Mobile conveyors - An alternative

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15 Νοε 2013 (πριν από 3 χρόνια και 6 μήνες)

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Mobile conveyors
-

An alternative
and cost

effective way to handle
bulk material in Ports and Inland
terminals.


By: Philip Waddell




Common Misconceptions of

Mobile conveying equipment.




1
-

Dust Containment and Extraction

not possible on mobile Equipment


2
-

Spillages at transfer points and
under belts

1 + 2 = Dust
Containment and Suppression

Full length dust covers, Sealed transfer points, Undertrays (Spillage),
Side Wind protection,
Dust
Extraction / Suppression
systems and 360 degree trimmer chutes


Common Misconceptions of

Mobile conveying equipment




3
-

Limited Mobility Options Available.



4
-

Takes too long to move from hatch to
hatch on larger vessels.

3. Complete
Site
Mobility Options Available

Wheels and Rails

Tracks

Wheels

Track Mounted

Wheel Mounted

Rail Mounted

4. All Travel Mobile Ship
-
loader

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

Movement

In
-
Line

Parallel

Radial

Steering


Common Misconceptions of

Mobile conveying equipment.




5
-

Limited Options Available for
Discharge chutes and trimming.


6
-

Mobile Conveyors can only be used
for smaller vessels at smaller
capacities.

5. Telescopic Cascade Chutes

Telescopic Cascade Chute

-
Up to 20 metres Long
with Optional Trimmer.


-
Chute blocked load of
10 Tonnes material.


-
Customised to suit the
particular material
characteristics.


Telescopic Free
-
fall Chute

5. Telescopic Freefall Chutes

-
Typically Up to 10
metres Long


-
Customised to suit
the particular material
characteristics.


-
Optional Dust
Extraction Units.


6. Vessel Sizes

-

River Barges and Coasters










Direct feed by Trucks to wheel mounted unit

Direct feed by Trucks to Track mounted unit

Fed by FELs to Track and wheel mounted unit

Fed by FELs to Track mounted unit

-

Panamax / Baby Cape Vessels

Direct feed by Trucks to Ship loader

Direct feed by Trucks to Ship loader

Fed by FELs to Hopper and Ship loader

Fed by gravity reclaim to Ship loader

6. Vessel Sizes

TELESCOPIC TECHNOLOGY


>20 metre Telescopic
(in / out)
ability
allows
for complete trimming
of Handymax vessel
for maximum
flexibility


Telescopic
fully raised and extended

c/w 360 degree
trimmer chute

Telescopic
fully lowered and retracted

c/w 360
degree trimmer chute


Raise / Lower (> 20
Deg Range)of
conveyor for differing
draft/ tide heights
when loading.

Telescopic
and Luffing Abilities


Radial (left/right) feature
allow
several hatches to be
loaded from
one
single
feed
-
in point


Driven radial wheels for
left/right
travel


>3
x Hatches
from single
feed
-
in point

Radial Trimming Abilities


Alternative

to Mobile
harbour crane
loading a Vessel

CASE STUDY 1
-

AFRICA

MOBILE SHIP LOADING


Model



-

TS 2058 and HF 2020

Peak Capacity

-

2000Tph Iron Ore

System Fed by

-

CAT 988 FELs.

-
System:
All Travel Mobile Ship loader and


Hopper feeder

-
Material:

Iron Ore


2.4 t/m3


2000TPH

-
Application
:
Loading iron ore to Baby Capesize


vessels from wheel loaders

Africa

Up to 16 metre
Freeboard Heights

Up to 43 metre
Beam Widths

Up to 25
metre
Outreach









Loading Sequence and Hatch Change

Calculations /Timings
.

-
Typically 16 Number of
Hatch Changes



-
Typically Hatch Distance of
1810 Metres



-
TS 2058 Parallel Travel
speed of 1 km per hour.



-
Single Hatch Change travel
period in
2 minutes

Typical Loading Sequence for Panamax Vessels

















Hatch Moves
(No)

Hatch Move
Distance
(Metres)



Hold 7

Hold 6

Hold 5

Hold 4

Hold 3

Hold 2

Hold 1

1





8000













2









8000





2

65

3





3700









2

65

4











8000



3

100

5



8000











4

135

6













8000

5

165

7

8000













6

200

8







8000







3

105

9



3700











2

70

10











4000



4

135

11









3300





1

35

12

3540













4

135

13













1760

6

200

14







4000







3

95

15

1000













3

105

16













1000

6

200

Totals

12540

11700

11700

12000

11300

12000

10760

54

1810



82000









Phase 1 of production Ramp up


up to
6 million tpa
.



Reliability of System


Required load
1
-

2 panamax vessels per
week.
Previous systems proved unreliable.



Productivity


2000tph system
and up to
500,000 T/ month
.



Designed to cater for testing conditions




a)
Weather Conditions


high moisture and high temps.

b)
Ground Conditions


Rainy season with potential for
rutting

c)
Material


very abrasive, claggy and sticky in rainy season

d)
Skill levels of local operatives

e)
Robustness to take constant feed from CAT 988






KEY TECHNICAL CONSIDERATIONS
.

CASE STUDY 2


LATVIA

MOBILE SHIP LOADING


Model



-

TS 542, TL 530 and HF 514

Peak Capacity

-

500Tph Fertiliser

System Fed by

-

Liebherr 458 FELs.

Latvia

-
System:
TS 542 Radial Telescopic ship loader, mobile
links and mobile hopper

-
Material:

Fertiliser (Dust extraction and covers on
entire system)

-
Application:

Ship
-
loading from warehouse

Latvia

200 metre
conveying distance





Phase 1 of production Ramp up


up to 1 million tpa.



Dust Extraction and Containment


Required to comply with
EPA standards with close proximity to Riga City.



Sealing of transfer points and Spillage prevention


no
spillage on jetty and completely sealed transfer points.



Productivity


500tph system
and up to
500,000 T/ month.



Designed to cater for testing conditions




a)
Weather Conditions


Low sub zero winter temperatures.

b)
Material


very corrosive to conveyor structures








KEY TECHNICAL CONSIDERATIONS
.

CASE STUDY 3
-

INDIA



MOBILE RAIL WAGON LOADING


Model





-

TU 1015 R

Peak Capacity



-

1200Tph Iron Ore

System Fed by



-

Trucks and FELs
.

Client wanted a system to prevent damage to
their rolling stock of wagons caused by pay
-
loaders as well as more accurate and even
loading system.

The Final Solution


TU 1015 R fed by Trucks

TU
515R
Tracked Mobile Radial Truck Unloader Rail Wagon
loading directly from Trucks @ 500TPH





Accuracy

of

weighing

critical






a)
Penalties

for

overloading



6

x

Standard

Cost
.

b)
Maximum

Efficiency

of

wei ght

in

Each

Wagon

(Max

70
T/

wagon)

c)
Even

loading

of

Rail

wagons




Reliability of System




a)
Remote location

b)
Heavy application
(Iron Ore Material Density 2.4

2.8T/m3)



Multi Functionality and Mobility Criteria




a)
Stacking at Railway siding when no Rakes

b)
Rail Wagon loading when rakes present.


KEY TECHNICAL CONSIDERATIONS
.

CASE STUDY 4
-

MALAYSIA


MOBILE RECLAIMING AND BLENDING


Model




-

TU 1015 R

Peak Capacity


-

1000Tph Coal

System Fed by


-

Trucks and FELs.



Design suitable for typical Stockyard layout

with limited space between stockpiles and Stacker
Reclaimer Belts and road access

The Final Solution TU 1015 R feeding coal onto
Stacker Reclaimer conveyor line

TU Radial Unit fed from wheel loaders operating between
stockpiles and reclaiming line



3D, Side and Plan Views




Accuracy

of

weighing

critical



Blending

purposes
-

pre

set

weights

and

manual

settings

option

on

control

panel



Reliability of System


Required to feed furnace during
breakdowns/ maintenance of SR.



Communications with Central Control room


WIFI and
Ethernet Connections



Multi Functionality and Mobility Criteria




a)
Blending



Accurate from 100Tph


1000tph.

b)
Emergency Reclaiming


SR Breakdown or Maintenance.

c)
Stacking in passive areas
of Stockyard.

d)
Inter yard Transfer
of material.

e)
General Stockyard duties.



KEY TECHNICAL CONSIDERATIONS
.

Weighing Systems Control Settings
on Panel
Mimic









Pre set Weights


Blend%

Tph


10%



140


20%



280


30%


420


40%


560


50%


700


60%


840


70%


980


Total Reclaim

Rate:


1400Tph

Manual Settings

100


1000Tph

Weighing Systems


Methodology.









Manual Settings

100


1000Tph

-

Dual Idler Weigh Belt Scales
weigh the product on incline
belt.


-
Pulse Signal is sent back to
PLC every 10 Seconds.



-
Based on this signal the PLC
adjusts the speed of the Feeder
to maintain the preset weight
required for blending/
reclaiming.


-
Used in conjunction with
Stacker Reclaimer to send a
accurate blended coal to the
furnace



GLOBAL CLIENTS USING MOBILE
CONVEYING EQUIPMENT

Blue Chip Clients

CONCLUSION

WHY USE MOBILE CONVEYOR SYSTEM?



Ideal for Rapid Deployment for Phase 1 and 2 of export facilities. Can
be redeployed to stockyard for phase 3.



Enables quick revenue stream for material being exported in first
year of operation.



Can be used in rental fleets for short term contracts and moved from
site to site. (Contract loading)



Limited civils infrastructure required for jetties.



Can also be complementary to fixed installations.



Innovative and operating cost saving solutions.



Limited Planning Requirements.



Resale Value of the equipment.



Dual Functionality of the Equipment.



Improve Carbon Footprint.



Improve Health and Safety.