotation, the rotary motion provides
for product or fuel transport. Challenges
for energy and data transmission are
multiple, and include:
v huge slipring diameters (up to seven
metres and above);
v need for high power transmission (high
amperage);
v high temperatures (above heat shield up
to 80°C);
v need for data transmission in parallel
with power; and
v last but not least, a demanding
environment with the presence of
cement dust.
Conductix-Wampfler’s experienced people
can tailor every solution to customer
needs by means of designing and
manufacturing products at its global
facilities. Its team can support customers,
and help them to make the right selection
and give the right consistency for their
applications.
www.drycargomag.com
NOVEMBER 2021

DCi

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Handling cement with Vortex loading solutions and aerated conveying

ENGINEERING & EQUIPMENT

systems
Loading of cement can be a complex outlet scavenger to prevent dusting to
endeavour. From environmental and safety atmosphere between loading cycles.
concerns to efficiency, many factors are
taken into consideration by cement plants ADVANTAGES OF AERATED BIN BOTTOMS
when developing a loadout process. Vortex The addition of an aerated bin bottom
Global has identified key wear points, provides many advantages to a cement
reinforced those areas with abrasion handling process. These products are
resistant materials, and added features to utilized to move lighter weight material
reduce the time it takes to perform that is capable of being fluidized. During
maintenance on various components. the process of fluidization, air is passed
through static, dry material, causing the
LOADING SYSTEMS PROVIDE SOLUTION FOR material to acquire fluid-like characteristics.
CEMENT HANDLING The dry, solid material flows better and is
Loading spouts provide facilities with fast easier to handle in its fluid-like state.
and steady material flow during the loading The aerated bin bottom is located at the
of dry bulk solid materials in open or Vortex loading bottom of a silo or a hopper and can be
enclosed vessels such as trucks, railcars, spouts equipped especially beneficial on storage silos with
ships, and barges. Cement plants across the with in-line especially large diameters. Aeration of the
globe use loading spouts in their systems. filtration material within the bin eliminates the
Designed to capture fugitive dust, prevent systems are bridging and ratholing commonly
material waste, and ensure plant and designed to associated with bin storage and allows the
environmental safety — Vortex Loading collect fugitive material to flow at a much smaller angle of
Spouts require minimal maintenance and dusts by means repose.
service expenses. of air
When loading trucks and railcars with withdrawal. IMPLEMENTING SLIDE GATES INTO LOADOUT
dry bulk solid materials, including cement, PROCESS
the speed of load out is a key concern. For In some loading applications, slide gates are
optimal performance, loading spouts can be sourced to assist in various aspects of the
used in tandem with accessories specifically loading process. Vortex Global’s slide gates
designed to accelerate the loading process. The Vortex In-Line Filtration system is are ideal for controlling the flow of dry bulk
located at the material feed inlet to collect material. Designed to extend the service
CAPTURING DUST WITH FILTRATION fugitive dusts by means of air withdrawal. life of the valve and the ability to perform
SYSTEMS Fugitive dusts are captured in pleated maintenance without taking the valve out
In applications where dusting is a concern, polyester filter cartridges. Throughout the of line, Vortex slide gates are commonly
the addition of an in-line filtration system loading process, automatic reverse pulse used in the chemical, cement, coal, food,
can prevent dust from escaping to the jets inject compressed air to purge the grain, minerals, plastics and mining
atmosphere which addresses not only captured dusts back into the load. In industries.
safety concerns but maximizes profits by enclosed loading applications, the addition The Vortex Rounded Blade Gate is
eliminating the loss of product. of a self-sealing discharge seals off the designed to meet the most demanding

The Vortex rounded blade gate (left) and

www.drycargomag.com

Titan slide gate (right) can be used in

loading systems for both metering and
maintenance purposes.
NOVEMBER 2021

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ENGINEERING & EQUIPMENT

applications when handling heavy-duty

abrasive materials. The RBG Gate handles
dry material in gravity flow applications
where positive material shut-off and dust-
tight sealing is required. In loading
applications, the Rounded Blade Gate can
be used to meter the material being
handled. Should maintenance or work
need to be completed, a slide gate can be
used as a maintenance gate. The Vortex
Titan Slide Gate can be used in these
circumstances to stop material flow while
maintenance is completed downstream.

CASE STUDY: VORTEX LOADING SOLUTIONS

ASSIST AT CEMENT TERMINAL
In this application, a cement terminal
utilizes products from Vortex’s line of
loading solutions and aerated conveying
systems to handle cement.

FEATURES:
This 14” (355mm) loading spout stack up
features a Vortex Aerated Bin Bottom, Titan
This stack-up featured a
Slide Gate, Rounded Blade Gate, Dust Filter,
Vortex loading spout, in-
and Retractable Spout with Self-Sealing
line filtration system,
Discharge.
aerated bin bottom,
rounded blade gate, and
Titan slide gate.

APPLICATION:
The aerated bin bottom provides a
constant material flow, the rounded blade
gate offers metering of material, and the
Titan slide gate is utilized as a maintenance
gate should work on downstream
equipment be required.
The Dust Filter draws dust away from
the loading hatch and then pulses that dust
back into the load. The Self-Sealing
Discharge closes when the spout is
retracted — prohibiting internal dust from
escaping to atmosphere.
www.drycargomag.com

The previous 15-minute truck loading

time has been reduced to less than five
minutes per truck.

ABOUT VORTEX
For over 45 years, Vortex Global has
provided quality slide gates, diverters, iris
valves and loadout equipment designed
specifically for handling dry bulk solids in
gravity, vacuum, dilute, or dense phase
applications. Vortex equipment is
engineered for dependability, durability, easy
NOVEMBER 2021

maintenance, and offers proven solutions to

material handling and process efficiency
problems. With an in-house team of
engineers, Vortex products can be
This cement terminal utilizes a variety of products from Vortex
completely customized for individual
Global’s loading solutions line in their loadout process.
DCi applications or special installations.

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Clinker and cement import terminals

ENGINEERING & EQUIPMENT

All photos:
courtesy of
Duro
Felguera.

INTRODUCTION possibility for transporting clinker is using The latter usually employs screw conveyor
Even though cement production in the self-unloading bulk carriers with discharge technology. These ship-unloaders can
United States is expected to remain stable booms. unload ships from 5,000dwt up to Panamax
over the next few, it is anticipated that the size. Pneumatic ship-unloaders, on the
local consumption of this product will UNLOADING EQUIPMENT other hand, are designed to unload ships up
substantially increase, with not so many Cement may be unloaded using either a to 50,000dwt. Very seldom, cement may be
cement plants planned to be built in the pneumatic or a mechanical ship-unloader. unloaded using clamshells in combination
near future. In order to fulfill the future gap
between the consumption and the
production of cement, it will be necessary
to import either cement or clinker in large
quantities.
In the following sections, we will
describe the different equipment used to
import, handle and efficiently store cement
and/or clinker in large quantities.

IMPORTING EITHER CEMENT OR CLINKER

The importing cost per tonne of cement
may be relatively higher, than the cost of
the same tonnage of clinker. Furthermore,
MARTIN® CLEAN BELT
in both cases, it is necessary to have an
infrastructure to unload, convey and
temporarily store these products in large
SYSTEMS & SERVICES
quantities. If it is decided to import clinker Eliminate material carryback and increased cost of
to produce cement, a grinding facility will operation involving manual cleanup, damage to belts
be required, either at the reception port or
and systems, and downtime and lost production.
at a remote location, which will increase
the total project cost as well as the cost of Martin® clean belt systems and services ensure
the whole operation. All these factors, your conveyor belts are cleaner, safer, and more
including the freight cost of the ships, productive by providing unsurpassed cleaning
should be taken into account when
performance and remote monitoring with industry-
deciding the optimum importing operation.
leading technology, experience, and knowledge.
The chart above summarizes the
different equipment required to unload,
convey and store either cement or clinker
imported by ships.

TYPE OF SHIP
Cement may be imported using either self- FACTORY DIRECT SALES & SERVICE
unloading vessels or open hatch bulk
carriers. The freight cost of self-unloading CALL 800-544-2947
vessels is normally higher than that of open
VISIT MARTIN-ENG.COM
hatch bulk carriers. Therefore, it is
important to take into consideration these ® Registered trademark of Martin Engineering Company in the US and other select locations. © 2021 Martin Engineering Company.
Additional information can be obtained at www.martin-eng.com/trademarks and www.martin-eng.com/patents

factor to calculate the final cement’s CIF

(cost, insurance, freight) cost.
Clinker is imported using open hatch
bulk carriers, which normally have cargo
gears or cranes installed on deck. Another
ENGINEERING & EQUIPMENT

Ecological
hoppers.

with ecological hoppers. Grab cranes.

Due to the abrasiveness
of clinker, it is recommended
to use clamshells to unload
this product. In this case it
may be used either the
cranes installed onboard the
bulk carriers, or a grab crane
installed on the pier, which
discharge to an ecological
hopper.

CONVEYING EQUIPMENT
Cement may be conveyed
pneumatically, using either
dense phase pumps or a
screw pump. Depending on
the conveying distance, it may
be recommended to use
mechanical conveying equipment, such as a pipe conveyor or a conventional covered belt conveyor.
Clinker is conveyed using mechanical equipment, either a pipe conveyor, or a conventional covered belt conveyor.
To convey either cement or clinker, it is strongly recommended to avoid transfer points to reduce the dust emission areas. All transfer
www.drycargomag.com

Pipe conveyors.
NOVEMBER 2021

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 ENGINEERING & EQUIPMENT
FACHS – main components.

points must be equipped with an efficient FACHS (Fully Automated Cement cement.
dust collecting system. Horizontal Storage) was designed with the Clinker can be stored inside a
intention to avoid the used of front-end warehouse, using a tripper car or a stacker
STORAGE FACILITY loaders with operators to reclaim the unit, in combination with a portal reclaimer
Cement can be stored using either vertical
silos, domes or flat storage facilities, which
should be designed with at least 15% more
capacity than the largest ship to be
unloaded.
Dry cargo warehouses may be
converted into cement flat storages. This
will avoid pilling and costly civil works.
However, the main disadvantage of the flat
storage facilities is the inefficient reclaiming
system, which normally consists of front
loaders, or a large amount of open
aeroslides covering the entire flat storage
floor. Flat storages are ideal for terminals
which will import cement on ships up to
50,000dwt.
In order to improve the efficiency of the
reclaiming of cement from flat storages, a Portal reclaimer and
new system has been recently developed. stacker unit.
This new cement storage system known as

Side reclaimer. or a side reclaimer. It is also possible to

store clinker on domes, which clinker is www.drycargomag.com
reclaimed through the bottom of the
dome, by means of feeders.

CONCLUSIONS
The following factors should be taken into
consideration to select the optimum
equipment required for a cement or clinker
importing terminal:
v ship’s freight cost;
v CIF cost of cement and clinker;
v possible cost of a grinding facility;
v storage system; and
NOVEMBER 2021

v unloading and conveying system.

Duro Felguera has the technology and

experience to design and supply the
necessary equipment for a cement/clinker
import terminal. DCi

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ENGINEERING & EQUIPMENT

Capotex — many years of covering cement conveyors worldwide

Spanish company Capotex specializes in the covers. Capotex offers a wide range of to protect the health and integrity of
manufacture of a wide range of materials, products in order to cover conveyors, not workers and the surrounding populations.
accessories and designs for conveyor belt only to protect the environment, but also The new safety and sustainability
www.drycargomag.com
NOVEMBER 2021

DCi

84
 LISTENOW
VERLADESYSTEME FÜR SCHÜTTGÜTER

We make sure that nothing gets lost!

For over 50 years, our loading systems for bulk materials
have been synonymous around the world with long-last-
ing and reliable technology.

regulations, as well as those relating to the conservation and

care of the environment, have generated, in the industrial
market, the need to evolve and improve infrastructure and its
resources. Replacement
loading hoses
Big engineering, mining and cement companies face new +49 7152 5090
0
challenges to ensure compliance with the legislation, protecting
the investment of their projects, their infrastructure, their
workers, and protecting the raw materials that are transported.
By covering the belt conveyors, it is possible to ensure:
v job security: the use of covers improves operational safety,
avoiding the risk of trapping, trawling accidents and material
falls.
v dust reduction: due to the covers, dust emissions are › Bulk loading systems for open and closed loading
reduced by protecting both the environment and nearby
› Loading with no segregation e.g. with FLOW-stop
populations and the health of workers.
technology
v complementary systems: the covers facilitate the
installation of other systems designed to improve health and › Dust-free loading
safety conditions: anti-fire, anti-explosion, anti-noise systems, › High quality loading hoses e.g.
dust suppression spray systems. made in wear-resistant PU-flex
v transport efficiency: the covers on the belts reduce the loss › Positioning System LIS-pos
of product being transported by escape or fall;
› First-class service:
v belt conveyor component protection: a suitable cover
Start-up and installation
system protects the belt conveyor against inclement weather
Revision and repair services
conditions (wind, rain, snow, humidity) reducing maintenance
System maintenance, modernisation and upgrading
costs due to less wear and damage of its components such as
belts, rollers, etc. avoiding a negative impact on productivity › more informationen at www.listenow.com
and operating results. For example, prolonged exposure to
UV radiation can damage the top rubber surface of the
conveyor belt, causing oxidation which can contribute to
surface cracking and belt tearing. LISTENOW GmbH & Co
v company image: a good policy of environmental protection Dieselstrasse 21
and reduction of accidents at work all contribute positively to 71277 Rutesheim / Germany
improving a company's image.

+49 7152 50900
 [email protected]
 www.listenow.com
ENGINEERING & EQUIPMENT

New Siwertell ship-unloader ordered to double cement handling

capacity in Kuwaiti port
Bruks Siwertell has won a new order from
returning customer, Kuwait Portland
Cement Co, for an ST 490-M Siwertell
ship-unloader, equipped with a new side tilt
motion for enhanced through-ship
efficiency. It will join another cement
handling Siwertell ship-unloader in Shuaiba
Port, Kuwait City, Kuwait, which has been
securing environment-friendly material
handling for the operator for over two
decades.
“Kuwait Portland Cement has benefited
from 20 years of experience using our
Siwertell screw-type technology,” says
Peter Göransson, Sales Manager, Bruks
Siwertell. “It knows what our unloaders
deliver; time and again the technology
has proven its capabilities, demonstrating
reliability, efficiency, and environ-
mental protection in terms of emissions “The new unloader is part of the two out-loading units,” says Göransson.
and noise. operator’s long-term vision. It has been “This is a great asset, delivering increased
“In fact, the main reason why the designed as a fully assembled, heavy-lift redundancy and ensuring that any
operator returned for a second unit is the mode delivery, but will actually be demurrage costs are kept to a minimum if
outstanding operational performance of its transported in breakbulk,” he explains. there is an issue with the downstream
original delivery,” continues Göransson. “This enables it to be relocated, fully conveying system.”
“Our ongoing service support, along with assembled, to a new location should the Like its predecessor, the new unloader is
Bruks Siwertell’s through-life commitment customer wish to do so in the future, also designed to operate in Kuwait’s
to maintenance and spare parts were other minimizing any transition downtime.” extreme climate. To accommodate
major deciding factors.” Planned for delivery to the port in mid- predicted temperature rises in the region,
The new unloader will deliver even 2023, the rail-mounted unit will handle the latest unit can withstand ambient
higher levels of performance and through- various cement types and deliver a summertime temperatures of up to 55°
ship efficiency to Kuwait Portland Cement. continuous material handling capacity of Celsius.
“It features a new side tilt motion, which 800tph (tonnes per hour), discharging
offers an enhanced reach into the corners vessels up 50,000 dwt. It will be installed ABOUT BRUKS SIWERTELL
of the cargo hold as well as under the hatch on an existing jetty next to the operator’s Bruks Siwertell is a major supplier of dry
coamings,” he adds. “As a result, less older ST 490-F, rail-mounted Siwertell bulk handling and wood processing
material is left for the clean-up phase, unloader. systems. The company designs, produces
which reduces vessel turnaround times, Both the current and new unloader will and delivers systems for loading, unloading,
raising the utilization rate of the jetty and be equipped with a total capacity regulating conveying, storing, and stacking and
therefore profitability. system, maximizing the use of each unit, but reclaiming dry bulk materials, alongside
“Also, all Siwertell unloaders offer a ensuring that they do not overfill the equipment for chipping, screening, milling
www.drycargomag.com

layer-by-layer unloading process, which downstream conveying system. They can and processing wood for the biofuel, board,
minimizes the chance of airborne emissions also directly discharge to bulk trucks via a saw mill, pulp and paper industries. All
from avalanches in the cargo hold. The side truck loading arrangement underneath the equipment is designed to ensure
tilt function adds to this capability,” ship unloader’s gantry. environmentally friendly and efficient
Göransson notes. “The new unloader is equipped with operations.

Starlinger AD*STAR block bottom valve bags to package cement

In the mid-90s last century, Starlinger & Co proven to be a highly protective and eco- THE TECHNOLOGY
GmbH patented a new type of block friendly alternative to the existing types of Starlinger provides the full range of
bottom valve sack that combined the shape cement packaging. It is now used all over technical equipment and know-how
of a paper block bottom sack with the the world for packaging a wide range of needed for the production of AD*STAR
NOVEMBER 2021

flexibility of a plastic film sack and the free-flowing goods besides cement and sacks: polypropylene tape extrusion lines,
strength and durability of woven other building materials, among them tape winders, circular looms for fabric
polypropylene tape fabric. fertilizer, chemicals and resins, but also production, coating and printing machinery,
The so-called AD*STAR sack is flour, sugar and animal feed. Currently, as well as the ad*starKON block bottom
produced out of coated polypropylene tape more than 17 billion AD*STAR sacks are sack conversion lines. The entire AD*STAR
DCi fabric by means of hot-air welding and has produced worldwide per year. technology has been developed with the

86
 ENGINEERING & EQUIPMENT
focus on high sack quality: this ensures
smooth and trouble-free cement filling on
the most modern filling lines. A high degree
of automation in sack production is a key
factor for achieving the best sack quality.
With this purpose in mind, Starlinger’s
latest sack conversion line model
ad*starKON HX has been equipped with
intelligent features for achieving optimum
sack quality. The input material for the
conversion line is fabric produced on
circular weaving looms; as a result of the
weaving process, slight variations in fabric
size may occur. To compensate for these
variations, fabric dimensions are monitored
during sack conversion, and bottom
forming and closing are automatically
adjusted in order to produce a sack with
precise geometry. Another feature
automatically adapts the length and
position of the cover and bottom patches
to achieve a perfect fit on each cement
sack. The result is a tight sack that protects moisture;
the cement from external influences such v no spillage or leaking thanks to the
as moisture, and perfectly closed corners polypropylene coating;
prevent the loss of cement due to leakage. v adjustable air permeability due to
Waste is significantly reduced — both in optional micro-perforation — keeps
terms of sack production waste and dust formation to a minimum and
cement loss. Little cement loss means that protects moisture from entering the
there is no need to replace it; thus, less sack (longer shelf life);
packaging is required. The ad*starKON v they are tamper- and theft-proof;
block bottom sack conversion lines cover a v sack production is fully automated; and
broad format range, from a sack capacity of v attractive sack design for improved
only five litres up to 100 litres. brand promotion.

ADVANTAGES STRONG AND LIGHTWEIGHT SACKS:

Starlinger AD*STAR sacks provide the BENEFITS FOR THE CEMENT PRODUCER AND
following advantages: THE ENVIRONMENT
v they are suitable for automated filling AD*STAR sacks are economical in the use
and palletizing. of raw material, have an extremely low
v they are brick-shaped and strong for breakage rate, help to reduce CO2, and can
improved stacking, and they occupy less be either recycled or reused for other benefit for the cement producer. The
floor space in storage facilities; purposes. Each one of these ecological special characteristics of tape fabric ensure
v high strength — even when exposed to advantages also turns into an economic high strength and durability while
significantly less raw material is used in the www.drycargomag.com
production process. As a result of the
material characteristics and the special
production process, the empty weight of an
average AD*STAR sack holding 50kg
cement can be as low as 65g. In
comparison, a same-sized two-layer paper
sack weighs about 140g, and a PE film sack
150g — both have almost the double
weight of an AD*STAR sack. The lighter the
sack (while offering equal strength and
protection), the less raw material input is
required. This not only keeps sack
NOVEMBER 2021

production costs low, but the economical

use of raw material also helps to reduce the
carbon footprint.
The low breakage rate of AD*STAR
sacks has both environmental and
economic effects. Compared to sewn DCi

87
ENGINEERING & EQUIPMENT

polypropylene sacks, the risk of

contaminating earth and water with the
content — e.g. cement — is almost zero.
Secondly, there is an enormous savings
potential for cement producers as breakage
rates in the life cycle of paper sacks (filling,
conveying, palletizing, stacking, loading,
transporting, unloading, …) are about 4% to
5%, whereas only 1% of the AD*STAR
sacks are damaged in the course of their
life-cycle.
Another big issue is CO2 emissions: the
cement industry is responsible for about
7% of total global CO2 emissions. By

efficiency is a major focus of Starlinger in

technology development. Starlinger
machines are energy-efficient, easy to
handle, and operate with minimum raw
material input and low waste generation.
As the company also has a business unit for
the production of plastics recycling
machinery, the idea of easy-to-recycle
plastic packaging played an important role
for packaging product and process
development from very early on. With the
Circular Packaging Concept, Starlinger has
set the first step for recycling industrial
packaging. The concept aims to establish a
closed product loop for FIBCs (big bags) —
used FIBCs are collected, cleaned, recycled
and turned into new FIBCs again. Together
with a European project partner, Starlinger
reducing the breakage rate, millions of emissions have paved the way for a wide- has successfully carried out trial runs and is
tonnes of CO2 emitted during cement range use of AD*STAR sacks. “Big Chinese now promoting the implementation of the
production could be saved additionally each cement producers such as Anhui Conch concept with other FIBC producers. The
year. Cement or Hubei Huaxin Cement have long-term goal is to establish a circular
been using AD*STAR cement sacks for a economy for woven plastic packaging by
LATEST PRODUCT DEVELOPMENT: long time already,” explains Markus setting up collection schemes and providing
AD*STAR *EASY Grabenweger, Starlinger Sales Manager the technology for recycling and producing
The new patented easy-open feature allows China and Southeast Asia. “After the new sacks with recycled content/made
for quick and easy emptying of AD*STAR publication of the new Cement Bag entirely of recycled material.
cement sacks without the use of Standard, other renowned cement
mechanical tools. To open the sack, a strip producers such as Red Lion Cement, ABOUT STARLINGER & CO GES.M.B.H.:
that is welded to the bottom patch of the Southern Cement, Southwest Cement and Starlinger is a Vienna-based mechanical
www.drycargomag.com

sack is simply pulled off. This means that Gansu Qilianshan Cement have officially engineering company with production sites
woven plastic sacks are now catching up announced the changeover to AD*STAR in Weissenbach and St. Martin, Austria, as
with paper sacks in this regard and greatly cement sacks. Due to these developments, well as Schwerin, Germany, and Taicang,
facilitate the daily work of end consumers. the sales of our AD*STAR production China. As a major global supplier of
The development of the AD*STAR *easy equipment in China have drastically machinery and complete lines for woven
sack was prompted by the great demand in increased. Currently, we have an installed plastic bag production, recycling and PET
the market, which is also reflected by the production capacity of three billion extrusion and refinement, Starlinger & Co
increasing number of conversion lines sold AD*STAR sacks per year in China, and Ges.m.b.H. is a synonym for leadership in
equipped with the easy-open feature. capacities for another three to four billion quality and technology in over 130
sacks are already in the pipeline for 2022.” countries. Founded in 1835, the family-
RECENT DEVELOPMENTS IN THE MARKET Latest AD*STAR projects also include owned business has been exporting
The publishing of the new “Chinese machine sales to Indonesia, Kazakhstan and machines worldwide for more than 50
NOVEMBER 2021

Cement Bag Standard (GB/T 9774-2020)” Côte d’Ivoire. years with an export quota of over 99.5%.
in October 2020 marks the biggest Sales and service centres in Brazil,
milestone in the history of cement FOCUS ON SUSTAINABILITY AND CIRCULAR China, India, Indonesia, Mexico, Nigeria,
packaging in China. The stringent plans of ECONOMY Thailand, Russia, South Africa, USA and
the Chinese government regarding Besides aiming for highest quality and Uzbekistan ensure quick and professional
DCi environmental protection and CO2 efficiency in packaging production, resource technical support and service. DCi

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 ENGINEERING & EQUIPMENT
Spreading the love
with the right fertilizer handling equipment

The portal reclaimer removes the bulk material

in layers from the side slopes and transports it
through a primary crusher to a belt conveyor at a
capacity of 600tph (all photos: BEUMER Group
GmbH & Co. KG).

Louise Dodds-Ely

BEUMER Group supplies shiploading system for urea fertilizers to

www.drycargomag.com

Malaysia: perfect timing

Since the 1980s, Asean Bintulu Fertilizer currently the most widely used nitrogen the leading producer in Malaysia. Twenty-
(ABF), a subsidiary of the leading Chemical fertilizer in agricultural industries world- five companies are part of the group,
manufacturer in Southeast Asia, Petronas wide, mainly due to its comparably low offering a wide range of chemical products,
Chemicals Group Berhad, has a production costs. The demand is continuously such as olefins, polymers, methanol and
location for carbamide fertilizer (urea) in increasing due to the world’s growing fertilizers, which are urea-based for
the Malaysian coastal city of Bintulu global population. The manufacturing plant example. Their customers are based in
(Sarawak) on the island of Borneo. To meet in the coastal town of Bintulu on the about 30 different countries. The most
growing demands, BEUMER Group was Malaysian island of Borneo has been one of important markets include Malaysia, China,
NOVEMBER 2021

contracted to modernize and increase the the biggest of its kind in Asia for many India, Thailand, Indonesia, Japan, South
performance of the plant between the years. It is operated by Asean Bintulu Korea, Taiwan, the Philippines, Vietnam,
longitudinal stockyard and the ship loading Fertilizer Snd. Bhd., a subsidiary of Petronas Singapore, Australia and New Zealand.
system. The scheduling was very Chemicals Group Berhad (PCG). To meet the growing demand for urea,
streamlined. PCG is one of the largest manufacturers Asean Bintulu had to increase the capacity
Carbamide, also known as urea, is of chemical products in Southeast Asia and of its export facilities. BEUMER Group was DCi

89
ENGINEERING & EQUIPMENT

The new system loads the

urea fertilizer fast and
reliably onto ships in the
port of Bintulu.

awarded with the contract as a general Project Manager at BEUMER Group. “This cooperation with PBJV Group, developed a
contractor, and in a consortium with the means that we had to integrate our new technical solution which they presented to
PBJV Group Sdn Bhd from Malaysia, which systems into the existing ones in a way that ABF together with a schedule that met all
took over the assembly of the system. The ensured that the material flow from the the required milestones. Asean Bintulu
service provider from Malaysia is longitudinal stockyard to the ship was not Fertilizer was convinced by the system
responsible for the transport and interrupted.” Another requirement was providers hard work over the course of the
installation of onshore and offshore that the already available hardware and proposal phase.
pipelines, in addition to other activities. The software components from third-party AFB's production location is running
company also equips ships for its respective suppliers needed to be updated to match 24/7. “To minimize the downtime, we had
jobs in the oil and gas industries. the increased performance.” The only 55 days scheduled to complete the
maintenance of the entire system will entire integration, which was quite a
COMPELLING ENGINEERING AND TIME become a lot easier thanks to this challenge,” admits Beintmann. BEUMER
MANAGEMENT modernization, because all components are Group took over project management and
“This order was a brownfield project,” on the same technical standard,” describes engineering, supplied all the systems and
explains Heinrich Beintmann, Senior Beintmann. BEUMER Group, in supervised installation and commissioning.

The shiploader is in operation

24/7 hours at the port.
www.drycargomag.com
NOVEMBER 2021

DCi

90
 Shiploader before
starting operation.

ENGINEERING & EQUIPMENT

The scope of supply included a portal The assembly of the portal reclaimer ADAPTED TO THE PERFORMANCE
reclaimer for 600tph (tonnes per hour), the and ship loader was less time-critical, REQUIREMENTS
shiploader for 1,000tph, a fully automatic because the team could start working on it The portal reclaimer traverses the
tripper conveyor for filling the longitudinal already prior to the 55-day shutdown, longitudinal stockpile with the urea fertilizer,
stockpile, a mimic panel to comfortably before the production plant was closed removes the bulk material in layers from the
monitor and control the system, the down. The assembly of the portal reclaimer side slopes and transports it through a
adjustment of the motor control units, a in the longitudinal stockpile offered an primary crusher to a belt conveyor at a
substation, a transfer station with a capacity entirely different challenge. “The low capacity of 600tph. The portal reclaimer is
of 1,000tph and a screening station, the ceiling height made it impossible for us to fully automated. An existing side reclaimer
most critical element in the schedule. The assemble the reclaimer on the floor and adds another 400tph from a second
system supplier installed a solution with a then set it up, as we usually do,” saud the longitudinal stockpile into the system.
capacity of 2 x 500tph. BEUMER expert. The system supplier had “The existing belt conveyor systems
“We had to disassemble the existing to find another solution: “Here we had to were not designed for the higher
screening station down to the main assemble it segment by segment. performance of our new portal reclaimer,”
supports of the building and provide it with Challenging and time consuming.” says Otto Schmelzer, Engineering Manager
entirely new technology,” explains BEUMER and PBJV were up for the at BEUMER Group. “Which meant that we
Beintmann. The transfer station divides the challenge, and, in close co-operation, had to upgrade the drive stations that were
material flow towards ship loading and developed installation drawings and already there.” Not a problem for the
truck loading. This allows the customer to procedures for each work package, in system supplier: because, you want all
load either ships or trucks or both at the compliance with the strict safety systems used by the customer to run
same time. requirements of all parties involved. seamlessly with each other, BEUMER

The portal reclaimer removes the

bulk material in layers from the
side slopes and transports it through
www.drycargomag.com

a primary crusher to a belt conveyor

at a capacity of 600tph.
NOVEMBER 2021

DCi

93
 ENGINEERING & EQUIPMENT
continuously develops not only its own
products further, but its Customer Support
takes care of upgrading mechanical and
control technology manufactured by third-
parties. “Our customers are incredibly
satisfied with our modification concepts,
because our goal is to keep already existing
structures as much as possible,” explains
Schmelzer. This helps companies to reduce
their costs, by reducing the number of
necessary components and ensuring fast
return on investment. Adding shorter The portal reclaimer removes the bulk
installation and handover times was also material in layers from the side slopes and
particularly important with this project. transports it through a primary crusher to
a belt conveyor at a capacity of 600tph.
EFFICIENT SHIPLOADING
Belt conveyors transport the urea over the
screening and transfer stations to the new with the milestones of the entire project,” conveying, loading, palletizing, packaging,
ship loader, also supplied by BEUMER says BEUMER expert Beintmann. “And the sortation, and distribution. With 4,500
Group. The mobile and swivel-mounted cooperation between the PBJV Group has employees worldwide, the BEUMER Group
shiploader has a telescopic chute and a been exemplary.” has annual sales of about €950 million.
throw-off belt conveyor to make loading as The commissioning for the shiploader BEUMER Group and its subsidiaries and
efficient and flexible as possible. “With this took less than three weeks, the entire sales agencies provide their customers with
system, our customer can now load ships system was completely commissioned after high-quality system solutions and an
with 1,000tph,” says Beintmann. eight weeks and handed over to the extensive customer support network
Petronas and Asean Bintulu Fertilizer operator. around the globe and across a wide range
are completely satisfied with the solutions, of industries, including bulk materials and
the progression of the project and the ABOUT BEUMER piece goods, food/non-food, construction,
work of the BEUMER and PBJV The BEUMER Group is an international mail order, mail and airport baggage
consortium. “Our part aligned perfectly manufacturer of intralogistics systems for handling.

Growing Into
Performance.
Full range of dry bulk solutions.
The Moduflex loading chutes are designed to grant high capacity,
great performance, and long-term reliability. The Moduflex sturdy
structure allows its installation in heavy duty environments, like ship
loading, rail and road transport, and warehousing. Cimbria is a global
leading manufacturer of conveying equipment, covering a wide
range of dry bulk applications from agricultural products to industrial Dust Free
commodities, cement, fertilizers and other raw materials. Our broad Outloading
experience ensures our clients receive the customized solutions they Clean and
need to grow their business. Safe Work
Modular
and Flexible

Cimbria.com
Cimbria Unigrain A/S
Herning, Denmark
Phone +45 72 42 24 00
[email protected]
ENGINEERING & EQUIPMENT

Cleveland Cascades’ chutes prevent degradation of fertilizer cargoes

Known as a vital bulk commodity selected cones have a maximum capacity of
throughout the industry, fertilizers must be 2,800m3/hr surpassing the customers’
handled carefully in order to minimize the requirements and allowing for any material
level of product degradation and dust surges.
generation during loading procedures. Liner selection was of utmost
Without a safe, reliable and efficient loading importance as various materials would be
system in place, dry bulk fertilizer loading loaded through the system. It was decided
can have a negative impact on the that UHMW PE (ultra-high-molecular-
environment. weight polyethylene) would serve as the
The Cleveland Cascade Ltd loading best choice, due to its low co-efficient of
system utilizes a series of inclined cones to friction reducing the ability of the material
direct material flow and reduce the velocity to ‘cake’ and stick to the liner. Because of
and impact of the material. A state of ‘mass this, an anti-static path had to be provided
flow’ is achieved, allowing the material to and was achieved by using stainless steel
move as a single mass throughout the banding between each of the cones and
system to form stockpiles at the outlet then attaching these to the head chute and
reducing the effects of segregation. Dust Close-up of the carrier steel fabrications.
generation is practically fully negated CC850’s head A unique aspect for this system was the
through the use of the Cascade system chute. ability to store the retracted system
eliminating the need for expensive, high- underneath the boom through the use of a
maintenance dust extraction and filtration stowing winch. This meant that when not
systems. remain level as the luffing boom of the ship in use the whole system could retract as
Many systems have been supplied for loader manoeuvres to load between the luffing boom was raised effectively
the loading of fertilizers by Cleveland operating angles of –2° to +11°. occupying less area around the port.
Cascades across Europe, Africa, Asia and In a fully extended state, the system can
North & South America. Some examples of reach 20m long from the interface to the CC900
these are discussed below: outlet; a retracted operational length of This project is a Cascade storage loader for
7.7m can be achieved which is measured to indoor application to be used for the
CC850 the base of the skirted outlet. This system loading of polyhalite and was supplied in
A Cascade shiploader was supplied for was provided with a head chute 2018 to Loftus, UK. When fully extended
loading fertilizers at rates of up to 2,100tph maintenance platform allowing routine the system reaches a length of 15m and can
(metric tonnes per hour) to the Port of inspections to take place alongside achieve a retracted length of 4.5m whilst
Aqaba located in Jordan. A pivoting head observations for material behaviour during still remaining operational.
chute is featured to allow for the system to loading. For this system, the cone size required
Given the loading rates and the density were the Cleveland Cascades Ltd 600 GRP
of the product it was apparent from the profiled rim cones. These are one of the
inception of the project that a large-sized smallest cones produced and given the
cone would be required. The required system length careful consideration was
volumetric rate for this project was necessary with regards to cone stacking
calculated to be 2,211m3/hr, this meant that
the Cleveland Cascades Ltd 1700 GRP CC900 head
profiled rim cones were required. The chute.
www.drycargomag.com
NOVEMBER 2021

CC850.
DCi CC850 with skirt.

96
 ENGINEERING & EQUIPMENT
trimming spout are
supplied for each system.
This allows for
conventional loading to
take place forming material
stockpiles using the skirted
outlet. Following this, any
void space within a vessels
hatch can be utilized
through using the trimmer
outlet by providing material
throw in a controlled
manner to occupy the
available area.
The telescopic system is
CC900. operated by a remote
drum winch and features a
complete suite of electrical
and oscillation during operation. Ceramic components for system
tile lining is applied to the cones to provide safety and automation. DCi
a long lasting wear-resistant liner without Trimming spout.
impeding the flow characteristics of the
material. These cones have a maximum
volumetric throughput capacity rated at
246m3/hr which was ideal for the set-up
given the requirements provided by the
customer. The low 80tph feed rate
complimented the small cones allowing
them to fill to the correct level without
overspilling occurring.
At the outlet of the system a heavy
rubber skirt is in place. Cleveland Cascades
commissioning engineers set up the system
to automatically raise as the polyhalite
comes in to contact with the material
detection probes whilst still maintaining
contact between the material pile and
skirted outlet. This further aids with
preventing dust from escaping outside of
the system and into the surrounding
environment.

CC943-6
Four identical systems have been supplied
to Vistino, Russia for the use of loading
fertilizers. Each system is attached to an
independent shiploader via a fixed head
chute design. They can achieve and
extended length of 31m whilst having the
Remote care for
capability to retract to as short as 6.6m.
Varying liners are used throughout the
your belt weighers
system, within the head chute stainless
steel is featured for corrosion protection
and to provide extra wear resistance as
• Virtual front panel to your belt weighers
material enters the system from the • Virtual site presence from your CST support team
conveyor belt. The cone selection for this
project were the Cleveland Cascades Ltd
• Leaders in belt weigher technology
1700 GRP profiled rim cones which feature
UHMW PE liners; this is apparent for the
trimmer also and provides ample abrasion
1300 784 449
protection as the material is brought under controlsystems.com.au
control as it travels through the cascade.
Both a skirt and interchangeable On screen, remote interface for (i) Symmetrical Dual Redundant Scale in South America. (ii) Traffic lighted calibration
status in Australia. Both concepts patent pending). (iii)Myscale customer accessible calibration history.
 ENGINEERING & EQUIPMENT
Moerdjick, Netherland – double
wall silo by B.S.P. Engineering.

A Trip
to Italy
Italian Engineering

Jay Venter

Bespoke bulk handling equipment from B.S.P. Engineering

HISTORY

Spiral construction system.

B.S.P. Engineering – Bulk Storage Plants
Engineering — was founded in 1997 by the
entrepreneur Franco Montorfano, thanks
to his 30 years of experience in the bulk
storage field. This company, now managed
by Montorfano’s sons Silvia, Marco and
Mauro, is the natural evolution of previous
business and engineering experiences
acquired — also thanks to the
co-operation of international companies
that owned high technological patents.

BSP ACTIVITY www.drycargomag.com

B.S.P. Engineering designs, manufactures
and installs equipment intended for the
storage (spiral silos), the extraction
(planetary extractors) and handling of bulk
materials (conveyors, bucket elevators
etc), either solid or liquid (tanks) thus
supplying customers with complete
turnkey facilities. and waste treatment. machines for the construction of the silos,
The core business is not limited to just The continuous research and the manufacture the spiral cylinders with an
the food and agricultural fields (grains & development activity have allowed B.S.P. outer double-folding wall and an inner flat
seeds, flours, starch etc.) but it extends to Engineering to become a major force in the and smooth wall. No bolts are necessary
the larger and more complex industrial storage, extraction and handling of any bulk with this constructive system.
NOVEMBER 2021

fields, including: aggregates (cement, materials. This technology, which allows for the
petcoke, flyash, lime, gypsum etc.), plastics construction of silos ranging from 2.7 to 25
& chemical (rubber, PVC, urea, alumina, BSP EXPERTISE metres in diameter and up to 40 metres in
KCL, sodium dichromate etc.), biomass BSP metallic spiralled silos are built directly height, makes it possible to eliminate all the
(woodchips, rice husks, olive residue, on the installation site from steel coils. BSP defects of the traditional bolted silos, such
animal and vegetable flours etc) and sludge specialized operators, using special BSP as: the formation of rust due to the use of DCi

99
ENGINEERING & EQUIPMENT

BSP venting roof.

bolts; or undulating steel plates, a source of Unloading bulk products from silos — involved into the design of all the
dust deposits, or insects and the formation particularly poorly flowing materials — can equipment in the storage plants, such as:
of moulds causing pollution of the stored be a problem: the experience and the v bucket elevators;
product. co-operation of Italian and French v belt conveyors, chain conveyors, screw
The clear advantages for the engineers were able to remove those conveyors, flight conveyors, vibrating
construction process include the easy obstacles that were once considered conveyors;
assembly of the silos and their erection insurmountable. v conical extraction systems, vibrating
directly on the site without previous The planetary extraction technology — extraction systems;
processes in the workshop. These all better known as ‘FIFO’ (First In-First Out) v pneumatic conveying systems;
translate into economic advantages arising concept — works by collecting the v venting systems;
from a short manufacture time and lower product across the whole surface of the v processing automation systems; and
transport costs. This enables BSP to keep flat bottom silo and conveying it towards a v any kind of steel supporting structures,
staying competitive in the market. central outlet. This makes it possible to carpentries, piping, walkways, ladders,
To face specific static requirements, unload the first product loaded into the etc.
particularly in the cement storage field, silo, thus avoiding de-mixing of the product
BSP, in recent years has developed and and formation of bridges. B.S.P. Engineering operates both in the
applied a new technology, always The tunnel beam — Rotobox Planetary national and international markets, by
connected to the spiral constructive Extractor — crossing the silo diameter and supplying its customers with turnkey plants
system: the double wall spiral silo. In containing all the motorizations and drive (EPC).
practice, after manufacturing the first silo mechanisms, enable the operators to More and more frequently important
with the aforementioned method, a second provide easy maintenance of all the international groups operating in the fields
spiral wall is erected all around, with a extractor components, even when the silo of cement, biomass and foodstuffs etc. rely
250mm interspace between the two walls, is full of product. on BSP to provide guaranteed high-quality
which is then filled in with concrete, thus Besides manufacturing spiralled silos technology and fully automated
giving the whole structure perfect stability. and planetary extractors, BSP is also installations.
The most recent patented innovation is
the BSP venting roof. This is a structural 3D image —Rotobox Planetary
www.drycargomag.com

element comprising self-supporting male Extractor.

panels and female panels operating like
venting devices. All panels are fixed among
them by special PVC bolts.
This BSP certified expertise works like
the lid of a coffee mocha pot: after venting
the explosion, the female panels reposition
into their natural place and the special
bolts only need to be replaced for the roof
to be restored.
This system is also safer than any other
venting device, because it eliminates any
NOVEMBER 2021

residual safety risk, like traditional covers

flying away.
B.S.P. Engineering achieved another
important engineering contribution with
its planetary extractors for flat bottom
DCi silos.

100
 “A man who stops advertising to save
money is like a man who stops a clock to
save time”
– Henry Ford

TM

DRY CARGO
DCi

international
To find out how you can benefit from advertising in the world’s only monthly dry bulk
publication contact Jason Chinnock or Andrew Hucker-Brown on: Tel: +27 31 583 4360;
Fax: +44 1206 700840; Email: [email protected]
 Photo by LEITNER S.p.A.
BECAUSE

PARTNERSHIP

MATTERS.
Solutions for any industry

Mining, Cement, Salt and Steel and Recycling, Ports,

Coal and Quarries Sugar Power Crushing and Imp/Exp
Lignite and Tunnelling Plants Plants Screening Terminals

Rulmeca offers a wide range of quality Rollers/Idlers, Motorized Pulleys, Pulleys and components
used in the most demanding applications in belt conveyors material handling.
We are close to you, whenever you need us, with a global network of sales and service centers.

RULMECA HOLDING S.p.A

Via A. Toscanini,1
I- 24011 Almè Bergamo
Tel. +39 035 4300 111
Mail [email protected]
rulmeca.com

Rulmeca
Moving ahead
Conveyor rollers and components from top Italian manufacturer

ENGINEERING & EQUIPMENT

Rulmeca designs and machinery, equipment
manufacturers rollers and and systems for bulk
components for and unit handling
conveyors and is one of applications. Rulmeca
the world’s foremost believes it has
suppliers of premium something important
components for material to offer to its
handling. customers. Its
Rulmeca solutions are international presence
used both in bulk and unit makes it possible to
handling. It offers the widest range of very little maintenance providing the design access the most efficient sources of
products available on the market: and the installation has been correctly procurement, thus boosting the
rollers/idlers, motorized pulleys, pulleys, performed. competitiveness of the offering. At the
drum motors, drive rollers and other Rulmeca doesn’t only sell products but same time, its extensive network of
components. finds solutions. affiliated companies and business partners
Today’s movement of goods and bulk The close partnership with customers, means that it can always be in close contact
materials demands state-of-the-art OEMs, engineering companies and end- with customers.
methods. users has made Rulmeca one of the most As a vertically integrated manufacturer,
During the project design stage for the trusted brands in the industry. the company has the flexibility to respond
transport of raw materials or finished The development of the company has to individual needs whenever they arise.
products, the choice of the method must reached impressive and significant levels.
favour the most cost-effective solution for The company philosophy has always ABOUT RULMECA
the volume of material moved, the plant been, and continues to be, to satisfy, the The Rulmeca Group, with headquarters in
and its maintenance, its flexibility for needs requests and problems of customers, Bergamo (Almè), Italy, is internationally
adaptation and its ability to carry a variety providing not only products but a service respected in the production of components
of loads and even be overloaded at times. based on specialized technical competence. and equipment for all types of conveyors,
Rulmeca Group products are developed Every day and on all continents, Rulmeca providing a service based on a specialized
and produced to meet the most demanding products improve the performance, safety technical competence.
everyday challenges of all major handling and reliability of systems, equipment and Founded in 1962, the Rulmeca Group
applications. machines within the handling industry. has grown to be a prominent partner to
Bulk handling applications include: coal Along with the products, which help to the global materials handling industry.
and lignite mining, cement, steel, quarries, handle and move bulk materials and unit Today, Rulmeca Group’s global business
tunnelling, power plant installations, ports, loads all over the globe, the Rulmeca incorporates the product brands Rulmeca,
salt and fertilizers, sugar plants, recycling Group is also moving ahead. Precismeca and Melco.
and demolition, crushing and screening, Building on the experience in supplying
import and export terminals. to OEM and end-users in Italy, one of The Rulmeca Group’s strengths include:
Unit handling applications include: Europe’s key markets for unit handling v family-owned company with nearly 60
airport, security and x-ray screening, postal, applications, Rulmeca has developed a years’ experience in manufacturing and
parcel and e-commerce, manufacturing and comprehensive range of components for marketing of components for materials
automation, distribution centres and internal logistics: made by Rulmeca. handling industries;
warehousing, food and fish processing and The aim is to remain the preferred v 1,200 employees in eight manufacturing
beverage processing. supplier and trusted partner for its companies and nine sales companies;
Rulmeca’s research departments are customers who produce and engineer v global approach with strong presence in www.drycargomag.com
equipped with dedicated test Europe, Asia, America, Africa and
facilities, where the products are Australia;
thoroughly examined under v significant investment in own
extreme conditions and the R&D, technologies and quality
company is committed to the systems;
development of new products and v largest range of rollers and
the continuous improvement of motorized pulleys of any supplier
the current range. globally;
The electrical and mechanical v strategic focus on building up
components of the conveyor — local service centres to support
such as rollers, drums bearings, the businesses of its customers;
motors etc. — are produced v financially sound;
NOVEMBER 2021

according to the highest standards. v long term perspective;

The quality level reached by major v extremely high-quality
manufacturers guarantees function products;
and long life. v consulting;
The principal components of v global presence acting locally;
the conveyor, rollers and belt, need v service. DCi

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ENGINEERING & EQUIPMENT

Negrini’s electro hydraulic equipment now with Remote Control Industria 4.0
Negrini has introduced a new tool,
Remote Control Industria 4.0, which
further enhances the company’s electro
hydraulic grabs.
The tool is ideal for routine
maintenance and to improve the
efficiency of customers’ production
processes.

FEATURES OF REMOTE CONTROL INDUSTRIA 4.0:

v Monitoring and control of processes
in electro-hydraulic equipment;
v Real time scans and diagnostics;
v System communication via Wi-Fi or
data sim;
v Notifications via email, sms or
smartphone, tablet and PC;
v Preliminary production analysis;
v Routine maintenance alert;
v Failure prediction;
v Immediate alarm in case of failure or
malfunction.

THE SMART GRAB

With Remote Control Industria 4.0
installed, the grab parameters
automatically adapt to the type of
material being handled without the need
for human intervention, thus maximizing
production and reducing costs.
In the presence of high-density
materials such as mineral, the grab speed
is reduced and the hydraulic pressure is
increased, parameters otherwise not
suited to lighter materials such as coal or
cereals, where we see a change in speed
and reduction in hydraulic pressure
which would otherwise be unnecessarily
high, causing energy wastage and wear.
The most important advantage
offered by the Remote Control Industria
4.0 device installed on Negrini’s
equipment concerns the processing of
www.drycargomag.com

data, thus allowing preliminary

production analysis and failure prediction.
Notifications are sent via email and sms
and each time an event occurs, either an
incident, arrest or maintenance request is
recorded.
Costly machine downtime is therefore
avoided while maximizing production,
reducing periods of non-activity and
minimizing expenses normally incurred
by corrective maintenance works.
The client and Negrini S.r.l. will have
NOVEMBER 2021

total control over the condition of the

equipment via Wi-Fi or a data sim, using a
smartphone, tablet or PC, and will
receive all notifications sent by the
system so as to always be informed on
DCi machine requests and events.

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ENGINEERING & EQUIPMENT

A day to commemorate the first 60 years of Oli Spa

OLI SpA formally opened its new facility in market. To do this, you need a thinking
Medolla, near Modena on 16 October head that makes this system of production
2021. The company is a multinational in possible, and that ‘head’ is here in Medolla,
the field of industrial vibration technology, where we are today. OLI’s success is the
designing, producing and marketing result of a clear, well-defined strategy, long-
industrial vibrators, electric vibrators, term investments, and the training of
concrete vibrators and frequency managers, company executives and staff.
converters, as well as a wide range of The financial crisis of 2008 and the terrible
products designed to adapt to many earthquake of 2012 meant that we spent
applications in a wide variety of industrial five years focusing on reconstruction. But
fields: ranging from the medical to we managed to grow just the same. We re-
construction sectors, and from the established the company and maintained
automotive to energy industries. our growth by moving production to other
The inauguration of the new building sites, as everything here was totally
coincided with the sixtieth anniversary of destroyed.
the founding of the company. Since its “It was a tough slog with everyone
direction under Vainer Marchesini, the helping out: customers, suppliers, the State,
business has grown to become a global the Region and President Bonaccini, all of
reference point in its sector, and is now whom have always been by our side. But
also involved in the design and the greatest contribution was from our
construction of complete systems for own people: people whose drive, sacrifices,
eBikes and electrospindles, working in passion, commitment, sense of belonging
collaboration with the University of and talent have made all this possible. We
L’Aquila. The company’s headquarters is in have emerged from all these misfortunes in
Medolla, the site where the products are a better state. The growth of this company
developed and the company’s 23 has also been due to the growth of the
international branches and six production corporate entity and our highly skilled
plants in five continents are all workforce; we are among those businesses
co-ordinated. Piero Corsi, who founded who have encouraged talent back to Italy. I
OLI in 1961, was also present at the appeal to everyone, because we Italians
inauguration. should not just sell our companies to
The company’s General Manager, foreign multinationals — we are able, as we
Giorgio Gavioli, gave the following have demonstrated, to do much more. We
explanation: “Today represents something should be masters of our own destiny,
very important for OLI, but not a point of because we have all the necessary
arrival: our aim is to always look ahead, and capabilities.”
not to stop. Our products are constantly
evolving, as well as our business. We open ABOUT OLI SPA
OLI branches wherever the market OLI combines the virtues of Italian
requires products, respecting the language, expertise with the global strategy of the
culture and tradition of the places we are Wolong Group of which the company is
involved in, on all five continents. part. Indeed, the business continues to
“Our company operates on a global follow the four tenets of the philosophy
www.drycargomag.com

market, but has its headquarters in developed over the past six decades:
Medolla; some would call it a ‘glocal’ listening, collaboration, proactiveness and
company, i.e. a localized business with a responsibility.
global reach, and I think this is one of our The company now has 500 employees
secret weapons. This is why we are around the world, and a turnover of about
interested in professionals who share our €110 million. The mining industry is
vision: that of an open, accessible world, constantly evolving and facing countless
with skilled, dedicated people, who want to challenges: process efficiency, productivity
develop both professionally and in human — combined with efficient use of soil,
terms.” . water, and energy — in harsh conditions
Vainer Marchesini, President of the where environmental impact plays an
WAMGROUP, added this: “OLI is a global increasingly important role.
NOVEMBER 2021

company, and there is a profound The mining sector requires particularly

difference between localization, demanding applications, maximum
delocalization, internationalization and performance, and reliability, so it is
globalization. This is a global company, a essential to optimize machinery and
company that produces pieces and then improve performance and operational
DCi assembles them wherever there is a efficiency to keep competitive. DCi

106
 ENGINEERING & EQUIPMENT
Quality matters
an essential reference guide to
conveyor belt selection

ot all conveyor belts are created complex. Literally billions are spent every process when a conveyor is proving to be

N equal. In this special feature for Dry

Cargo International, Leslie David
explains the criteria used to assess the
year buying, fitting and running them but
much can go wrong (and often does!) when
a belt is not up to the task it was chosen to
problematic. It is important to be
absolutely sure that the actual specification
of the belt is correct in the first place.
www.drycargomag.com

properties and characteristics of single and perform. However, you do not need to be Good belt selection involves making an
multi-ply rubber conveyor belts and the a conveyor belt expert to make an assessment based on quite a wide-ranging
influence each part of the criteria has on informed selection as long as you make criteria. To be honest, for many people
whether or not a belt will be fit for its intended good use of the information available to who work with conveyors, much of the
purpose. you. criteria is meaningless to them although
they would understandably be reluctant to
A COMPLICATED SUBJECT THE TECHNICAL DATASHEET admit it. All responsible manufacturers,
Industrial conveyor belts appear to be very Selecting a conveyor belt involves making a service companies and traders should, as a
simple structures to the casual observer. In complicated assessment of all available matter of course, automatically provide a
very basic terms, they are simply thick parameters including the conveyor system technical datasheet (TDS) for the specific
bands of black rubber that run around itself, the materials being conveyed, the version of the belt that they are proposing
NOVEMBER 2021

metal conveyor frames. They transport a working conditions and health & safety. For to supply because this where much of the
multitude of different materials thereby new conveyor installations the first stage of selection criteria should be found. The TDS
performing a hugely important role in any belt selection should involve the use of should be supported by the manufacturer’s
ports and transshipment terminals a belt calculation programme overseen by a product documentation (product specific
throughout the world. In reality however, professional conveyor belt engineer. It can datasheet) because this should contain
conveyor belts are technically very also be a good idea to follow the same important additional information such as DCi

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ENGINEERING & EQUIPMENT

both sides referred to as ‘the covers’.

Technical datasheets are therefore based
on these two fundamental elements. Each
element has its own criteria for testing
methods and performance standards. On
most technical datasheets, data relating to
the carcass is usually shown first.

THE CARCASS
The carcass provides the innate strength of
any conveyor belt. It not only has to bear
the loads placed upon it but also repeatedly
flex around the drums and pulleys of the
conveyor structure. The internal structure
of the belt carcass dictates the tensile
strength of the belt. Because of its
fundamental importance, the tensile
strength is usually the first piece of data
shown.

SELECTION CRITERIA — TENSILE STRENGTH AT BREAK

(N/MM)
Virtually all industrial conveyor belts are
defined by their tensile strength. The
carcass absorbs the force when tension is
applied to the belt. The greater the
required tensile force to move the
transported material, the greater level of
The first stage of any belt selection should involve the use of a belt calculation programme strength demanded of the belt carcass.
overseen by a professional conveyor belt engineer. Importantly, the strength under load needs
to be consistent throughout the belt both
recommended minimum and maximum the test standard. In longitudinally and transversely in order for
pulley diameters and maximum useable other words, was the the belt to steer and handle correctly. The
widths. performance standard tensile strength of a belt is measured
My best advice is to always insist on achieved? according to the ISO 283 test method.
seeing a technical datasheet and a product Unfortunately, unless Quite simply, this involves pulling a section
datasheet before you place an order. Even specifically stated otherwise, technical of belt apart and measuring the force that
the design and clarity of the documents can datasheets provided by manufacturers and it will endure before it breaks.
be a good indicator as to the profes- traders almost invariably only show generic As I touched on earlier, a typical
sionalism of the supplier you are dealing information such as the minimum standard technical datasheet will simply state the
with. It is also wise to request a certificate demanded by a specific test. Some do show
of (manufacturer’s) origin so that you know a few ‘actuals’ but it is extremely limited.
the true provenance of the belt in the event The data therefore does NOT reflect the
of a problem. actual performance achieved during the
test or even a level of performance that the
www.drycargomag.com

TEST METHODS AND TEST STANDARDS ARE buyer might reasonably expect. This even
NOT THE SAME applies to the dimensional measurements
Alongside each part of the criteria on the and acceptable tolerances such as the
technical datasheet should be details of any thickness of the top and bottom covers.
applicable test methods and international Apart from Dunlop in The Netherlands,
standards such as ISO or DIN for example. which shows actuals on its technical
When assessing quality credentials it is datasheets on most applicable values, this
essential to differentiate between what is shortcoming applies to all suppliers.
simply an approved method of conducting a The vast majority of conveyor belts in
particular test (the test method standard use today are either single ply or, most
itself) and the actual quality or performance typically, multi-ply. For the benefit of the
standards attained during that test. In itself, uninitiated, their construction consists of
NOVEMBER 2021

the fact that a belt has been tested two elements — a fabric ply carcass, most
according to a certain method actually commonly Polyester warp and Polyamide
means very little. What is important is the (nylon) weft (EP) fabrics, with a thin layer of
actual level of performance achieved during rubber in between the plies (skim rubber
the testing compared against the minimum or inter-ply rubber). This structure is The tensile strength of a belt is measured
DCi acceptable level of performance dictated by covered by an outer layer of rubber on according to the ISO 283 test method.

108
 ENGINEERING & EQUIPMENT
minimum tensile strength that the ISO 505
manufacturer/supplier is claiming the belt tear
will achieve. A poor quality belt will often strength
be borderline and, due to inconsistencies in testing.
the production process and the quality of
the fabric plies used, sometimes below the
required minimum strength. When
competing on price, manufacturers will
habitually keep every aspect of the
construction cost to an absolute minimum.
The better quality conveyor belts will have
a safety margin included, ideally as much as
10% or more.

SELECTION CRITERIA — CARCASS TEAR STRENGTH

(N)
Depending on the working environment
and the kind of materials being conveyed,
the overall tear strength of a conveyor belt
can be hugely important. For clarity of (measured according to the ISO 252 test width conveyor frames. However, being
meaning, a ‘tear’ is best defined as what method) literally involves pulling the layers thin and flexible also makes the belt more
happens when a piece of material (a section apart and measuring the force required in sensitive to damage from material impact
of carcass or rubber cover) is pulled apart Newtons per millimetre. and sharp edges. The thickness of a carcass
in opposing directions. Although there is a When it comes to adhesion, can be increased simply by increasing the
defined method of testing (ISO 505: 2017) manufacturers need to strike a balance amount of rubber between the fabric plies
there are no standardized performance because there should obviously between a and/or the number of plies. The downside
requirements. strong bond between all of the layers so to this is that the belt will become more
The test consists of mounting two cut that the belt stays intact under load and rigid and could prove to be problematic
ends of a test piece of belting or rubber while being subjected to repeated flexing. and actually lead to internal damage within
cover in the jaws of a tensile testing However, if the adhesion level is too high the carcass.
machine. An initial tear is made in the test then this can create problems when trying With larger width belts and bulky, heavy
piece, which is then pulled apart in to make a spliced connection joint because material dropping on the belt from height,
opposing directions. The force necessary a section of the rubber skim needs to be the extra rigidity created by increasing the
to propagate the tear is then measured. removed. thickness will provide added resistance to
Examination and analysis of the multi-peak these elements. In reality, quality
tear resistance test traces is conducted in SELECTION CRITERIA — THICKNESS manufacturers try to match the most
accordance with ISO 6133. The measurement method for carcass commonly expected usage of a belt type to
thickness is ISO 583. The actual thickness the carcass design for each specific belt
SELECTION CRITERIA — ADHESION BETWEEN THE of the carcass largely determines the type and strength. In other words, making
PLIES suitable usage range for the belt. A very the carcass thick and rugged enough but
The strength of adhesion (bond) between thin carcass will require less material to without limiting the application area by
the various layers of plies and between the manufacture and be cheaper in cost. It will being too thick or too thin.
plies and the covers is also a standard part typically be easy to flex around pulleys and
of the assessment criteria. The adhesion be able to take a troughed shape in narrow SELECTION CRITERIA — ELONGATION
The elastic elongation (stretch properties) www.drycargomag.com
of a carcass are more important than many
people may realize. Using test method
ISO 283, the amount of elongation is
measured while the test piece is under a
tension that is the equivalent of 10% of the
stated tensile strength. Again, a balance has
to be achieved because the belt needs to be
able to accommodate geometric changes
such as pulleys and transitions. On multi-
ply belts, insufficient elongation can lead to
Measuring
shear stresses, which in turn can cause
adhesion
delamination (separation) issues. However,
NOVEMBER 2021

literally
too much elongation would result in
involves pulling
insufficient tension in the belt.
the layers apart
Generally speaking, the maximum
and measuring
elongation (at maximum operational
the force
tension, being 10% of the nominal belt
required.
breaking strength) for multi-ply belts would DCi

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ENGINEERING & EQUIPMENT

materials, high material temperatures or

The belt carcass plays a vital role in
where the conveyed product contains oil of
minimizing the effects of impact
any kind, such as grain for example. Within
and trapped sharp objects.
this, the ability of the rubber covers to
resist abrasive wear will have a very
significant bearing on the wear life of the
belt. The destruction of the covers will
allow the carcass materials to be exposed,
which will then gradually deteriorate and
lose integrity and strength. This will
eventually lead to rupture of the belt and
costly downtime and spillage.

SELECTION CRITERIA — ABRASION RESISTANCE

[MM³]
The two most commonly referenced
standards for fabric reinforced belting are
the international ISO 14890 (with abrasion
resistant classes H, D and L) and German
DIN 22102 (with abrasion resistant classes
Y, W and X). In Europe the longer-
established DIN 22102 standard is still very
be 1.5% for lower tensile belts, max. 2.5% used in the exchange. A direct often used, although the most current
for the mid-range and 3% for the really high consequence of less material of lower version of this standard references the ISO
tension belts. Personally, I would not elasticity is that impact resistance and rip 14890 on most topics, making both more
expect to see much more than 1% in the resistance are markedly reduced, making or less identical. Generally speaking, the
lower range and 2% in the high tension the belt even more vulnerable to damage DIN grade ‘Y’ (or ISO 14890 closest
classes. Anything appreciably less than that than usual. equivalent grade ‘L’) relates to ‘normal’
would mean that the belt is more sensitive The objective of using purely polyester service conditions and DIN grade ‘W’
to dynamic failure and more prone to fabric is to minimize costs because (close to ISO 14890 grade ‘D’) for
damage. polyester costs some 30% less than nylon. particularly high levels of abrasive wear.
Although a highly tempting price may DIN grade ‘X’ (close to ISO 14890 grade
RESISTING DAMAGE provide a clue, the deception cannot be ‘H’) is regarded as the most versatile
Crucially, the carcass and the fabrics that detected without laboratory testing so the because in addition to resisting abrasive
are used within it play a very important manufacturers are confident that their wear it also has good resistance to cutting,
role in handling (dissipating) the impact of dishonesty is very unlikely to be exposed. impact (from high drop heights) and
objects falling on to the belt and also gouging, usually caused by heavy, sharp
resisting the propagation of tearing and THE COVERS materials. To achieve these characteristics
ripping when objects become trapped and In the majority of cases, the quality of the the rubber compound contains a higher
penetrate the outer covers. This is a key outer covers have the greatest influence on than usual element of natural rubber (NR)
reason why Polyester warp and Polyamide the performance and operational lifetime of and is therefore usually the highest priced
weft (EP) fabrics are most commonly used. a conveyor belt. This most certainly applies option.
Although not part of the criteria used in the case of belts that need to be able to The method used to measure abrasion
within a technical datasheet, the type of resist the ravages of heavy, sharp, abrasive resistance (ISO 4649 / DIN 53516) involves
fabric used will be stated on the document
www.drycargomag.com

as part of the belt designation. For

The use of EE fabrics instead of EP reduces
example, EP 400/3 4+2.
troughability, impact resistance and rip resistance.
Worryingly, laboratory testing is
revealing that more and more belts,
including many that are being manufactured
in Europe, are being declared as having an
EP (polyester/nylon mix fabric)
construction when they actually have
entirely polyester (EE) fabric plies. A simple
one-on-one replacement of the Nylon with
Polyester is not possible due to the lower
elasticity of Polyester because it would lead
NOVEMBER 2021

to a very rigid carcass with a significant

reduction in troughability. A belt that will
not seat properly often results in
misalignment of the belt relative to the
conveyor structure. Therefore, a much
DCi lower amount of polyester weft material is

110
 ENGINEERING & EQUIPMENT
moving a test piece of the rubber across
the surface of an abrasive sheet mounted
on a revolving drum and is expressed as
volume loss in cubic millimetres, for
instance 150mm³.
The key factor to bear in mind when
looking at abrasion test results is that
higher figures represent a greater loss of
surface rubber, which means that the higher
the figure the lower the resistance to
abrasion. Conversely, the lower the figure
the better the wear resistance.

SELECTION CRITERIA — TENSILE STRENGTH AT BREAK

(MPA)
The tensile strength of belt covers is
measured according to the ISO 37 test
method and is typically expressed as
amount of force in megapascals (typical ISO 4649 / DIN 53516
range of 15-30 MPa). During this test, the abrasion testing.
material is stretched up to the point of
failure. This point of rupture (referred to as As with the tensile strength, the until it breaks. The damage acts as an
‘the ultimate tensile strength’) indicates elongation of the covers also has an initiation to a further tear and inevitable
how much force or stress the rubber can important bearing on the elastic elongation break of the sample. The sample will
withstand before breaking and has properties of the belt as a whole. This typically break at a lower tension than the
considerable influence on the overall means that even if the carcass has good undamaged sample.
tensile strength of the belt. As I mentioned mechanical properties, if the quality of the In real life, the covers of a conveyor belt
earlier, technical datasheets provided by rubber covers is poor then this will have a will be damaged by material impact. When
manufacturers almost invariably only show seriously detrimental effect on overall the tear strength is low, these small areas of
the minimum standard demanded by a performance, handling and the ability of the damage become larger areas of damage as
specific test or, in many cases, simply the belt to withstand physical punishment (such a result of the strain placed on the covers
test method reference number and nothing as heavy, sharp material falling from height) by continuous flexing around pulleys and
more. This therefore does not reflect the and rip and tear propagation. Typically, drums. However, rubber covers with a high
level of performance that you might some 70% of a conveyor belt is made up of level of tear strength will contain the
reasonably expect. rubber so despite its critical role, it is damage much more effectively, thereby
usually the primary target for cutting achieving a longer operational life.
SELECTION CRITERIA — ELONGATION AT BREAK (%) corners. Although international standards only focus
The elongation at break is the extent a on the ultimate tensile strength, evaluating
rubber material can be strained (%) before SELECTION CRITERIA - TEAR STRENGTH [N] / the tear strength in combination with the
it breaks. Using ISO test method 37, tensile [MPA] expected operational conditions of the belt
force is exerted in order to stretch the Testing the tear strength of the rubber is a worthwhile exercise. Belts conveying
rubber to breaking point. The elongation at covers is similar to the testing of tensile large and sharp materials greatly benefit
break is expressed as a percentage of the strength. The difference is that a specifically from a cover rubber that has both good
original length of the test piece. designed and pre-damaged sample is pulled tensile strength and high tear strength.
www.drycargomag.com
The elongation of the covers has an SELECTION CRITERIA — HARDNESS (SHORE]
important bearing on the elongation The hardness of rubber covers is usually
properties of a belt as a whole. measured by the depth of indentation
caused by a rigid ball under a spring load or
dead load (ISO 7619). The spring-loaded
meter gives Shore A values of hardness
ranging from 0 to 100. For the majority of
rubber cover grades a hardness of between
60 to 65 Shore is the expected norm.
As with the degree of elasticity
(elongation), there is a relatively fine
balance that needs to be achieved by the
NOVEMBER 2021

manufacturer because anything outside of

this range can make the covers prone to
damage. Although soft rubber covers may
provide better damping on impact, the
greater amount of deformation will still
make it subject to damage. Conversely, a DCi

111
ENGINEERING & EQUIPMENT

hard cover may eventually lack the mean that the belt supplied
ability to allow bigger will actually meet that
deformations because over the Ozone & ultra standard.
course of time, all rubber violet light This may sound very
materials become harder and lose causes rubber cynical but blind acceptance
flexibility as a result of ageing. to literally can prove to be extremely
This natural ageing process is disintegrate. expensive. Naturally, there
accelerated when belts are should be an element of
subjected to heat or chemicals. trust in any transaction.
However, it is important to
SELECTION CRITERIA — OZONE & consider the growing
ULTRAVIOLET LIGHT RESISTANCE (EN ISO evidence of misleading
1431/1 PROCEDURE B) information right through to
Despite its crucial importance in outright deception in the
terms of operational lifetime, conveyor belt industry.
resistance to the damaging effects Taking the time to study
of ozone and UV is rarely ever the technical datasheet
mentioned by traders or (TDS) for the specific belt
manufacturers in their product you are being offered,
documentation. This is almost together with the
certainly because the anti- manufacturer’s product
ozonants that need to be used specification datasheet
during the mixing process of the before you place your order
rubber compounds are relatively will certainly be time well
costly. Ozone becomes a spent.
pollutant at ground/sea level and
exposure is unavoidable. It ABOUT THE AUTHOR
increases the acidity of carbon After spending 23 years in
black surfaces and causes logistics management, Leslie
reactions to take place within the promote the oxidation of the surface of the David has specialized in conveyor belting
molecular structure of the rubber resulting rubber resulting in a loss in mechanical for over 15 years. During that time, he has
in surface cracking and a marked decrease strength. In both cases, this kind of become one of the most published authors
in its tensile strength. degradation causes the covers of the belt on conveyor belt technology in the world.
Likewise, ultraviolet light from sunlight to wear out even faster than they should. DCi
and artificial (fluorescent) lighting also My advice is to always make ozone & UV
accelerates deterioration because it resistance a required part of the
produces photochemical reactions that specification when selecting any rubber
conveyor belt, especially
if the belt will be
Blind acceptance of operated in a coastal
promised quality location.
can prove to be
extremely expensive. BLIND ACCEPTANCE
Because of the everyday
pressures of working life
www.drycargomag.com

and, indeed, budgetary

pressures, it is very easy
to fall into the trap of
simply accepting that the
specification promised by
the belt supplier will be
what you actually receive
on site. The same applies
to the level of Acknowledgments: Conveyor belt selection is a
performance and quality massive topic involving a complicated assessment of
standards claimed by the all available parameters relating to the actual
conveyor system, materials being conveyed and
supplier. As I explained numerous belt specification options. Although I have
NOVEMBER 2021

earlier, just because there tried to ‘keep to the basics’, it has nonetheless been
is a test method or a challenging task. I am therefore deeply indebted
to Rob van Oijen, manager of application
quality standard reference engineering for Dunlop Conveyor Belting in The
shown alongside a Netherlands, for his invaluable technical and
particular characteristic professionally impartial assistance in the compilation
of this article.
DCi it does not necessarily

112
 BREAKBULK & BAGGING
Bag & baggage
developments in the bulk bagging industry
FIBCs made with rPP in
front of a Starlinger
recoSTAR dynamic
recycling line.

Closed-loop technology for FIBCs: Starlinger’s green solution

major supplier of extrusion and for single use, and their disposal via landfill FIBCS BECOME FIBCS AGAIN

A weaving technology for FIBC fabric

production, Starlinger & Co GmbH is
continuously working on improving production
or incineration causes serious environ-
mental damage with high CO2 impact. Of
those FIBCs which are recycled, a large
The ‘Circular Packaging’ concept that
Starlinger presented in 2019 aims to create
a circular economy in which FIBCs become
www.drycargomag.com

and materials technology. Two of the part is turned into products of lower value FIBCs once more. This concept is unique
company’s latest innovations aim at making (i.e. downcycling). insofar as it represents a holistic approach
heavy-duty woven plastic packaging more Due to government legislation such as that involves and documents various stages
sustainable by using the DfR (Design for the UK Plastic Packaging Tax, the EU Plastic of the FIBC life cycle such as
Recycling) approach and enabling the addition Packaging Levy, or directives aiming at manufacturing, usage, recovery, washing,
of recycled content in FIBC fabric production. more sustainable plastic packaging and recycling.
proposed by organizations such as the The challenge in the recycling of FIBCs
FIBCs, also called big bags, are omnipresent Global Plastics Pact by the Ellen McArthur is that they come in different forms: with or
in logistics as a lightweight and economic Foundation, recyclability of and recycled without polyethylene liner, coated or
type of packaging for free-flowing bulk content in plastic packaging is becoming an uncoated, and with loops and seams
goods. Made predominantly from increasingly important topic also for FIBC consisting of different kinds of plastic.
NOVEMBER 2021

polypropylene (PP), they show a CO2 producers. Therefore, the first step in creating a
balance per 1,000 litres of transported Apart from lowering the carbon circular economy for FIBCs is ‘design for
goods that is far below that of rigid footprint of FIBCs, the recycling and use of recycling’. This means that the FIBCs are
containers such as drums or octabins. Even recycled content in this type of bulk designed in such a way that they can easily
though they are well-suited for recycling, packaging also saves costs for raw be recycled and processed into regranulate
75% of all FIBCs worldwide are designed materials. of high quality. DCi

113
 BREAKBULK & BAGGING
packaging, Starlinger shares of 50% rPP and more are possible.
worked on developing The new SPB melt filter, developed
a process for recycling especially for processing rPP, ensures
polypropylene and excellent melt filtration for the high tape
using it in FIBC quality required. On Starlinger’s heavy-
production. The high duty circular looms the produced tapes are
product standards for turned into FIBC fabric. In the last step,
this kind of packaging the FIBC conversion process is performed
require highest quality in accordance with DfR rules, i.e. without
of the recyclate to polyester multifilament yarn for sewing and
guarantee safe use and using easily removable PE liners and
handling and have been information labels, making the new FIBC an
taken into account in easy-to-recycle type of packaging.
the ‘Circular Packaging’ Properties such as tensile strength,
concept. weight and safety factor of FIBCs with rPP
After use, the FIBCs content are the same as those of FIBCs
Production steps in the Starlinger are returned to the made of virgin material and have been
‘Circular Packaging’ concept. FIBC filler. This tested using standard testing procedures
The second important step is creating a guarantees that they are similar in and certified equipment.
material passport in which the entire life composition and show the lowest possible
cycle of the FIBC is documented: from the degree of contamination, as they do not THE ULTIMATE GOAL: FIBCS MADE OF UP
materials used for its production up to the enter the post-consumer stream and are TO 100% RECYCLED MATERIAL
last filling and the filled product. This mixed with other plastics. The FIBC An alternative for FIBC producers is FIBC
traceability facilitates collection and manufacturer collects them and prepares fabric made of PET tapes. Besides its high
reprocessing and helps to create a uniform the used FIBCs for recycling: they are strength and form stability, which makes
material stream which increases the quality shredded, washed, and subsequently PET fabric perfect for heavy-duty
of the material to be recycled. processed into rPP on the Starlinger applications, PET can be recycled and
‘recoSTAR dynamic’ recycling line. The refined so that its properties are the same
RECYCLED POLYPROPYLENE IN FIBCS recycled polypropylene regranulate is then as those of virgin material. With a method
As the topic of recycled content is added in the extrusion process on the called solid-state polycondensation (SSP),
becoming more important in plastic Starlinger ‘starEX’ tape extrusion lines — the molecular weight of recycled PET can
be restored to its original level, thereby
yielding material that is literally ‘as good as
Circular looms new’, even after having been recycled many
producing rPET times. This means that with PET, the
fabric for FIBCs. recycled content of a FIBC can even be up
to 100% — with PP, this is impossible to
achieve due to the irreversible degradation
of the material in the recycling process. In
addition, the food-grade quality of rPET
produced with the FDA- and EFSA-
approved Starlinger PET recycling and
decontamination process also opens up
multiple possibilities for food-contact
packaging, enabling FIBC manufacturers to www.drycargomag.com
broaden their customer base.
All this makes PET perfect for closed-
loop FIBC production based on Starlinger’s
‘Circular Packaging’ concept. PET offers a
whole range of advantages that can benefit
the logistics industry. And with millions of
FIBCs being produced worldwide every
year, the potential to save resources
through the use of recycled material is
enormous.

TECHNOLOGY IS THE KEY

NOVEMBER 2021

Starlinger has been working since 2010 on

developing the process and equipment for
converting PET into woven fabric —
initially from virgin material, then recycled
pellets, and ultimately, from PET flakes. This
was something that no technology DCi

115
 BREAKBULK & BAGGING
provider had managed to achieve FIBC made from Packaging” concept is available
up until this point, as the 100% rPET flakes. here:
conversion of PET to plastic https://vimeo.com/492062555 or
tapes is not a straightforward https://youtu.be/A6qPEpXGRiA.
process and entails many
challenges. Starlinger was able to ABOUT STARLINGER & CO
draw on its knowledge and GES.M.B.H.:
experience in the area of PET Starlinger is a Vienna-based
recycling, as the company has engineering company with
been developing technology for production sites in Weissenbach
plastics recycling for more than and St. Martin, Austria, as well as
30 years. Building on this Schwerin, Germany, and Taicang,
foundation, Starlinger spent China. As a global expert in the
considerable time and resources supply of machinery and complete
on research and development in lines for woven plastic bag
the past 11 years and now offers production, recycling and PET
the full equipment for rPET FIBC extrusion and refinement,
production — from PET recycling Starlinger & Co Ges.m.b.H. is
lines to PET/rPET extrusion and synonymous with leadership in
weaving technology. Like PP quality and technology in over 130
FIBCs with recycled content, countries. Founded in 1835, the
FIBCs made from rPET meet all family-owned business has been
the required safety criteria and exporting machines worldwide
do not differ from conventional for more than 50 years with an
FIBCs regarding construction and handling. production has been met with export quota of over 99.5%.
Both approaches of Starlinger’s ‘Circular considerable interest from the industry, Sales and service centres in Brazil,
Packaging’ concept have been successfully and innovative packaging producers are China, India, Indonesia, Mexico, Nigeria,
put into practice by leading FIBC testing the possibilities of PET fabric on the Thailand, Russia, South Africa, USA and
manufacturers during trial projects. The FIBC market. Uzbekistan ensure quick and professional
technology for using rPP in FIBC A video presenting the rPP “Circular technical support and service.

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BREAKBULK & BAGGING

What is the most

compact high speed
bulk bag filling machine
available?
DIFFERENT-FIBC-BAGS HIT THE GROUND
RUNNING
Around the world, lockdown measures are
easing. This means that, for the first time in
months, many manufacturers across the
USA, EU and UK are seeing a jump in
demand and a need to ramp up their
output. Businesses manufacturing and
packaging products in Big Bags want to
resume high-speed production as soon as
possible.
A natural step would be for these
businesses to expand their current
facilities for ones that are bigger and better
equipped. However, moving premises can
be costly, time consuming and impractical.

A better option would be to upgrade the existing Big Bag filling

systems with a modern model that performs more functions,
at a faster pace and in less space.
Below is a breakdown of what Big Bag compact filling
machines are available, and advice on how to choose the one
that best meets a business’s needs.

WHAT BIG BAG FILLING MACHINES ARE AVAILABLE & WHAT

SIZE ARE THEY?
When it comes to a system that’s compact and modular,
bagging specialist Webster Griffin recommends the IBC-PF2
Big Bag filling machine. It fills solid materials ranging from
foods and aggregates to minerals and plastics.
It’ is an ideal space-saving solution that businesses can start
off with, as it’s easy to install and can easily be expanded on in
the future. In addition to taking up just 2 x 2m2, it requires less
headroom than other Big Bag filling machines. However, its
bagging speed is limited to between five and ten bags an hour.
Medium- and high-speed filling machines exist, offering speeds
www.drycargomag.com

of 10 to 30 bags per hour (via a 4.5 x 6.0m2

machine) and 30 to 90 bags per hour at
(via a 4.5 x 8.5 machine).
Many machines perform dual functions
that further save space. The IBC-PF2 does
this by weighing and filling bags at the same
time. It also monitors each bag’s weight for
accuracy, subtracting the pallet’s weight so
just the bag’s weight is presented.

BUILDING ON A BIG BAG FILLING

MACHINE
NOVEMBER 2021

Even when a larger Big Bag filling machine

is selected, most can be customized to
perform additional functions that could
save space in the customer’s facilities.
For example these include empty bag
DCi inflators and automatic bag topping up via

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 BREAKBULK & BAGGING
www.drycargomag.com

the filling spout. Spouts can be equipped with inflatable collars to prevent dust
emission. Many machines also employ patented semi-suspension technology to
ensure that each bag is neat and stable when packaged.
These neatly shaped bags help the user to save more space by being easier to
palletize and stack. Fully automatic Big Bag filling machines can eliminate manual
labour by reducing the hands required for operation.

FINDING THE MOST SUITABLE SOLUTION

NOVEMBER 2021

Juggling filling needs against the available space can be challenging.

Operators want a machine that optimizes the space available but that won’t take
added time and effort to operate.
Operators also need it to fill their Big Bags at the required speeds to meet the
desired production output. Webster Griffin is an expert, and can offer technical
advice to ensure the right choice. DCi

119
BREAKBULK & BAGGING

How did Webster Griffin help BAL (Building Adhesives Ltd) palletize
many different sizes of bags automatically?
Building Adhesives Limited (BAL) is a
ceramic tile fixing adhesive supplier with a
considerable presence in the UK and
Germany. It manufactures a range of tile
adhesives and grouts for building,
contractors and specifiers from its factory
in the UK. As Webster Griffin previously
provided BAL with palletizing systems, the
company turned to Webster Griffin for
assistance with palletizing its bagged
powder products for distribution.

WHAT KIND OF SOLUTION DID BAL

REQUIRE FROM WEBSTER GRIFFIN?
BAL contacted Webster Griffin to design a
new high-speed palletizing line capable of
producing neat and square pallets of its
materials in valve sacks. The system also
needed to apply cardboard sheets. In
addition to having to accommodate bag
sizes and weights ranging from 10kg to
25kg, BAL also required the system to
work 24/7 without human intervention.
Finally, the system was to be integrated
with an existing pallet stretch hooding
machine.

IN CONSIDERATION OF BAL’S
REQUIREMENTS, WHAT SYSTEM DID
WEBSTER GRIFFIN INSTALL?
Webster Griffin recommended that BAL
install an Okura high-speed, intelligent
A1600 palletizing robot system. To make
the robot easy and intuitive to use it
was equipped with a colour
touchscreen control panel. It also
featured Okura OXPA-QmV Easy-
Teach software with preloaded employees up to work on
palletizing patterns. This would allow other tasks within the factory.
BAL to follow pre-set palletizing
patterns as well as create and save new ABOUT WEBSTER GRIFFIN
www.drycargomag.com

programmes themselves. The Webster Griffin has extensive

integrated pallet transport roller experience in working with
conveyors make the palletizing process businesses from all over the
automatic from start to finish. An world which require
adjustable bag pick up hand ensures the palletizing solutions. Whether
system could cater for different bag you are looking for a new
size. A slip sheet feeder ensured robot palletizer, or would like
cardboard slip sheets were accurately to integrate one into your
placed before palletizing. The pallet existing bagging or packaging
magazine included had the capacity to they installed it at BAL’s plant. The line, Webster Griffin can help. The
accommodate 400 kg in weight or ten palletizing system was immediately put to palletizing system is customized to the
pallets. work to create neat, compact and stable user’s specifications, and can also guarantee
NOVEMBER 2021

pallets for storage and distribution. that the system is supplied as a turnkey
WHAT BENEFITS DID BAL EXPERIENCE Palletizing throughput increased up to package, with Webster Griffin taking
AFTER THE INSTALLATION? 1,100 bags an hour, to meet the business’s responsibility for the concept, installation,
Webster Griffin’s team of engineers production capabilities. Because the design, manufacture of the equipment,
manufactured and factory tested the system was fully automated, it helped the factory installation and ultimate
DCi palletizing system. Once it passed testing, business become more productive, freeing performance by your side.

120
The growing popularity of FIBCs to transport dry bulk ingredients

BREAKBULK & BAGGING

Increasingly, manufacturers are While competitors
recognizing the advantages of such as Flexicon and
transporting dry bulk ingredients Spiroflow offer bulk bag
in flexible intermediate bulk fillers, Hapman is one of
containers (FIBCs or bulk bags). the few that designs the
The savings in ingredient costs, equipment for the
material handling, warehousing application rather than
and transportation requirements trying to make a standard
can be substantial. design fit an application. Its
These benefits can only be engineers also work with
realized when appropriate filling customers to offer viable
equipment is applied. Properly cost saving and/or value-
designed FIBC filling machines added options to meet
deliver a dense, stable package their needs and goals.
that can be safely and easily
stored, transported and HAPMAN BULK BAG
discharged. The savings that FILLER OPTIONS;
properly filled FIBCs deliver can v Quick-release safety
be augmented by automating the hooks: the redesigned
filling system to increase filled bag quick release safety hooks
output. offer a single switch level
Hapman has been in dry, bulk to quickly and safely
material handling for over 65 release a filled bag.
years. As the inventor of the v Accurately fill FIBCs
tubular drag conveyor in the with the tote or drum
1940s Hapman’s product line filling adapter.
grew to other conveying and v Batch weigh control
material handling technologies systems available.
such as, flexible screw conveyors, v Stainless steel or
dust collection, bag compactors, carbon steel.
feeders, bulk bag unloaders and v Fill bags more
full system designs, as customer completely with the
needs expanded and changed. The vibration table.
Bulk Bag Filler has been a part of v Get precise results with
the Hapman product line since load cells.
1999 where Hapman recognized v Increase productivity
the growing need for both light for continuous applications
duty, standard or custom heavy- with optional roller
duty, bulk bag fillers. conveyor.
Hapman bulk bag fillers are v Maximize bag capacity,
used across an array of industries. improve filled bag
While customer confidentiality is stackability with the bag
of upmost importance to Haman, pre-inflator and de-aerator. www.drycargomag.com
the company does serve clients in v Improve stackability and
mining, chemical, industrial, food, safeguard operators with
dairy, animal feed, nutraceutical, motorized height
and pharma. Recently, it closed a adjustment.
deal for four bulk bag fillers for a v Protect operator safety
large Canadian chemical company with traversing and quick-
and multiple stainless steel releasing rear hook
batching unloaders to a food assemblies.
Hapman’s loss-in-weight bulk bag unloader.
manufacturer. v Hang weighing system
Hapman offers two types of fills bags more precisely
Bulk Bag fillers. The heavy-duty, HD series, maximum dust control. The NT series bag and requires no recalibration when
is designed for FIBCs at two tonnes of filler is a cost effective and simplified moved to different locations.
NOVEMBER 2021

total weight and less, while the light-duty, design. Both options are made with
NT series, is designed for FIBCs at one cantilevered heavy-gauge steel tubing with Hapman’s newest option is a spout
tonne of total weight and less. The HD- three-sided access for ease of accessibility clamping system to assist in mitigating dust
series bag filler offers forward-traversing, and can feed directly from the customer’s emissions during discharge reducing loss of
self-locking hooks for easily securing bag equipment or one of Hapman’s three types product or dusting, keeping plant areas
loops and an inflatable bladder for of conveyors. clean and workers safe. DCi DCi

121
 INDEX OF ADVERTISERS

Company Page Company Page

A/S Cimbria 95 Mack Manufacturing Inc 73

Alex Stewart International Corporation Ltd Back Cover Martin Engineering 81

Associated British Ports 33 Negrini Srl 105

BEUMER Group GmbH & Co KG 13 NK Tehnologija SIA 94

Bosch Rexroth AB 51 ORTS GmbH Maschinenfabrik 45

Cambelt International LLC 92 Quarry Mining LLC 71

Cleveland Cascades Ltd Inside Front Cover RULMECA HOLDING S.P.A. 102

Control Systems Technology Pty Ltd 49, 97 SIBRE - Siegerland Bremsen GmbH 7

CRS - Container Rotation Systems Pty Ltd 3 SIG Società Italiana Gomma Spa 101

DCL, Incorporated 62 Starlinger & Co. Gesellschaft m.b.H. 114

E-Crane Worldwide 65 STATEC BINDER GmbH 117

HP Handling SRL 91 TAKRAF GmbH 69

Italgru S.r.l. 98 Terex Deutschland GmbH 9

J & B Grijpers b.v. 75 thyssenkrupp Industrial Solutions AG Inside Back Cover

Jimway Enterprise Co., Ltd 53 Van Beek 77

Jotun A/S 18 Verstegen Grijpers BV 21

Liebherr-Hydraulikbagger GmbH 5 Vigan Front Cover, 36

Listenow GmbH & Co. 85

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Mining Technologies

Wagon unloading stations

With more than 100 years of experience our customers benefit from a unique
know-how in the field of bulk materials handling. We offer complete wagon
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or contact [email protected]