Dry Bulk - Autumn 2022 by PalladianPublications

AUTUMN 2022 - VOLUME 7 NUMBER 3

Port and

transshipment solutions CBG series

Some of the most valuable things in life are invisible.

40 Is Cyber Security A Risk In Dry Bulk?

Ports & Terminals Review 2022

21 Welcome to Dry Bulk’s annual Ports & Terminals Review. Read on to catch up with the latest activities of port and terminal operators from across the world.

Bob Domnick, Superior Industries, USA, addresses how dry bulk handlers can utilise a radial telescopic conveyor for many functions at port.

61 The Key To Reliable Gearboxes

Dr Heinz-Peter Ehren, Kumera Getriebe GmbH, Germany, provides insight into the comprehensive service solutions offered for gearboxes.

Mobile TeleStacker ® Conveyor Ship Loaders from US-based Superior Industries are multi-functional machines that can perform loading, unloading, stockpiling and transloading capabilities. A combination of telescoping technology, unlimited travel capabilities, and the company’s ability to design and manufacture the highest capacity portable conveyor are considered distinct advantages. Read more about the technology on p.44 in this edition of Dry Bulk or visit bit.ly/sup-ship.

16 Coal’s Not Going Anywhere

Cover Story

Dennis Blauser, Marietta Silos/USA Silo Service, outlines how the company restored life to an abandoned cement Gearboxessilo.

05 Regional Report

Sudip Saha, Future Market Insights, India, provides an overview of some of the recent developments in the Asia-Pacific dry bulk industry.

CONTENTS

Graham Rawlings, Concetti, UK, details how companies can manage the challenges of packing fertilizer.

Coal plays a major role in global development, especially in developing economies such as India. Riya Vyas, iEnergy Natural Resources Ltd, India, examines why coal consumption will grow in the near future and peak out by 2030.

Alfonso Garrido, SYMAGA Silos, Spain, considers silo storage as an offer-ready solution to enhance grain quality and improve food security.

Cranes, Grabs & Shiploaders

Conductix-Wampfler evaluates whether cyber security is a risk in the dry bulk industry.

48 Perfecting Fertilizer Packaging

31 A Bulk Material Handling Breakthrough

12 Dry Bulk Developments In The Asia Pacific

Roemer Braacx, Verstegen Grabs, the Netherlands, explores how grab monitoring systems can improve performance.

Paolo Magaldi, Daniele Ricci, and Lorenzo Lepore, Magaldi, discuss how companies can use conveyor technology to control dust emissions in material handling operations.

Commodity Report: Coal

News

03 Guest Comment

57 Not Beyond Repair

44 The ‘Swiss Army Knife’ Of Material Handling Systems

CBP006075 AUTUMN 2 22 VOLUME NUMBER

Conveyors & Dust Control

publisher endorse any of the claims made in the advertisements. Printed in the UK. Dry Bulk is a fully-audited member of the Audit Bureau of Circulations (ABC). Dry likeBulk magazineDryjoinBulk@DryBulkMagazinefollow

37 Let’s Push Performance

© Palladian Publications Ltd 2022. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither does

Domes, Silos, Hoppes & Bunkers

53 The Solution Is Silo Storage

Bagging, Packing & FIBCs

ON THE COVER

Ship RoadConveyloadersunitsmobileship unloaders Truck www.vanaalShipStorageloading&reclaimunloadersSTbulkhandling.Com The answer to your bulk handling questions

GUEST COMMENT

Jessica Casey jessica.casey@drybulkmagazine.com

DEPUTY EDITOR

MANAGER

ADMINISTRATION

EDITOR

SENIOR

DIGITAL ADMINISTRATOR

Biomass accounts for the majority of UK dry bulk trade, with the Drax power station alone burning 8 million t of wood pellets last year. How the UK Government responds to the energy crisis in the short and medium term is likely to have the biggest impact on dry bulk volumes, but there are some trends in other sectors that are already being noticed.

Meanwhile, as some generators have turned to biomass, volumes have increased steadily over the last decade, nearly doubling since 2012. How new UK Ministers respond to the energy crisis will affect whether this growth levels off, as seemed likely a year ago, or continues growing quickly if more coal-fired power stations convert to biomass.

quarterly by Palladian Publications Ltd. Annual subscription (quarterly) £50 UK including postage, £60 overseas (airmail). Claims for non-receipt must be made within four months of publication of the issue or they will not honoured without charge.

Laura White laura.white@drybulkmagazine.com

Louise Cameron louise.cameron@drybulkmagazine.com

Rod Hardy rod.hardy@drybulkmagazine.com

Palladian Publications Ltd, 15 South Street, Farnham, Surrey, GU9 7QU, UK // t: +44 (0)1252 718999 // w: www.drybulkmagazine.com

DRY BULK (ISSN No: 2059-9579) is published

MANAGER

SALES MANAGER

EVENTS

ry bulk cargoes account for more than one-fifth of UK port tonnage, with terminals handling 96 million t in 2021. Most of this throughput is imports, feeding renewable energy generation and the construction and manufacturing industries. As the trade association recreating most ports in the UK, including most major dry bulk terminals, the British Ports Association monitors policy developments that have potential to impact the sector.

DIGITAL CONTENT ASSISTANT Merili Jurivete merili.jurivete@drybulkmagazine.com

MANAGING

Stirling Vilijoen stirling.vilijoen@drybulkmagazine.com

James Little james.little@drybulkmagazine.com

Port throughput ores have declined over the last 20 years, from around 20 million t in 2000 to 11.4 million t in 2021. This may reflect reduced demand from steel and other UK manufacturers and construction industries. Global supply chain issues and other inflationary pressures have dented business confidence generally and in the UK construction sector specifically, despite strong demand. As the UK looks increasingly likely to enter recession, if we’re not already in one, these pressures will likely begin to impact inward volumes in 2023.

Ryan Freeman ryan.freeman@drybulkmagazine.com

GEORGE FINCH BRITISH PORTS ASSOCIATION

EDITOR

EDITOR Will will.owen@drybulkmagazine.comOwen

Kyla Waller kyla.waller@drybulkmagazine.com

The UK Government’s decision in 2015 to close all coal-fired power stations by 2025 has seen volumes decline dramatically over the last decade. Whilst a new government might be more sympathetic to coal, we do not expect this to reverse the decline in coal volumes in the longer term. However, there could be a minor short-term boost in volumes as some coal plants are put on standby in case of a difficult Winter, despite coal price forecasts for 2022 being 80% higher than 2021.

More widely, food and beverage manufacturing remains the largest manufacturing sector in the UK. Raw materials are sourced both from the UK and through imports. Government business surveys suggest that rising costs being felt by businesses are more acute in the food and beverage industry. Prices for imported ingredients are rising faster than domestic ingredients (23% and 14%), according to the Food and Drink Federation, which could impact throughput in 2023.

MANAGER

Leah Jones leah.jones@drybulkmagazine.com

Elizabeth Corner elizabeth.corner@drybulkmagazine.com

PRODUCTION

DIGITAL EVENTS COORDINATOR

SALES DIRECTOR

Agricultural product volumes have remained relatively stable in the last 20 years, although exports, which are significantly lower than imports, often vary considerably y/y. Overall throughput has declined somewhat since 2016, mostly driven by lower exports.

The biggest geopolitical event of 2021 has been the Russian invasion of Ukraine which has impacted grain and other Ukrainian exports. Russian aggression in Ukraine has not had a big impact on UK dry bulk volumes, however, as the UK imports little in the way of dry bulk cargoes from either Ukraine or Russia. Indirect impacts may affect volumes as sanctions have affected the price and availability of nitrogen-based fertilizers, and China has suspended urea fertilizer exports to ensure supplies for its domestic use. These developments led to the UK Government pausing plans for restrictions on the use of solid urea-based fertilizers in the UK – mooted in 2018 to lower carbon emissions although industry opposition also played a role. The government agreed to monitor emissions following a self-regulatory approach from the farming industry, but we expect to hear more about this from government in the next five years. Our initial assessment is that government pressure on solid urea fertilizers would increase demand for ammonium nitrate, which could increase volumes through UK ports significantly.

Pneumatic and mechanical ship (un)loaders Up to 2500 tph for loaders and up to 1200 tph for unloaders. Low noise & no dust emission Turnkey solutions for cereals, soy flour, fertilizer, pellets and more... Handle bulk with efficiency and reliability

etso Outotec has been awarded an order for a large belt conveyor package for delivery to a mining customer in the Americas. The value of the order is approximately €60 million, of which one-third was booked in

The achievement comes in line with Etihad Rail’s efforts to achieve the objectives of the UAE Railways Programme, the largest land transport system of its kind in the UAE, which was launched as part of the Projects of the 50, the largest set of national strategic projects that seek to set up a new phase of development across UAE for the next 50 years. The UAE Railways Programme aims to set a new

10 million tpy by supramax up to capesize bulkers, and performing both coastal and international trades.

awasaki Kisen Kaisha, Ltd (‘K’ LINE) has announced the signing of a memorandum of understanding with JSW Steel Ltd (JSW) for establishing a working committee for collaborative research on decarbonisation.

Minerals’ 2Q22 orders received and the rest in 3Q22.

AMERICAS Metso Outotec awarded conveyor package order

AUTUMN 2022 . DRY BULK . 5

JSW and ‘K’ LINE have agreed to collaborate together through the sharing of research, ideas, utilising, and leveraging on the respective party’s knowledge about new marine technology, alternative fuels and other fields potentially growing in the near future, so as to achieve net-zero greenhouse gas emissions in marine transportation by 2050.

The scope of delivery includes 3.5 km overland and in-plant conveyors, as well as shuttle head conveyors with a nominal equipment capacity of up to 21 000 tph.

tihad Rail, a developer and operator of the UAE National Rail Network, has welcomed the arrival of first batches of the company’s new and advanced rolling stock fleet. The locomotives and wagons, which reached the UAE via Zayed and Al Musaffah Ports, will operate across the whole network upon its completion.

The achievement was announced during an event, which was organised by Etihad Rail at Al Mirfa city in the Al Dhafrah region in Abu Dhabi, to unveil the new fleet of locomotives and wagons. The event was attended by His Excellency Shadi Malak, CEO at Etihad Rail, alongside Marty Haycraft – President and CEO at Progress Rail, and Henry Pang, Executive Director – MENA at CRRC, in addition to a number of senior officials from all sides.

The company has increased the size of its wagons, with the new fleet aiming to house more than 1000 multi-purpose wagons, three times of its current fleet. China’s CRRC Group, one of the world’s leading providers of sustainable development solutions of the railway industry, will handle handling the manufacturing and supply the new fleet of wagons.

UAE Etihad Rail welcomes first batch of new train fleet

roadmap for transporting goods and passengers via train across the country, which will contribute to developing a sustainable land transport system that connects the cities of the UAE via railways.

‘K’ LINE and its affiliated company ‘K’ Line (India) Shipping Private Ltd (KISP) have previously engaged in seaborne transportation of raw materials for JSW (‘K’ LINE since 2006 and KISP since 2014). ‘K’ LINE’s transported volume of iron ore, coal, limestone, etc. is reaching about

WORLD NEWS

The first batches have arrived in the UAE through Zayed and Al Musaffah Ports, which comes as part of Etihad Rail’s commitment to expanding its fleet of trains to serve the entire network. The company will increase its fleet of heavy freight locomotives to 45 heavy transport locomotives, which is equivalent to six times its current fleet. Progress Rail, a Caterpillar company of America and one of the world’s largest manufacturers of diesel and electric locomotives, will handle the manufacturing and supply of the new EMD® SD70 electro-motive diesel locomotives.

INDIA ‘K’ LINE starts collaborative research on decarbonisation with JSW Steel

6 . DRY BULK . AUTUMN 2022 WORLD NEWS

DIARY DATES

CONEXPO-CON/AGG 2023 14 – 18 March 2023 Las Vegas, visitToamericas-largest-construction-trade-showwww.conexpoconagg.com/north-USAstayinformedaboutindustryevents,DryBulkMagazine’seventspage:www.drybulkmagazine.com/events/

BELGIUM Grain and seed shipments from Ukraine to Euro-Silo resume

acGregor, part of Cargotec, has received two significant orders for heavy lift cranes. These orders, totalling more than €43 million, include the supply of 56 heavy lift cranes for 14, 62 000 dwt multipurpose vessels built at two shipyards in Asia.These orders were booked into Cargotec’s 2Q22 orders received. The vessels are scheduled to be delivered to the owners starting in 2Q23, and will be delivered until January 2026.

fter months of blockades, on 9 September 2022, a grain ship from Ukraine arrived at North Sea Port. The vessel moored at Euro-Silo at Sifferdok in Ghent.

TOC Americas 18 – 20 October 2022 Lima, home.htmlwww.tocevents-americas.com/en/Peru

The ship, ‘Zhe Hai 505’, left the Port of Odessa with 30 000 t of rapeseed on board. More ships are scheduled for mid and late September, which will help restart the transhipment of grain from Ukraine. During the first eight months of this year, the amount of grain shipped from Ukraine to North Sea Port fell by 60% compared to the same period in 2021. In a normal year, some 1.5 million t (2021) are imported, rising to as much as 2.1 million t (2019).

DM Agriculture, one of the largest fertilizer suppliers in the UK, has signed a three-year extension agreement with ABP for the import, handling, bagging, and processing of fertilizer at ABP’s Bulk Park at the Port of Immingham. It will see extensive fertilizer volumes come through the UK’s largest port by volume of tonnage.

World Coal Leaders Network 23 – 25 October 2022 Athens, https://www.coaltrans.com/Greece

AntwerpXL 04 – 06 October 2022 Antwerp, www.antwerpxl.comBelgium

POWTECH 2022 27 – 29 September 2022 Nuremberg, www.powtech.de/enGermany

TOC Asia 29 – 30 November 2022 www.tocevents-asia.com/en/home.htmlSingapore

GEAPS Exchange 2023 25 – 28 February 2023 Kansas City, https://geapsexchange.com/USA

Euro-Silo receives 4.5 million tpy of grain, seeds and derivatives, of which 25 – 30% comes from Ukraine, depending on the harvests. Under the auspices of the United Nations, a corridor for grain ships has been created in the Black Sea to allow the export of grain from Ukraine. Euro-Silo and North Sea Port are helping to establish this grain corridor. From the very start of the conflict between Ukraine and Russia, North Sea Port has been supporting companies and organisations that are seeking to mitigate these terrible events.

UK ABP signs new contract with ADM Fertilizer

The orders include totally 56 cranes with a size of 80 t and 150 t. All cranes are connected to the latest worldwide service support and equipped with an active safety system for the highest possible secure operation.

BulkEx22 18 – 19 October 2022 Warwickshire, www.mhea.co.uk/bulkex22/UK

MacGregor was selected as the supplier of these cranes thanks to its well-known design capabilities and customer’s trust in MacGregor’s delivery capability based on its earlier successes with similar solutions.

ASIA MacGregor receives orders for heavy-lift cranes

ADM Agriculture supply an extensive range of fertilizer products. ABP’s Immingham Bulk Park offers more than 1.3 million m2 of undercover storage.

REEL International delivers fully integrated bulk handling solutions to optimise your processes and performance nkmnoell.com reelinternational.comreel-alesa.comreel-moeller.com OUR

TOGETHER TOWARDS PERFORMANCE EXPERIENCE AND EXPERTISE FOR YOUR SUCCESS

With ALESA, MÖLLER® and NKM NOELL, REEL provides industry-leading performance and reliability within transportation and storage of fine-grained, mineral bulk materials. Other applications include operations handling high-wear and abrasive bulk materials. www.reelinternational.com Aluminium Bahrain BSC (Alba’s) Calciner and Marine aerial view

The ship will also pump seawater along its routes to collect microplastics floating in the ocean. The collected microplastics will be unloaded and analysed by the Chiba Institute of Technology and used to clarify the actual distribution of microplastics in the ocean.

US$15.8 million and delivered just prior to its statutory dry dock due Followingdate.these transactions, Eagle’s fleet will total 53 ships (91% scrubber-fitted) with an average age of 9.5 years. Since the company commenced its vessel renewal and growth program, it has executed 51 S&P transactions, acquiring 30 modern vessels and divesting 21 of its oldest and least efficient ships. These sale and purchase transactions have enabled the company to grow, while vastly improving overall fleet makeup; in terms of maintaining an attractive age profile, increasing cargo capacity per vessel, and reducing emissions on a per dwt basis.

The Tilbury Grain terminal has been in operation for over 50 years and is a key strategic facility in the Southeast of the UK for the grain import and export markets, handling over 2 million t of product from around the world. Grain is a key commodity in the UK food supply chain for a number of uses, most notably within the flour milling and bakery industries.

As previously disclosed, the company closed on the sale of the ‘M/V Cardinal’ (2004-built non-scrubber fitted supramax) in August 2022. The vessel was sold for

Workst.are also under way to replace the concrete silo and this is due for completion in December 2023. The new

concrete silo will add a further 34 000 t of automated storage, underpinning the grain terminal as the UKs largest import/export grain handling facility.

The terminal also operates a monthly coastal shipping service from Tilbury to its sister port in Kirkcaldy, Scotland, for Carr’s Milling.

tellar Harmony, a dedicated wood chip carrier, has been delivered at the shipyard of Iwagi Zosen Co., Ltd, a member of the Imabari Shipbuilding Group. The vessel will transport environmentally and socially conscious wood chips mainly from New Zealand, Australia, North America, and South America under a long-term contract between NYK and Marusumi Paper Co., Ltd.

JAPAN New wood chip carrier for Marusumi Paper Co. delivered WORLD NEWS

he Port of Tilbury’s Grain Terminal has completed major construction works with the commissioning of 10, 30 m, steel silos and a flat store with a combined storage capacity of 36 000 t.

improve propulsion efficiency) and an energy-saving governor (equipment that saves fuel and reduces the load during main engine operation), as well as an eco-friendly main engine with specifications that improve fuel efficiency during low-load operation.

UK 10 metal silos begin operating at Tilbury’s Grain Terminal

The metal silos will be filled and emptied using a new 650 tph transfer conveyor system. The conveyor also serves as an automated filling system for the 16 000 t flat store, which has a direct delivery system to two customer flour mill sites. Once fully operational, the combined silo and flat store facility returns the terminal’s total on site storage to 100 000

8 . DRY BULK . AUTUMN 2022

agle Bulk Shipping Inc., one of the world’s largest owner-operators within the midsize dry bulk vessel segment, has announced that it has expanded its fleet with the purchase of a high-specification 2015-built scrubber-fitted ultramax bulk carrier for US$27.5 million.

Stellar Harmony comes equipped with hybrid fins (energy-saving equipment installed on the rudder to

The vessel, which was constructed at Imabari Shipbuilding Co., Ltd, in Japan, will be renamed the ‘M/V Tokyo Eagle’ and will be delivered to the company during 4Q22.

USA Eagle Bulk Shipping acquires new ultramax bulk carrier

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.

Challenge your material limits

Hägglunds is a brand of Rexroth. www.hagglunds.com

CANADA Port of Belledune signs MoU with Niedersachsen Ports Wilhelmshaven

ärtsilä Voyage, part of Wärtsilä, has signed a contract for a five-year framework agreement with Associated British Ports (ABP), the UK’s leading ports group, to digitalise operations at its 21 ports. The project aims to accelerate the digital transformation of port calls and operations, making them as efficient, sustainable and safe as possible. The Wärtsilä Voyage technologies chosen for the project; Navi-Port, Navi-Harbour Vessel Traffic Services, and Port Management Information System (PMIS), will help ABP employees meet their targets, complement the company’s safety culture during port operations and optimise vessel planning and movements, which can have a positive impact on local, national and global supply chains.

10 . DRY BULK . AUTUMN 2022

The MoU also allows the ports to establish an ongoing dialogue focused on infrastructure developments; innovations and technology advancements in the maritime transport sector as it transitions to cleaner fuels and greener energy; best practices in liquid and dry bulk products storage and shipping, particularly in the areas of clean fuel and green energy; and support for the development of relationships between importers and exporters in Canada and Germany.

he Belledune Port Authority has signed a memorandum of understanding (MoU) with Niedersachsen Ports GmbH & Co. KG Wilhelmshaven, Germany, to collaborate on the movement of bulk commodities and manufactured products, between Canada andTheGermany.MoUwill support the MoU between the Governments of Canada and Germany to establish an energy partnership aimed at achieving net-zero emissions by 2050 through a transition to safe, secure, reliable, affordable, and sustainable energy.

WORLD NEWS

how to enable ABP to become an early adopter of state-of-the-art port management solutions, while also ensuring a strong return on investment aligned with the goals and ambitions of ABP.

The project, which began in June 2022, will span multiple phases across all of ABP’s ports. Wärtsilä’s Vessel Traffic Services system and PMIS are expected to be integrated into the Port of Southampton before April 2023, with other solutions subsequently being deployed across ABP’s other 20 ports. The agreement with ABP includes an ongoing human factor review to ensure the existing control room environment is optimised for people’s needs and is fully compliant with all national and international standards and guidelines.The framework agreement, valid for at least the next five years, formalises a shared vision and commitment from both organisations to develop modern smart port applications through extensive and long-term collaboration.

The MoU will allow the ports to form a relationship that will support the emerging needs of Canada and Germany’s

energy and manufacturing sectors, with a particular focus on the production, storage and shipment of cleaner fuels such as green ammonia, hydrogen, biomass and renewable natural gas.

UK Wärtsilä to digitalise Associated British Ports’ maritime operations

The Belledune Port Authority recently reached an agreement in principle with Cross River Infrastructure Partners to develop a green hydrogen production facility at the northern New Brunswick port. This development agreement will support the Port of Belledune’s efforts to diversify its business and develop new industries fuelled by renewable energy.

After a thorough international procurement process, ABP chose to collaborate with Wärtsilä Voyage, a technology developer accelerating the digital transformation of the maritime industry. Wärtsilä Voyage has a clear vision on

The MoU between the ports recognises the role that their operations will play in creating infrastructure aimed at the production, storage and shipment of clean fuels and green manufactured goods, for both domestic and intercontinental markets, and in assuring safe and secure access for the movement of clean fuels, green energy and other products between Canada and Germany.

12 . DRY BULK . AUTUMN 2022

Sudip Saha, Future Market Insights, India, provides an overview of some of the recent developments in the Asia-Pacific dry bulk industry.

AUTUMN 2022 . DRY BULK . 13

market share for the dry bulk market. 1 This is owing to the country’s rising imports of soya beans and iron ore. Meanwhile, in India, the exportation of agricultural products such as lentils and pulses is playing a key role in accelerating the demand for dry bulk in the Asia Pacific region. The government authorities from both these countries are also undertaking initiatives to cement their position in the dry bulk market.

he substantial presence of ports in the Asia Pacific region has created tremendous opportunities for importing and exporting goods. India, China and Singapore are prominent countries dwelling in the transportation of goods. The transportation of raw materials ranging from coffee to food grains, agricultural produce to fertilizers and metal components to non-hazardous chemicals are shipped by sea. Thus, dry bulk carriers, containers or vessels have gained huge traction across the shipping industry.

According to The Baltic and International Maritime Council, China imports are heading toward a 50%

An increase in carbon emissions as a result of shipping causes a threat to the environment, with National Pollution Register (NPR) reporting that 90% of the world's goods are transported by sea.2

Ensuring a safe dry bulk industry

Larger vessels: curbing carbon emissions

For instance, Nippon Yusen Kaisha and Japan Marine Science have introduced a new mooring system, named DynaMoor, to Japanese ports in collaboration with Trelleborg Marine Systems. The system can be installed on the pier of smaller and bigger areas. Post the installation, the system is connected to the ship. The system adjusts the tension of the mooring line and keeps the tension constant by using an electronically controlled hydraulic damper. This, in turn, makes the management of goods safer and more efficient. The added advantage of the system is that it will contribute to the reduction of greenhouse emissions throughout the supply chain including emissions from moored vessels at the port.

Various type of dry bulks such as capsize, panamax, supramax and handysize have gained popularity. However, these sizes are not able to meet the demand of curbing carbon emissions or carrying a larger quantity of material at once. This has led manufacturers of dry bulk to increase, modify and customise the size of dry bulk vessels, with dry bulk companies focusing on increasing the size of vessels, sometimes twice the size of conventional vessels, in order to accommodate more material and transport the material efficiently. Moreover, the capacity of dry bulk vessels to export a variety of raw materials has surged the demand for shipping through sea routes, leading dry bulk companies to offer sustainable solutions for shipping.

Oldendorff and South Pacific Shipping have signed a deal to load logs from the largest vessels in New Zealand. Not only will this be the biggest vessel to load logs from New Zealand, but loading a gearless ship will also be a first time experience for the New Zealand log export industry. The company is focusing on reducing the carbon footprint by maximising port throughput and making the supply chain as efficient as possible. The logs will carry twice the volume of conventional loggers. These logs will not require fumigation by Methyl Bromide as they will not be carried on decks. As the logs are sourced from Pacific Forest Products, they are supplied entirely from sustainable plantation forests. The vessel will transport the log from the port of Tauranga without the need for fumigation or lashing. As a result, this will enhance operational efficiency and make shipping faster and more efficient. The larger vessel will also produce a lower carbon output in comparison to a regular handysize logger.

The future of the dry bulk industry in Asia Pacific

14 . DRY BULK . AUTUMN 2022

Sustainability: helping dry bulk reach cleaner heights

As an example, Olderdorff Carriers in collaboration with BHP and Goodfuels, and along with the support of Authority of Singapore, have conducted a marine biofuel trial involving an ocean-going vessel bunkered in Singapore. The trial included the safety and understanding of the behaviour of fuel and its carbon emission levels. Through this collaboration, the company is making sea shipping activities greener by exploring the challenges of biofuels as a marine fuel. Furthermore, in April 2022, Olderdorff Carriers signed a letter of intent with BHP, Rio Tinto, Star Bulk Carriers and Globum Maritime Forum to together work on building a viable green corridor on the Australia to East Asia iron ore trade route. This green corridor concept is focusing on accelerating progress in understanding and tackling challenges associated with decarbonising shipping.

Dry bulk vessels are moored at ports with the help of mooring lines. The issue of the vessel staying stagnant in the sea has become a matter of concern for the shipping companies as sea swells, long period waves and hull shaking can disconnect the vessel. All of these factors can cause the mooring line to break. This, in turn, can affect the overall efficiency of port operations. Larger ships have increased the issue of hull shaking so, to increase operational safety at ports and to strengthen the connection of dry bulk vessels, manufacturers are focusing on integrating advanced mooring methods at ports.

Safety of goods is another issue currently being tackled by the dry bulk industry. Spilling of any raw materials will not only cause financial loss, but also ruin the health of marine life. Thus, dry bulk industries are designing advanced mooring systems and shipping companies are paying special attention to bulk terminals to reduce overall operational costs. Automation in bulk terminals can help ensure safe and efficient movement of goods, in turn improving the shipping of dry bulk.3

The import and export of dry goods is only going to increase in the upcoming years. Asia Pacific is the

Shipping by sea is the most efficient way of transporting everyday goods. On the other hand, the carbon dioxide emissions are polluting the sea and posing a threat to marine life. According to NPR, shipping by sea causes 3% of greenhouse emissions. 2 Rising pollution levels in India and China, along with the heightened demand for goods, is increasing the pollution levels in the marine life. Owing to this, dry bulk companies are not only focusing on assuring the safety of goods, but also the safety of marine life. Thus, companies are planning to fully decarbonise shipping routes by using biofuels to reduce carbon emissions.

Thus, the dry bulk industry is laying emphasis on integrating sustainability while shipping raw materials. To reduce the level of carbon emissions, shipping companies are planning to use biofuels and are creating green corridors. With these measures, the overall carbon emissions caused by the dry bulk industry is expected to reduce in the coming years.

hotspot of natural resources, with the wide presence of agriculture and other raw materials increasing the demand for goods from countries like China and India. Good quality ports and efficient labour is positively influencing the demand for dry bulk in the Asia Pacific region, and shipping companies are integrating automation to quicken the process of loading and unloading goods. This, in turn, is increasing the productivity rate at bulk terminals.

Moving ahead, companies are modifying and designing the sizes of bulk vessels and carriers according to the goods. This ensures that the goods will be spill-free and unharmful to marine life. Companies are no longer sticking to the conventional sizes of bulk vessels; larger sizes of bulk vessels are expected to become more mainstream and dry vessels are now being designed according to the quantity of material that needs to be transported. The large size of dry bulk vessels is helping in reducing carbon emissions and, subsequently, the popularity of larger dry bulk vessels are expected to soar in the nearSustainabilityfuture. is also playing a key role in changing the dynamics of the dry bulk industry. Shipping companies have shown a growing inclination towards using biofuels. Thus, the dry bulk industry is expected to become a cleaner and greener market in the future. Not only are companies focusing on using eco-friendly fuels, but they are also planning to create green

corridors to transport raw materials. With the help of modified dry vessels, a plethora of factors such as shipping more quantity at once, reducing labour costs and improving operational efficiency will be achieved. Thus, dry bulk companies are planning to improvise the overall workflow of dry bulk carriers.

2. NORTHAM, J., ‘Shipping industry is pressured to cut pollution caused by merchant fleet’, National Pollution Register, (2021), fleet?t=1661174881159industry-is-pressured-to-cut-pollution-caused-by-merchant-www.npr.org/2021/12/01/1060382176/shipping-

1. ‘Chinese imports heading for 50% market share of the dry bulk market after a turbulent year’, BIMCO, (2021), heading_for_50_market_share_of_the_dry_bulk_marketNews/Market_Analysis/2021/20210113_Chinese_imports_www.bimco.org/

References

3. ‘Bulk Terminals Market Outlook and Key Findings’, Future Market Insights, (2020), www.futuremarketinsights.com/ reports/bulk-terminals-market

Finally, countries such as India, China and Singapore are relying on technology to improve the operation efficiency of the dry bulk industry. Automated bulk terminals, integrating artificial intelligence to make real-time decisions and measuring raw materials through Internet of Things will make the process of carrying goods easier. Therefore, the increasing use of technology in the dry bulk industry will further accelerate the growth of the dry bulk industry and provide newer opportunities to the Asia Pacific region.

beumer.com SOME THINK THAT DIFFERENT.WETRANSPORT.MEANSEXTRACTIONMATERIALSRAWTRUCKTHINK Visit bauma,us!Munich, Germany October 24– 30, 2022 Hall B2, Stand 413

16 . DRY BULK . AUTUMN 2022

Support from the COVID-19 breakout

There was already the pressure of emissions on coal, but the COVID-19 pandemic provided further support on its movement and consumption. 2020 witnessed the worst decline in world GDP. Investment in fossil-based generation decreased considerably in 2020, by more than 10%, given lower demand and electricity prices, although there were notable differences between countries and regions. Reduced energy demand, rising output from renewable sources, and low gas costs all put pressure on coal's place in the power mix.

has been part of the development of the new world, and it is still contributing. There is evidence that coal has been used as source of energy since the 13th Century. Coal is contributing approximately 26% in global primary energy consumption, the second largest source after oil. And at the same time, coal is the world’s largest source of carbon emission.

The race to zero

The Paris Agreement then signalled the beginning of the race to zero emissions. Even though there was a net increase in operating coal-fired capacity following the agreement, the coal pipeline has shrunk: planned or announced projects for coal plants around the world have been cancelled or put on hold, and leading indicators of coal power capacity growth, such as construction starts, pre-construction activity, and plant completions, have decreased. Financial institutions established or improved their policies to forbid or restrict the financing of thermal coal, as well as to divest from it. This indicates a definite reluctance on the part of many governments and investors to finance new coal-fired power facilities.

AUTUMN 2022 . DRY BULK . 17

n May 2022, Nigeria’s Vice President, Yemi Osinbajo, articulated Africa’s energy situation as such: “No country in the world has been able to industrialise using renewable energy [yet Africa is expected to do so] when everybody else in the world knows that we need gas-powered industries forForbusiness.”ages,coal

The top five coal producing countries are: China, India, Indonesia, the US and Australia. The major consumers are: China (50%), India (11%) and the US (8%). The world consumes approximately 8 billion tpy of coal, resulting in 40% of total carbon dioxide (CO 2) emissions.

Hence, coal changed from a friend to an enemy once the world realised that in spite of being the largest source of energy, it is a ‘dirty’ fuel. This was also apparent in the Paris Agreement (COP21), where coal’s existence was put under pressure. This worldwide agreement on climate change aims to limit global warming to well below 2˚C (ideally to 1.5˚C) compared to pre-industrial levels, and control global greenhouse gas emissions as soon as possible in order to establish a climate-neutral planet. As coal is the world’s largest source of carbon emissions, the central theme of the agreement was to phase-out the coal from the energy source.

A turning point: the Paris Agreement

Europe was Moscow's primary export market; however, the reduction in that market has been offset by an increase in Russian coal exports to China and India. The world's largest coal importers are now dealing with energy shortages. At a time when coal prices are skyrocketing, receiving Russian coal at steep discounts to international standards is a welcome relief. Thus, a significant portion of the coal flow that was heading from Russia to the EU was diverted to China and to some extent, India, while

India’s economy got hit the hardest by the pandemic, with its GDP dropping by 7.2% in 2020 as it imposed some of the world’s strictest lockdown measures. During this time, coal demand for power generation and industry fell by 5% and 11%, respectively.

n Reducing the carbon intensity of the economy to less than 45%.

n Becoming a carbon neutral country by 2070.

n Installing 500 GW of non-fossil fuels energy capacity.

Only six months after COP26, the global energy scenario changed drastically. The current global energy crisis, Russia’s unprovoked invasion of Ukraine, is a major turning point in the history of coal.

The invasion of Ukraine by Russia and the unprecedented economic sanctions that followed have completely disorganised the global energy market, driving up the price of fossil fuels, and prompting debate in many nations about whether or not climate ambitions need to be scaled back in order to keep the lights on.

India did take five pledges to slow down the emission. These include:

Phase out vs phase down

Figure 1. India’s total coal and coke imports.

18 . DRY BULK . AUTUMN 2022

n Reducing total projected carbon emissions by 1 billion t.

However, despite taking these pledges, the world’s second largest coal producing and coal consuming country is all set to increase its production to meet ever-growing energy demand. India produced 773 million t in 2021, up by 6.33% y/y. India’s current year production has touched 463 million t during January – June 2022, which is 60 million t (14.88%) higher compared to the corresponding period of last year. India’s Ministry of Coal has the target to reach 1 billion t of coal production by 2024 (Figure 2).

As energy consumption dropped during the epidemic, imports were most severely impacted. Coal imports, which peaked at 260 million t in 2019, fell steadily over the next two years, to 230 million t in 2020 and 214 million t in 2021. The decline was steeper if coal imports for the power sector in 2020 – 2021 are compared to the pre-COVID year of 2018 – 2019, when such imports totalled 180 million t (Figure 1).

The result: Europe imports more coal; more investments are made in coal mining in India and China. Indonesia is hiking production; and many European countries delay power plant closures. For instance, the EU was importing a sizeable portion of its energy, including coal, natural gas, and crude oil, from Russia. In June, Russia cut off gas supplies to the EU, forcing the EU to scramble to find alternate fuel sources and even consider burning additional coal to make up for the reduced gas supplies, which pose an energy catastrophe in thePriorwinter.to the conflict,

More than 40 countries pledged to phase out coal at COP26 in Glasgow, but the last-minute change of India’s stand to ‘phase-down’ of coal from phase-out signalled that the country is nowhere near to removing coal from its energy source.

Ditching the pledge

Figure 2. India’s coal production. Source: Ministry of Coal, Government of India.

1 billion dream

n 50% energy requirements from renewable sources by 2030.

South African coal that was headed for India was redirected to the EU. The total imports of India from Russia between January – June 2022 increased by 129% compared to the corresponding period of last year (Table 1) and at the same time EU’s imports of South African coal surged to 4.09 million t, an eleven-fold increase.

The solutions for green developments, for instance electric vehicles, which are considered to

be the future, have been growing and seems to be a good solution to fight climate change. But are they worth it? Are they safe for the environment? The answer is depends. If the source of energy to power these vehicles does not come from solar panels, wind turbines or even nuclear or hydroelectric, their carbon dioxide emissions will be much higher. And if the electricity used to charge vehicles comes from the burning of fossil fuels, it does not matter if the electric vehicle is not polluting while being driven, as this pollution was already released in some distant power plant. Thus, many green solutions may not completely green and instead just change the point of pollution without breaking the cycle. factory-direct service, training and sales call 1-309-852-2384 or to access our education and professional development options visit martin-eng.com Learning

and click

Center

artin provides the most innovative bulk material control products in the industry. Self-adjusting skirting, wear liners and dust curtains effectively control fugitive material. Support cradles eliminate belt sagging and pinch points. Transfer chutes are engineered for optimal dust containment and air flow management.

Due to earlier-than-expected summer, rising power consumption and depleting coal supplies at power plants, India had its greatest power crisis in more than six years in April 2022, despite Coal India producing at record levels.

Our broad and varied line of conveyer belt components reduce harmful conditions, decrease maintenance and insurance costs, and increase overall productivity. Got dirt? We can help with all of your bulk material handling problems.

The world's reliance on fossil fuels is still expected to worsen, even as politicians and corporate executives frequently proclaim their dedication to the so-called ‘energy transition’. The barriers to sustainable development are highlighted by Economist, Kandula Subramaniam: “Given its nature of being untamable, renewable energy can never be a substitute for conventional sources of energy, and, hence, the country's demand cannot be met through renewable energy. The more renewable energy dependent the grid becomes, the more gas/liquid fuel power generation will be needed for grid security.”

For

EFFECTIVE FUGITIVE MATERIAL CONTAINMENT MAXIMIZES THROUGHPUT, EFFICIENCY & REVENUE

CMYCYMYCMYMCK DryBulk9-22_insertV1.pdf 1 8/23/22 12:47 PM

For all the talk of climate activism, developed nations are still on track to continue to rely mostly on fossil fuels for the upcoming decades.

Is green development a myth?

The energy crisis compelled India to abandon its intentions to reduce thermal coal imports and revive abandoned mines in order to meet growing electricity demand. In order to prevent a fuel crisis at the country’s strained power plants and build up buffer stock, the government also instructed power generation companies to import up to 10% of coal that was needed. Making the blending of imported coal mandatory for domestic power producers by government, India’s thermal coal imports for the month of June touched an all-time high of 20.13 million t. India’s total coal and coke imports also reached to historical high of 28 million (Table 2).

191 1

Coal 5.268 4.532 16.25 4.884 7.87

Coal will continue to play an important role in India's future. In the medium term (to 2025), India has one of the biggest potentials to surge coal consumption. Coal imports are expected to rise with India’s ambitious development projects. iEnergy Natural Resources estimates that India will overtake China and become the world’s largest importer of coal soon. 421 1510.05 219 120 223.3

India, being on the path of development, cannot grow without relying heavily on fossil fuels, given the fact that no country in the world has achieved industrialisation without the help of fossil fuels. An energy-starving nation with a high population, whose energy consumption is always expanding and predicted to explode in the future and with limited capital, has no choice but to fuel its economy with low-cost energy sources. The drive to meet this demand with a sustainable, reliable, and affordable supply resulted in coal being the best fit for the circumstance.

Thermal Coal 632 902 382 867 65.31 326 503 93.84 1

20.127 13.882 44.98 14.817 35.83 78.991 80.371 -1.72 94.756 -16.64 Anthracite 0.383 0.137 178.54 0.159 140.14 1.499 0.81 64.72 1.097 36.71 PCI Coal 1.101 1.121 -1.79 1.075 2.42 6.996 7.225 -3.16 6.756 3.55 Metallurgical Coke 0.169 0.318 -46.87 0.17 -0.8 1.309 1.239 5.63 1.937 -32.44 Pet Coke 1.005 0.354 184.06 0.746 34.76 4.615 2.031 127.27 6.814 -32.26 Total 28.05 20.34 37.89 21.85 28.38 120.38 120.38 0.08 135.75 -11.33 20 . DRY BULK . AUTUMN 2022

Coal’s contribution will remain significant in India’s energy basket in the coming years with the push to renewables. Indian demand for non-coking coal is expected to rise by 200 million t over the next three years to 2025, while output will reach 950 million t or higher. A higher amount of coal consumption is expected at least until 2030 – 2035, when the pace of coal consumption will then decline. Imports are anticipated to increase to 250 million t, or higher still to 260 million t. For the current year 2022, India might end its coal imports to 225 – 230 million t, but it will still require one more year to reach the pre-COVID import level of 260 million t.

Pet Coke 188 25 505 -99.26 Total 1 835 163 800 010 129.39 893 449

46 054 69

265 10.56 1

The development of India's economy depends heavily on coal. The country relies on coal to generate energy, and the steel industry also depends on metallurgical coal. According to Central Electricity Authority,

thermal energy’s installed capacity is 59% of India’s total installed capacity and contributes 74% in power generation. This implies that thermal fuels provide 74% of India's electricity requirements.

Table 1. India's imports from Russia: coal and coke (t) 2022June y/y m/m Year-to-date (January – June 2022) 2021June Change(%) 2022May Change(%) CY22 CY21 Change(%) (pre-COVIDCY19level) Change(%) Anthracite 315 068 113 912 176.59 100 946 212.12 1 185 979 829 289 43.01 1 010 355 14 CoalMetallurgical 231 703 44 000 426.6 22 000 953.2 708

Since imported natural gas is now the most costly fuel for power generation, switching completely from coal to natural gas would present India with significant economic problems. Geopolitical and external trade concerns would also be associated with imported gas, which will affect India's energy security.

CokeMetallurgical 679 -100 252 095 -100 203 088 637 072 -26.5 621 911 095 70.47 105.4 6 355 566 3 678 555 72.77 5 059 736 25.61

Conclusion

Metallurgical 26.967 28.506 -5.4 24.395 10.54

Thermal Coal

PCI Coal 655 490 213 176 207.49 444 000 47.63 3 257 787 1

44 000

Table 2. India's coal and coke imports (million t) 2022June y/y m/m Year-to-date (January – June 2022) 2021June Change(%) 2022May Change(%) CY22 CY21 Change(%) (pre-COVIDCY19level) Change(%)

817 100.87 1

Welcome to Dry Bulk's annual Ports & Terminals Review

Read on to catch up with the latest activities of port and terminal operators from across the world.

Figure 1. Two of the first fully mains-electric powered hydraulic cranes arrive at the Port of Ipswich.

The Humber ports have also seen additional requirements for animal feed and construction bulk materials, including conditioned pulverised fuel ash (PFA) and cementitious products. A 0.5-acre plot at Albert Dock Hull is being developed by a customer to accommodate additional volume flows of cementitious products which will be imported via a new 6000 m3 silo facility. ABP has constructed two bulk capacity storage sheds (approximately 40 000 t) in Hull and Immingham, which are in operation with long term contracts with two grain import/export companies.

The list of dry bulk commodities handled by the group increases each year, with sustained investment in ABP’s people, their safety, storage facilities, and equipment being a key part of the service offering to customers. ABP has invested over £300 million in the last six years in storage and handling equipment alone. The innovative design of new bulk storage facilities has improved discharge and loading performance as well as enabling the storage of more product in the same overall footprint.

In the next five years, more electrically powered material handlers and equipment running on hydrogenated vegetable oil will be introduced across many of ABP’s ports, ensuring that customer growth is sustained at the same time as the decarbonisation of industry accelerates.

This year, ABP has received new Mantsinen cranes, including two electric Mantsinen model 95ER cranes, which arrived at the Port of Ipswich in April 2022, the first of their kind in the UK. This was swiftly followed by the delivery of the world’s largest hydraulic crane, the gigantic model Mantsinen 300M Hybrilift to Immingham, and, in June and July, two Mantsinen 120M Hybrilift cranes to its Port of Garston, Liverpool. These new

South Wales has also seen additional requirements for animal feed, fertilizer, and construction material across several ports. ABP’s Ports of Newport, Cardiff and Swansea have also secured new dry bulk commodity customers, resulting in ABP’s plan to redevelop an additional eight acres of external storage to accommodate these additional demands.

In the last year, ABP has completed significant investment projects to support the growth of its dry bulk customers. Recent examples include the opening of the new £1.4 million Dutch barn for timber at the Port of King’s Lynn and the delivery of new equipment and welfare facilities at the Port of Garston, Liverpool, representing a £4 million investment. In 2021, ABP also launched 1000 acres of strategic development land to facilitate the growth of port-centric manufacturing, helping customers to build more sustainable supply chains.

22 . DRY BULK . AUTUMN 2022

ssociated British Ports (ABP) is the UK’s leading ports group, with 21 ports in key locations, including Immingham, the UK’s largest port by tonnage. Dry bulk commodities are a vital part of its business, and ABP has a £160 million per annum investment plan in infrastructure, equipment and skills to enable the group to fulfil it mission of ‘Keeping Britain Trading’ and support its customers’ growth.

Associated Britsh Ports, UK

In Southampton, following a substantial investment in the terminal, the group has concluded a new long-term contract with a key agribulk customer, for the export of wheat, barley, rice, and maize. General enquiries in the region have shown an increase in requirements for aggregates and cementitious materials, as well as

Since the start of 2022, ABP has seen a tremendous amount of activity on dry bulk volumes. In East Anglia, it has secured new long-term contracts with several aggregate supply customers, which has seen the group redevelop over 11 acres of land to accommodate the material supply demands from the regional construction industry.

cranes address the need to mitigate environmental impacts and improve efficiency across construction, agribulk and break-bulk cargo at the ports.

ABPrecyclables.isalsodecarbonising its own operations and supporting its customers in building more sustainable supply chains. To date, the group has invested over £60 million across its ports in electric/hybrid equipment and on-site solar arrays and wind turbines; this has contributed to a reduction of over 35% in its own carbon emissions since 2014. Over the last year, electric vehicles and cranes, electric charging points, more fuel-efficient pilot boats, and the UK’s first commercial shore power connectivity for cruise ships have arrived at ABP’s ports.

Over 70 years of experience have contributed to the design and functionality of the CBG series. This is our visualisation of one of the most valuable things for your company. With the new CBG 500 E, we now also offer an all-electric solution. www.liebherr.com

Reliability is one of them

Port and transshipment solutions CBG series

The challenges of the COVID-19 pandemic have highlighted the importance of robust supply chains, with both the Lumsden Point development and the new Dampier Cargo Wharf supporting the growth in direct shipping services. Direct freight options reduce reliance on trucking products from Perth to the Pilbara, which takes approximately two days. Demand for these services has increased faster than anticipated, with PPA identifying the need to triple its First Point of Entry facilities to accommodate inbound cargo less than two years after commencement.

PPA broke its throughput record once again in 2021 – 2022, with 733.1 million t of trade and 17 000 vessel movements through its ports. The value of commodities passing through PPA’s ports in 2021 – 2022 were estimated to be more than AUS$165 billion. This comes following a decade of strong performance, with technological advancements and port efficiencies driving y/y growth.

The Port Hedland Port Development Plan review, endorsed by the WA State Government, outlines the plan to maximise exports to 660 million t. A key component of that plan is the development of a multi-user facility and logistics hub, Lumsden Point, to facilitate forecast trade growth and diversification. The ultimate development for Lumsden Point includes two berths, channel access, turning basins and a central access road and service corridor connecting to the Great Northern Highway.

Figure 1. The Port of Port Hedland achieved a total throughput of 561 million t in 2021 – 2022, and is aiming to increase capacity to 660 million t as part of the Port Development Plan Review.

The Port of Dampier will also play a significant role in growing Pilbara ports’ capacity, with PPA progressing plans for a new multi-user wharf. This new wharf would support the proposed Perdaman Urea Project, encouraging trade diversification and creating regional jobs. The Northern Australia Infrastructure Facility (NAIF) announced a AUS$160 million investment in the wharf, which will be capable of berthing panamax bulk carriers, as well as accommodating cruise ships and general cargo vessels supporting the offshore oil and gas industry. A tender is expected to be released later this year for the design and construction of the wharf.

producers of nickel, cobalt, and rare earth elements. The Lumsden Point development will enable increased exports of battery metals and minerals, with the demand for lithium and copper concentrates expected to grow tenfold by 2030 as the demand for electric vehicles skyrockets. It will also support the development of the renewable energy industry, with the facility designed to accommodate the import of 90 m-long wind turbine blades and towers.

ilbara Ports Authority (PPA) is responsible for the ports of Ashburton, Dampier, Port Hedland and Varanus Island, which include two of the world’s largest bulk export ports (Port Hedland and Dampier).

To be able to continue to meet forecast demand, the world’s largest bulk export port authority is embarking on several transformational infrastructure projects to grow capacity and diversity trade in the Pilbara, Western Australia (WA).

With strong iron ore prices experienced in Australia in recent years, there is growing demand for access to Utah Point, which gives WA junior miners access to international markets. Utah Point is a multi-user facility, with stockpile areas enabling miners to truck iron ore to the port, ready to ship when they gather the volume required to fill bulk cargo vessels. PPA has recently received environmental approval to increase the facility’s annual throughput to 28 million t, which is an additional 4 million tpy.

24 . DRY BULK . AUTUMN 2022

The ultimate development is critical to facilitate forecast trade growth and diversification. WA is the world’s leading producer of lithium and is ranked among the top five global

A decade ago, the Port of Port Hedland’s annual throughput was approximately 200 million t, with the maximum capacity estimated to be 495 million t. In 2021 – 2022, the Port achieved a total throughput of 561 million t. Through comprehensive modelling and simulations, PPA now believes the maximum capacity to be 660 million t, though investment in key infrastructure is needed to get there.

The development has been recognised as a priority by Infrastructure Australia and the WA government, with it being identified as a priority project and a AUS$78 million funding commitment being made in the 2022 – 2023 State budget to progress works. This builds on previous investment in Lumsden Point, including initial reclamation, dredging and remediation works and the development of a temporary module offloading facility.

Pilbara Ports Authority, Australia

PPA is continuing to work closely with port proponents and stakeholders to help deliver strong economic returns for Australia. This long-term planning also includes the development of five greenfield ports, including Balla Balla, Cape Preston East, Cape Preston West, Urala and Aketell.

1 at Port of Corpus Christi.

26 . DRY BULK . AUTUMN 2022

Figure 2. Pig iron at the Port of Corpus Christi Bulk

Bulk Dock 2 is capable of loading coal, pet coke, sulfur and other dry bulk materials directly to vessels/barges from bottom dump, railcars, trucks or storage pads. Bulk Dock 2 is home to a radial ship/barge loader which has been serving port customers since 1985, and is capable of moving 1500 tph. Bulk Dock 2 has a dock draft of 45 ft and a slip length of 1270 ft. Adding to the loading efficiency is a network of conveyers spanning 3800 ft.

Bulk Dock 1 is capable of discharging coal, ore, minerals and other dry bulk commodities directly from vessels to railcars or trucks. This dock and its equipment also have vessel loading capabilities when special handling is required. In 2019, the Port of Corpus Christi purchased and received a new Liebherr 550 LPS Harbor Crane at Bulk Dock 1 to support the discharge of dry bulk commodities, as well as adding a conveyor system to allow for loading direct to dump trucks. Over the last year, the new crane has added approximately 20% increased productivity overall when unloading dry bulk cargoes. An 835-ft slip length and 34-ft draft at the dock is capable of berthing a panamax class vessel. Dry bulk commodities may be unloaded to a hopper/conveyer system and directly to truck or rail cars. Maximum unloading efficiency may be gained by going directly to ground and hauled to numerous pad sites available throughout the facility.

he history of the Port of Corpus Christi originated in 1926 when it opened for business, primarily as an agricultural port in a time when cotton was king. Today, the Port of Corpus Christi handles a diverse portfolio of cargoes including but not limited to grains, barite, pet coke, sulfur, pig iron, iron ore fines and various aggregates.

Port of Corpus Christi, USA

The Bulk Terminal is undergoing a capital improvement project that includes improvements to rail infrastructure, docks, pad sites and access roads which will offer optimised efficiency for users.

Steel Dynamics Inc (SDI) invested in the build out of a new steel plant in Sinton, Texas. The Port of Corpus Christi supports the importation of pig iron, zinc ingots and other metals used in the fabrication of steel coils. Pig iron arrives via vessel and is offloaded using the Liebherr 550 before being stored on site on a designated storage pad. Zinc ingots make their way to the Port of Corpus Christi via rail and are stored in one of the Port’s dry storage warehouses. Pig iron makes its way to SDI via rail gondolas and the zinc is loaded to truck and driven to the facility. Steel coils required for the startup of the SDI facility are also imported via vessel and offloaded using ship/shore cranes and trucked to the ArcelorMittalfacility.alsocalls on the Port of Corpus Christi to handle overflow of hot-briquetted iron and iron ore fines from their ArcelorMittal facility located at the Port of Corpus Christi - La Quinta Channel. The iron ore fines and HBI make their way to the bulk terminal via rail and are loaded using the Liebherr 550 directly to covered barges and sailed to their destinations.

54 ft via a channel improvement project currently underway). Two bulk docks at this terminal facilitate the loading and unloading of vessels to rail or truck.

Many of these cargoes make their way to the Port of Corpus Christi Bulk Terminal located on the north side of the Tule Lake Channel, in the inner harbour encompassing 240 acres. The bulk terminal has quick access to the Joe Fulton International Trade Corridor, allowing cargo to make its way to a vast network of Texas highways and interstates. Rail connectivity at the Bulk Terminal is accessible by three Class I railroads: BNSF, KCS and UP. Rounding out the logistical advantages of the Port of Corpus Christi and its Bulk Terminal asset is a deep draft ship channel with a current depth of 47 ft (authorised to

FigureTerminal.1.BulkDock

THE LEADER IN DRY BULK LOGISTICS

The

Port of Corpus Christi is uniquely positioned to get dry bulk goods from point A to point B — safely and efficiently. Our dry bulk logistics resources include: Liebherr 550 LPS crane 240-acre Bulk Terminal Access to three major Class 1 railroads: BNSF, KCS and UP 47’ deep channel — currently dredging to 54' Learn more about our capabilities at portofcc.com Gearboxes in all sizes between 3 - 40 tons in weight and torques up to 2500 kNm for mining conveyors with experience of more than 100 years. Gearboxes for new capacities and efficient increasing revamping. throughoutservicesmaintenancesEngineering,andsupervisionatyourdisposalminingworld. Kumera Getriebe GmbH Bonner Strasse 38 D-53842 Troisdorf-Spich Tel.:Germany+49 2241 988 – 0 Power Player in Conveying Gearboxeswww.kumera.com

For shipping and port customers from trade and industry, simplifications in the accessibility of Germany’s largest universal port also facilitate the advantage of routing more cargo via Hamburg. On land, environment-friendly rail is the main supplier of freight transport, linking inland market regions with the port swiftly and reliably. With high-performance routes, smart logistics solutions and growing use of low-emission energy sources and technology, Hamburg is on course for sustained growth.

In addition, a number of powerful cargo-handling facilities specialise in handling scrap metal or building materials, including Rhenus Midgard with its terminal in Hamburg-Harburg, and EMR which runs a terminal for scrap and disposal products in Hamburg-Steinwerder. Aurubis operates as one of the largest copper recycling locations in the world. The recycling capacity will increase sharply – equipped with the latest technology and enhanced environmental protection, the system can continue to process up to 100 000 tpy more complex recycling raw materials.

The second stage of the fairway adjustment was authorised on 24 January 2022. This represented the achievement of the project target of enabling bulk ships and other large ships with a draft of up to 13.5 m to reach the Port of Hamburg, irrespective of the tide. Depending on the tide, even greater drafts are possible. In comparison to the situation before the fairway adjustment, inbound and outbound shipping now gains from a draft increase of between 1 – 1.9 m. Irrespective of the tide, megamax vessels with a width of up to 62.5 m and a length of 400 m can now move about the port with a draft of up to 13.1 m. Prior to adjustment, the figure was no more than 11.4 m. A favourable tide makes 15.4 m feasible, compared to the previous 13.6 m.

Moreover, Hamburg offers further specialised terminals for dry bulk cargo handling, including Louis Hagel with its own storehouse for dry bulk cargo and a railway connection. The Terminal Louis Hagel specialises in the transloading, storage and blending of high-quality fertilizers.

ulk cargo handling is an important element in sustaining the diversity and universality of the Port of Hamburg. Hamburg is not only Germany’s leading port for containerised cargoes, but also for bulk cargoes. In due consideration of the state of the tide in the Port of Hamburg, berths for ore, coal and grain mega-carriers have water depths sufficient to permit loading and discharging. Hamburg is one of Europe’s top hubs for suction goods, with silo storage capacity totalling more than 1 million t. Vessels can berth directly in front of the large silos, where high-performance equipment takes over loading and discharge.

HANSAPORT is Germany’s largest dry bulk cargo terminal. The staff operates automated handling and storage technologies which enables them to handle approximately 9 million tpy of iron ore and 5.5 million tpy of coal. The four unloaders with their jumbo grabs, five stacker-reclaimers, two rail loading terminals and the shiploader work completely automatically.

HANSAPORT possesses 15 tracks of full train length where trains (ore and coal) wait to be handled at rail loading station. Approximately 150 000 t are moved (loading, unloading and storing) here every 24 hrs in day and night operations at the quay (780 m long) or on the open storing space (350 000 m2).

Figure 1. HANSAPORT – Germany’s largest dry bulk cargo terminal. Source: Hafen Hamburg Marketing e.V.

28 . DRY BULK . AUTUMN 2022

The grab cargo volume for 2021 was 21.6 million t, and reached a growth of 11.2%. In terms of imports, 18 million t of grab cargoes were handled in Hamburg, up 12.2% on 2021. Imports of coal reached 5.5 million t (up 15.9%), and ore imports reached a volume of 10.5 million t (up 10.6%). In addition to the steelworks of Northern and Eastern Germany and Austria, customers include industrial plants and power stations. Exports of grab cargoes showed an increase of 6.2% and reached a volume of 3.6 million t in 2021. At 6.4 million t, the total handling of suction cargoes was stronger than the previous year.

Port of Hamburg, Germany

Among the ports of Northern Europe, Hamburg is a hub for agricultural products such as grain, oilseeds and feedstuffs and is the leader in Europe, with a silo capacity of about 1 million t of suction cargo. Three terminals in Hamburg cater for the handling and storing of wheat and other agricultural products. Totalling 255 000 t, G.T.H. Getreide Terminal Hamburg has the largest agricultural product storage capacities in the Port of Hamburg. Another provider is Silo P. Kruse, with a capacity of approximately 80 000 t. ADM Hamburg operates silo capacities of 180 000 t of feedstuffs, grain and oilseeds. The list of terminals handling large volumes of suction cargoes is completed by K+S Group and HaBeMa feed components.

IN YOUR WORLD There’s no time for down time. That's why we make solids & bulk handling components that are made to perform www.vortexglobal.com Learn more about Vortex Slide Gates, Diverters, Iris Valves & Loading Solutions at: Heavy Duty Slide Gates AeratedConveyingEngineered for handling everything from the finest powders to the most abrasive agregatesDiverterValves SLoadingpouts BE WISE WHEN YOU ADVERTISE Everyone wants to get what they paid for. Dry Bulk is independently verified by ABC, because we want our advertisers to know they’re getting the exposure they’ve been promised. ABC. See it. Believe it. Trust it. www.abc.org.uk 2018_be wise when you advertise house ad_A5 landscape.indd 1 08/04/2019 12:24:18

olent Gateway Ltd (SGL), located in Marchwood, Southampton, is the UK’s fastest growing port. It is already making its mark in the dry bulk sector, with recent vessels including Tertnes and Trimnes. The port is currently being developed to create 64 ha. of port-centric logistics space with connectivity by sea, rail and road for commercial business use.

Tipper trucks moving material to storage site.

As a result, not only can the port accommodate large vessels, it can also offer storage for dry bulk and building materials if needed, with more storage capabilities than any other facility on the south coast. It also has the ability to act as a supply depot by bringing everything in, using SGL as a staging ground before repacking and delivering throughout the UK.

30 . DRY BULK . AUTUMN 2022

SGL is in the final stages of confirming a brand-new contract with an aggregate supplier, which will see the port create a new, dedicated aggregates handling facility and in turn create up to 60 new jobs. The agreement includes provisions for a new asphalt plant and concrete plant, with the capability for up to 400 000 tpy of material initially, with capacity for much more.

The development plans, which were approved in February 2022, see an investment of £50 million, with input from third parties expected to reach £200 million. It will create much-needed additional port capacity capable of accommodating global vessels of up to 205 m in length and a broad range of cargoes, supported by storage and logistic space.

Solent Gateway Ltd, UK

SGL is working with several potential clients interested in leasing large sites on a long-term basis to develop their own manufacturing or processing facilities, which would be supported by vessels using Marchwood Port’s marine facilities and SGL’s highly trained staff for import and export activity. SGL is uniquely placed to support regular shipping and import/export activity on the one hand, whilst offering long-term leases to clients running operations that require waterside locations and port facilities. The team is also liaising with several grain export vessels, which are expect to start arriving in the coming months.

As road haulage issues will continue to affect many of the UK supply chains moving towards Christmas in particular, coastal shipping and rail have vital parts to play in the distribution of dry bulk cargo. One SGL’s key features is its unique rail connection direct to berth, which allows customers to discharge from ship to rail. The port is served by 13 km of rail siding and its own dedicated locomotives, which helps customers to achieve greater efficiencies and boost their environmental credentials by reducing lorry miles and subsequently carbon dioxide emissions. The rail connection is utilised effectively by many of SGL’s existing customers to forward their freight after arrival. This is part of the additional services on offer, alongside extensive warehousing, haulage and customs clearance.

SGL’s offering of a new port and logistics facilities in a single location means it can act as a seamless extension of a business, providing in-depth knowledge and experience to improve supply chain efficiency. The team’s experience with a variety of different cargoes means its proven track record ensures that the process will be simple, secure and stress free.

Figurejetty.2.

The environmental benefits of moving aggregates by sea cannot be underestimated as traffic congestion, carbon emissions and road noise become increasingly important. The use of warm-mix technology and recycled asphalt products (RAP) in asphalt production also minimises carbon output. Finding an environmentally friendly way to transport aggregates is paramount to a greener future in the sector.

From being able to take up to 400 000 t in the next three years, it aims to have the capacity for up to 1 million t in the next six years, an ambitious but achievable goal.

Figure 1. Aerial view of granite chips being discharged onto the

The port is also uniquely positioned as a tax site and customs site as part of the successful Solent Freeport bid, and puts SGL at the forefront of being able to benefit businesses for the long or short term.

AUTUMN 2022 . DRY BULK . 31

he need to control dust emissions in material handling operations is becoming an increasingly key issue due to more stringent environmental and occupational health and safety regulations.

Figure 1. Magaldi Ecobelt® B-type completely enclosed in a steel casing.

Paolo Magaldi, Daniele Ricci, and Lorenzo Lepore, Magaldi, discuss how companies can use conveyor technology to control dust emissions in material handling operations.

Depending on the transported material, dust emissions can be a crucial aspect for the health of workers. For example, respirable crystalline silica dust presents a great

Conventional conveying systems for dusty materials

Figure 2. Dust accumulation in a tunnel with a conventional deep bucket conveyor.

Conventional technologies to convey dusty materials include pneumatic systems, belt conveyors, screw conveyors and scraper chain conveyors in enclosed or semi-enclosed configurations.

The Magaldi Ecobelt B-type design has the same

Exposure and emissions limits depend on the type of dust. However, plant owners are required to implement all counter-measures necessary to keep operators away from dusty working conditions.

can be very severe, especially at the loading/unloading points with consequent health risks for operator during periodic access for maintenance and inspection.

A different type of pan conveyor is the deep bucket one where pans are replaced by buckets. This type of conveyor is used in the cement industry and for those applications where a high inclination is required. The buckets allow to contain the transported material and reduce its spillage. However, dust dispersion is still present along the conveying path (Figure 2).

Conveyor design

The Ecobelt B-type can be designed completely enclosed in a steel casing, thus avoiding dust generation and emissions. This reduces worker’s exposure to airborne dust and, along with noise at minimum levels, contributes to a healthier and more comfortable working environment (Figure 1).

Compared to conventional deep bucket conveyors using chains, the enclosed design of the Ecobelt B-type does not represent an issue since: n Maintenance can be carried out from outside. All idler supports are installed outside the casing, allowing simple inspection at any time and lubrication with the belt in operation. The other elements are designed for continuous operation and can be checked during preventive maintenance, over a multiyear schedule. n Fines accumulation is eliminated since the conveyor can be equipped with a dedicated recovery system able to collect the fine residuals on the bottom and reload them to the buckets.

32 . DRY BULK . AUTUMN 2022

Dust containment

risk to the health of workers because the prolonged exposure to excessive concentrations can cause lung disease silicosis. According to the Occupational Safety and Health Administration, workers must be protected from silica dust exposure above the permissible exposure limit (PEL) of 50 μg/m3 of air, averaged over an 8 hr day.

In case of high temperatures and/or very abrasive materials, the above systems can suffer from wear and/or temperature issues that lead to unpredictable failures and frequent maintenance demand.

To meet the requirement of dust emissions containment, even in the most severe conditions including high temperatures, with abrasive materials, over long distances and with steep inclinations, Magaldi has designed and patented a new conveyor equipped with buckets, so called Ecobelt® B-type. This conveyor combines the reliability of the mesh belt conveyors (i.e. Magaldi Superbelt® technology) with flexibility and versatility.

The Magaldi Ecobelt B-type is a mesh belt conveyor. This type of conveyor is typically made of partially overlapped steel pans bolted on a steel double wire mesh. The driving force is transmitted by friction between the head pulley and the mesh belt, while a pneumatic take-up device on the tail pulley provides a constant tension. The steel belt is supported by carrying idlers across its entire width: it works similarly to rubber belt conveyors.

The most effective way to achieve this task is to employ leading-edge technologies that are able to raise efficiency, reduce dust and spillage, and contribute to meet (or exceed) safety regulations.

A possible alternative can be represented by pan conveyors, for which material is transported over pans connected to chains for motion transmission and rollers/wheels to support chains and pans. Typically, these conveyors are in open execution to allow inspection and maintenance activities to rollers and chain elements. For such conveyors, open execution is required to avoid fines accumulation on the bottom of the casing, that would cause the equipment to stop over time. When these conveyors are installed inside galleries, dust concentration

The Magaldi Ecobelt® B bucket conveyor reduces material spillage to a minimum and protects the environment from dust emissions. Magaldi Power SpA via Irno 219 - 84135 Salerno, ITALY Ph. +39 089 688111 - group@magaldi.comwww.magaldi.comItalsominimizes: • footprint (inclines up to 75°) • noise level <75 dB(A) • energy consumption • O&M costs • spare parts requirement WE REDUCE E VERYTHING TO MINIMUM. E VEN THIS AD.

n The patented method of connecting the buckets to the mesh belt leaves all elements free to thermally expand in any direction, without permanent deformation. As a result, the Magaldi Ecobelt B-type is able to withstand high temperatures. On the contrary, chain conveyors suffer from high temperatures that reduce chains hardness or, in case of temperature gradience along pans and chains, can generate extra-stresses, deformation and cracking.

Case study

The whole revamping project concerned the cooling line downstream the rotary kiln with the replacement of the existing grate cooler by a cyclone cooler.

The client requested a mechanical conveyor able to transport the hot artificial pozzolana from the upstream rotary kiln to the downstream riser gas duct connected to the cyclone cooler (Figure 3).

The main features related to the Ecobelt B-type technology include:

n No dust generation and emissions.

n Conveying capacity up to 700 m³/hr.

It must be pointed out that, in this scheme, the mechanical conveyor receives the hot pozzolana directly from the rotary kiln without any upstream cooling equipment.

Moreover, an enclosed configuration was strictly required to avoid dust dispersion and to control the ambient air flow rate entering the gas riser duct working at negative pressure.

Figure 3. Hot pozzolana conveying system flow sheet.

n Buckets widths ranging 500 – 1600 mm.

In 2021, Magaldi was awarded a contract for the supply of an Ecobelt B-type to convey hot pozzolana (800˚C) from the rotary kiln to the downstream cooling system. The Magaldi Ecobelt B-type was installed in a cement plant as part of the revamping project of the existing artificial pozzolana production line.

n Material temperature can be up to 1100˚C (e.g. clinker, slag, HDRI).

n Reliable transport of hot, fine, dusty and abrasive bulk materials.

n Low power demand.

n Wear is negligible since material is slowly conveyed with no relative motion against steel parts. On the other hand, conventional conveyors based on chain/sprockets for motion transmission, suffer from chain wear: every single element of the chain is subject to continuous abrasion, in the area of contact with the following one especially when they are moving around the sprocket. This type of wear rapidly increases when chains operate in a hot environment eventually with abrasive dust.

n Maximum inclination 75˚.

n Belt speed up to 0.35 m/sec.

n Flexible layout arrangement and expandable design.

n Noise level typically <75 dB(A).

The project requirements can be summarised as: n Hot material (up to 800˚C).

34 . DRY BULK . AUTUMN 2022

n Low and easy maintenance.

working concept. The flat pans are replaced with the buckets keeping the advantages of the mesh belt conveyor technology and maximising the dust containment in theComparedbuckets. to other conventional technologies using chains (pan/deep bucket conveyors), advantages of the Ecobelt B-type include:

n Open or fully enclosed belt design.

n The Magaldi Ecobelt B-type noise is <75 dB(A). Instead, the conveyors using chains show a much higher noise level due to the mechanical engagement among chains and sprockets and the relative motion among rollers and steel parts.

n The mesh design is based on a multi-link concept: even if the double-wire mesh is severely damaged, the mesh is still able to guarantee the suitable traction force and the conveyor can continue to run without sudden failures. Plant operators can schedule belt maintenance, according to operation needs, whereas conventional pan/buckets conveyors have to be immediately stopped if a chain breaks or a support idler fails, thus leading to a forced shutdown of the upstream equipment.

3. MAGALDI, P., MARRAZZO, A., RICCI, D., ‘Hot Sand Transportation, a New Breakthrough Technology’.

n Conveying rate (50 tph).

overcome any issue related to the temperature of the conveyed product.

n High dust content (up to 30% below 90 microns).

Bibliography

To meet these requirements, the client selected the Magaldi Ecobelt B-type conveyor. In order to operate with high material temperature, the conveyor design was customised. This included:

n Air intake valves to control the cooling air flow from ambient. In particular, it was agreed a cooling air of around 5 tph (in a ratio 1:10 with material flow rate). The negative pressure prevailing inside the gas riser duct allows to draw ambient air into the system for conveyor internal cooling.

n Bucket and mesh belt in stainless steel.

The Ecobelt B-type conveying hot pozzolana was commissioned in August 2022. The system has been operating smoothly since then, providing a confirmation of the expected performances in terms of dust containment and temperature resistance.

n Revamping with existing equipment/structures in a tight space.

After completing the thermal analysis on a single belt bucket, a simplified 3D model was prepared in order to investigate the thermal cycle of the entire conveyor. Despite the conveyed product's high temperatures, the belt buckets reach a steady-state temperature ranging 200 – 250˚C (Figure 5).

That is possible since the belt return section is cooled by ambient air entering the conveyor, producing a repetitive loading and unloading cycle of the buckets with a temperature that grows over the time until an equilibrium is reached.Afterpositive

In the case of an enclosed casing configuration, it meets the most stringent environmental regulations in terms of dust emissions.

1. BASETTI, F., RICCI, D., and SAVASTANO, S., ‘Magaldi Superbelt® reliable handling of clinker’, Beneficial effects of dry bottom ash extraction and recycling in modern PCF power plants, (2018).

4. Conveyor Equipment Manufacturers Association, Belt Conveyors for Bulk Materials, 7th edn., (2020).

Conveyor technology, such as the Ecobelt B-type conveyor, can provide an effective solution to handle hot, very fine, dusty and abrasive bulk materials, over steep inclinations and fitting into layouts with narrow spaces. The design allows to

For the design of the Ecobelt B-type conveyor, a cost-effective approach based on 1D and computational fluid dynamics (CFD) models were used to predict and simulate the bucket surface temperature. The steady state heat load of the belt buckets was evaluated through the thermal analysis of their 3D model.

AUTUMN 2022 . DRY BULK . 35

results of the CFD simulations, an experimental test rig was set in order to test the belt temperature resistance. The single bucket was heated over 600˚C by means of a gas burner and belt operation was tested running it in such critical condition (Figure 6). Furthermore, a thorough inspection of the buckets was carried out and no permanent deformations were detected.

Figure 4. Results of thermal analysis of belt bucket.

Figure 5. CFD simulation results.

Figure 6. Schematic model of mesh belt conveyor equipped with buckets.

Based on the belt bucket geometry and a considering a conveyed product at 800˚C, a thermal analysis was carried out to verify the temperature profile inside the buckets (Figure 4).

Conclusions

n Needs of enclosed conveyor to avoid dust spillage to the environment and/or false air entrance.

n Insulation layers to limit the external casing temperature.

2. BASSANO, N., CORAGGIO, G., and MANTELLINO, C., ‘Increased Dependability in Mechanical Conveying of Hot DRI Charge’, Proceedings of the Iron & Steel Technology Conference, (16 – 18 May 2022).

HIGH CAPACITY SOLUTIONS Reclaim bulk materials from your ground pile or shed into trucks quickly and easily. www.bunkersweeper.com Proven and reliable Australian design solutions backed by a supply chain of high quality components from around the Customisedworld.“Self-propelled” Drive Over Hopper & Loader to suit any port application. 750TPH model also available. www.bunkerstacker.com kiliceng.com.au /kilicengineering +61 (8) 8268 5333 enquiries@kiliceng.com.au Bulk Material Reclaim and Customised Port Applications. Dry Bulk Magazine Online Visit our website today: latestwww.drybulkmagazine.comThehomeforthedrybulkindustrynews,analysis,commentandevents DB_Website.indd 1 14/02/2017 10:46

AUTUMN 2022 . DRY BULK . 37

Roemer Braacx, Verstegen Grabs, the Netherlands, explores how grab monitoring systems can improve performance.

ith mechanical rope operated grabs, it is normally impossible to know how many operating hours or cycles are made in a certain time frame. This makes it practically impossible to predict maintenance or monitor productivity. Although this information is very important to determine the level of efficiency of the operation, in the past, it has been very difficult to collect this information from the operation.

In response, Verstegen Grabs, a leading manufacturer of rope operated mechanical grabs for the dry bulk industry, has developed a patented high-tech grab

monitoring system consisting of a measuring device with cloud connection mounted on the upper structure of the Threegrab.years of development and testing resulted in the GrabSense TM , which has recently been introduced to the global market. Customer feedback has been a very important factor in selecting the functionalities of the GrabSense. The system is also equipped with a specially developed battery, which can last for up to four years, even in extreme weather conditions ranging from -20 to +60˚C.

Solving the problem

The GrabSense makes it possible to register the operational performance of mechanical rope operated grabs and present it in a cloud-based platform.

38 . DRY BULK . AUTUMN 2022

The GrabSense brings the Verstegen grab live, and starts to communicate with its users. It offers an extensive and detailed insight into a bulk cargo handling operation. This is important as, in order to optimise a bulk handling operation, detailed information is needed. For example, different grabs are used for handling different types of bulk material. Therefore, measuring performance provides a clear insight into whether equipment is being used in an optimised way, subsequently improving overall productivity.

Figure 3. An example of the online dashboard.

Cloud-based platform

The first series of the GrabSense is in operation in the UK, Belgium, the Netherlands, the US, Denmark and the Middle East. Worldwide trouble-free operation of the system and a stable network connection were absolute prerequisites during the development of the system. Various tests at different locations worldwide and frequent software adjustments have brought the product to where it is now.

Putting it into practice

With the GrabSense, terminal operators can measure exactly what their grab is doing and gather a lot of information about their operation, collecting the information without any effort.

The online dashboard shows the following grab related information:

Figure 1. Measuring performance provides a clear insight into whether equipment is being used in an optimised way, subsequently improving overall productivity

For example, the company equipped three new grabs with the first test series in Belgium, the company’s first test location outside the Netherlands. The company soon discovered that connecting to the network was completely different abroad. The result was a continuous network search that consumed a large portion of the battery capacity in a relatively short time. A software update solved the problem and since then the system has been on-air continuously. The same solution worked for all other countries and regions where tests were running.

Figure 2. Based on the movements of the grab, GrabSense collects data and sends this to the cloud daily.

Based on the movements of the grab, the system collects data and sends this to the cloud daily. This data is presented to the user via a web-based platform in the form of a dashboard for all individual grabs that are equipped with a GrabSense. In this way, it is possible to see the number of working hours and cycles for each individual grab.

The next step in creating the most optimal bulk handling operation is gathering operational information. Making this possible in an easy and continuous way has led Verstegen to develop the GrabSense system.

n Location of the grab (GPS).

Operating hours and cycle times are registered per day, week and month. Building up this history enables terminal operators to make all kinds of different analysis and gives a good insight in the operation. Many more options are possible with the system, and several are currently being developed.

n More options will follow.

GrabSense can be installed at the company’s factory during the production of the grab, but it is also available as a retrofit kit for existing grabs. This makes it possible to equip new grabs, as well as existing grabs with the system to cover the hole bulk handling operation.

n Cycle times.

Conclusion

n Operating hours.

As the system shows the location of the grabs worldwide, it is also interesting for companies with multiple locations and for renting companies that need to know the exact location of every grab in the fleet.

Location of the grab (divulged via GPS) will enable users to monitor the exact position of their grabs. Companies that work with multiple cranes spread over a big port area can see which grab is on which crane, and also where a grab is parked on the premises.

‘Know what you’re doing’ leads to ‘Doing what you know’. As is the case with Verstegen, being in close contact with their customers can help companies improve their equipment again and again.

Information is key in this process of continuous improvement. The success of a product is not only determined by their quality, but it also depends on the way they are used by customers. Creating the highest possible value for customers is only possible by measuring the actual performance of the operation. It is not nice promises or hopeful expectations, but hard facts and figures that are the true teacher and which opens the way to improvement, ultimately giving prove of concept.

Related to the grab specifications, the number of cycles give a good indication of the productivity of the grab and the crane on which it is working. This also makes it possible to determine the average filling and efficiency of the grab for the specific dry bulk material.

n Number of cycles.

n Incidents (the number and intensity of shock loads).

The GrabSense registers the shock loads in all six, 3D directions. When the combination of these shock loads exceed a predetermined value, an incident report will be automatically generated. This report shows the date and time of the impact and the position of the grab in the unloading cycle. The intensity of the impact in all directions is also shown – this makes it possible to create a reconstruction of the accident.

Wi-Fi performance can suffer when faced with too many physical obstructions, overly long operating distances, or crowded frequency bands, all of which can be present in busy ports and shipping facilities. These performance challenges are also in competition with one another. While a Wi-Fi signal can be extended around corners and over greater distances using range extenders and repeaters, an increase in the amount of radio frequency (RF) interference in the same area can also be expected, resulting in a reduction in network performance when supporting a large network of active sensors and devices.

Performance issues are not the only concern for Wi-Fi networks at dry bulk loading and unloading facilities. Threat actors seeking to profit by disrupting operations for ransom or selling data can attempt to gain access to a wireless network with any number of Wi-Fi-compatible devices. Numerous prominent organisations, including the Atlantic Council, have noted that the rapidly growing risk of cyberattacks can come from various attack angles, meaning protecting every access point is important to

Unfortunately, interference with these data communications can lead to delayed signal transmission or lost data packets, which, when considering critical operations, could mean setbacks, equipment damage, injuries, and more. Therefore, reliable and fast data transmission is essential to successful port operations. It also means Wi-Fi may not always be up to the task.

Data transmission challenges in dry bulk

he marine transport sector (MTS) is a critical component of the global economy, accounting for a large portion of worldwide trade. Between the scale of the industry and the immense pressures to meet deadlines, keeping shiploading and unloading equipment running without incident is vital to the global economy.

Ports rely on large networks of intercommunicating sensors and devices to accelerate vessel turnaround times and meet ever-growing demands for efficiency. But, between the increased workload from a growing collection of smart devices and the heightened risk of cyberattacks, the networks supporting rapid processing are at risk. Modern Wi-Fi solutions are the go-to for facilitating local area networking, but a new technology penned by Conductix-Wampfler, PLi-Fi, is aiming to address Wi-Fi’s shortcomings.

Conductix-Wampfler evaluates whether cyber security is a risk in the dry bulk industry.

40 . DRY BULK . AUTUMN 2022

Efficient data communications are integral to modern dry bulk operations, and the means of transmission should be optimised for the environment and the equipment in question. Modern Wi-Fi is commonly used for data transmission between sensors and the various components of the equipment. A fast local area network (LAN) allows technology such as live video feeds, precision equipment controls, proximity sensors, and more to co-operate in real time for optimal performance.

AUTUMN 2022 . DRY BULK . 41

While cybersecurity has many critical aspects, one that is often overlooked is reducing accessibility to the network. Wi-Fi access points are generally considered a necessary component of any modern industrial setting with mobile equipment to accommodate the vast array of sensors and smart devices contributing to operations. This is because alternatives such as Ethernet and fibre-optic systems are also costly to set up and struggle to perform in large, dynamic environments with many moving parts, like ports.

Another advantage of PLi-Fi over Wi-Fi is set-up time and costs. Getting good performance from a Wi-Fi network typically requires expensive, time-consuming RF surveys, which changes in the physical environment can dramatically skew. On the other hand, PLi-Fi can reliably be applied anywhere there is an existing power conductor with minimal preparation and fast installation times. If blocking obstacles and relocating equipment could be a common challenge, the fast setup and lack of interference associated with PLi-Fi make it a compelling option.

preventing damage. Hackers can use creative ways to infiltrate a network and wreak havoc, possibly disrupting the use of software across a wide area or targeting individual devices through their programmable logic computers (PLCs).

42 . DRY BULK . AUTUMN 2022

Power Line-Fidelity (PLi-Fi) is a term used by Conductix-Wampfler to describe their new patented data communications system (NEXUS BB) for local area networks. Like Ethernet over power, NEXUS BB can utilise existing AC or DC power conductors to transmit data signals. With an advanced PLi-Fi modem on either end of the conductor, NEXUS BB can securely and reliably modulate a high frequency (2 – 50 Mhz) data signal onto the existing 50 or 60 Hz power supply. This does not negatively impact the power supply, and unlike other data over power solutions, NEXUS BB is specifically designed to accommodate the data transmission needs of mobile equipment, like gantry cranes and cable reels.

How do they compare?

advantages make a compelling case for PLi-Fi, there are still instances where Wi-Fi is a better option for equipment management or circumstances

PLi-Fi offers many similar capabilities to modern Wi-Fi, with several key distinctions that may make one technology or the other better suited for specific applications.

Whileactors.these

Unlike Wi-Fi, PLi-Fi is not affected by RF crowding, nor does it suffer due to obstacles, like shipping containers being positioned in the signal's path. PLi-Fi can provide a high-performance connection as long as a suitable power conductor is connected between the two PLi-Fi modems. Transmissions carry well over a longer distance than a single Wi-Fi access point, but just like Wi-Fi, performance does drop off after a long enough distance. As mentioned previously, Wi-Fi systems can potentially extend coverage, but this comes at a performance cost.

This generally points IT teams and operators toward installing Wi-Fi systems of access points (APs) and repeaters to extend coverage. The obvious risk here is that anyone can attempt to remotely gain unauthorised access to the network using a Wi-Fi-compatible device. While good cybersecurity practices will make access to a Wi-Fi network harder, there is still the potential that leaked credentials could lead to a security breach.

The final distinct advantage of PLi-Fi is based on cybersecurity. While advanced encryption and good cybersecurity practices can make both Wi-Fi and PLi-Fi very safe options, PLi-Fi can provide an additional layer of security by limiting access. The only way to even attempt to access the network is with an additional proprietary modem installed on the same electrical circuit. Considering the need to physically connect to the shared electrical circuit and the much smaller supply of these modems relative to the availability of Wi-Fi compatible devices, attempting to make an unauthorised connection, especially discretely, becomes very challenging for threat

What is PLi-Fi?

Another similarity between the two methods is that they can be encrypted to protect data during transmission. Industry-standard 128-bit AES encryption is recommended for all industrial control systems, and both Wi-Fi and PLi-Fi implement it. While more advanced encryption is possible with Wi-Fi, the 128-bit standard is generally all that is needed to provide excellent data protection duringHavingtransmission.similarperformance capabilities and encryption

The Stuxnet worm is one of the most widely known examples of PLC hacking. This virus was designed to disrupt operations by discretely sabotaging essential equipment long-term. While this kind of cyberattack is not currently as common in the MTS as other forms of attack, cybersecurity experts agree that the industry is indeed vulnerable to this kind of attack, with an assortment of sensors and devices that can be manipulated to cause impacts while moving cargo or critical load imbalances. Unfortunately, there is also a clear interest by threat actors to target MTS companies. Recent examples are easy to find, including major organisations such as CMA CGM and the International Maritime Organization (IMO), both of which were recently targets of significant attacks.

standards puts Wi-Fi and PLi-Fi on a similar baseline, with neither technology overshadowing the other. Ultimately, choosing which technology to implement should come down to evaluating their differing strengths and weaknesses.

To address these challenges to MTS organisations, PLi-Fi can be used separately or together with Wi-Fi networks to improve cybersecurity, performance, and reliability.

When it comes to performance, both solutions have the potential to offer high bandwidth and low latency connectivity. This high throughput data transmission is essential to most industrial control systems, mainly if they rely on motion control for time-critical precision movement or live video feed to influence operation.

n When looking to further tighten security by reducing access points.

n Where there is already substantial RF crowding negatively impacting the operation of a Wi-Fi network, PLi-Fi systems can reduce system strain.

Conclusion

where both technologies can struggle. While Wi-Fi’s ability to connect to a wide range of devices makes it easier to access for an attack, it also makes it compatible with many remotely distributed, potentially battery-powered devices. Wi-Fi networks can also support a larger quantity of actively communicating devices, though this comes at a performance cost.

For both PLi-Fi and Wi-Fi, increasing the transmission distance or the number of actively communicating devices on the same network reduces the amount of bandwidth available to each device and increases latency. While this may not be critical for every application, devices requiring a large volume of consistent bandwidth (e.g. video cameras) or operations technology that rely on very low latencies (e.g. proximity sensors) will be negatively affected, regardless of the data communications system used.

On the other hand, Wi-Fi is likely the preferred option if, for example, the devices on the network are moved around randomly within the signal range or are not located near a power supply. PLi-Fi is fully compatible with a range of power conductors, but the location of equipment must always be kept near the power conductor, which may not suit certain types of equipment.

Wi-Fi has the additional consideration that many devices transmitting over the same frequency band can reduce performance, potentially causing lost data packets. Because PLi-Fi is not affected by RF interference, utilising a hybrid system of both Wi-Fi and PLi-Fi can boost the efficiency of both technologies.

Who should switch to PLi-Fi?

The decision to implement PLi-Fi at a facility ultimately depends on the specific factors at that location. Some instances where operations teams should consider implementing PLi-Fi systems include:

n Where consistency and dependability are paramount, such as real-time motion control operations or live video feed for safety.

n When locations have barriers or other significant obstacles preventing Wi-Fi from effectively providing network coverage.

Whether organisations are considering full or only partial adoption, PLi-Fi systems are a plug-and-play solution that is extremely easy to set up, even without involvement from an IT team. Their broad compatibility with power conductors means PLi-Fi can easily retrofit many devices that rely on data communications if they use an Ethernet port to transmit data.

44 . DRY BULK . AUTUMN 2022

Bob Domnick, Superior Industries, USA, addresses how dry bulk handlers can utilise a radial telescopic conveyor for many functions at port.

Since then, Superior’s original 150-ft-long (46 m) TeleStacker Conveyor has stockpiled millions of tonnes of aggregate in a method that reduces segregation and allows the owner and operator to get more value for their material.

AUTUMN 2022 . DRY BULK . 45

The conveyor is able to reach multiple holds from the same feed point, which minimises the number of moves required to fully load a ship. This means that when operators are forced to move their equipment, there is no cargo hitting theAdditionally,ship. when material trajectory is controlled, material is also able to positioned into the ship’s hold, which eliminates the need to drop a loader or dozer in to move around material.

Reach new heights

Portability plus Mobility is another key component of the TeleStacker Conveyor’s success. Technology has been designed into both berth contact points to enhance movement.

A new beginning

Superior Industries, an American manufacturer of crushing, screening, washing and conveying systems, unveiled its first TeleStacker® Conveyor in 1997. The customer –Kraemer Mining & Materials, a sand and gravel producer in Minneapolis, Minnesota – was located just three hours from the company’s rural headquarters. This proximity allowed engineers to review performance regularly and gave factory-visiting customers an opportunity to see the value of the new radial telescopic conveyor up close. 25 years and almost 2000 manufactured units later, the first TeleStacker Conveyor continues active operation at this site.

s an alternative to more stationary systems, custom-configured mobile loading/unloading systems deliver advantages such as lower investment, quick assembly, ease of relocation, and efficiency on limited footprints. Most importantly, the goal is minimising load times and the time required to move equipment from one feed point to another.

TeleStacker Conveyors are used in a number of different applications. Today, one of the most popular utilisations is at coastal and inland terminals loading and unloading ships and barges.

The function of telescopic conveying is achieved when a stinger conveyor is mounted inside an outer mainframe conveyor of similar length. The stinger conveyor has the ability to move linearly along the length of the outer conveyor. Combined with variable height and radial travel, the Telestacker Conveyor is able to hit multiple targets without needing to relocate the entire conveyor.

The conveyor’s centrally-located set of wheels –historically known as radial travel tyres – allow the conveyor to move from side to side. Today, these tyres are capable of rotating 360˚ to allow for all kinds of travel positions including crab, carousel, inline and parallel.

Throughout many parts of the world, mobile conveying equipment is becoming the standard for loading and unloading materials in ports and terminals. Within the last decade, many port owners and operators converted from stationary loading structures to portable configurations to take part in the economic advantage afforded by the accelerated solution.

King-sized conveyors

At the tail end of the TeleStacker Conveyor – also known as the feedpoint – there are several technology features that can be utilised to improve mobility. Some of these include wheeled or tracked tuggers and powered or towable dollies. A mobile tail means the portable shiploader quickly moves wherever it is needed, whenever it is wanted.

Marine material handling facilities should view the telescoping radial stacking conveyor as a ‘system’ that can be custom-configured, via a wide range of available options, to meet the requirements of a specific application.

n ● Small footprint creates more dock space for other opportunities.

Figure 1. Combining radial travel with a stinger conveyor allows the TeleStacker Conveyor to hit multiple holds from the same feedpoint.

To date, the company has designed and built the widest (for peak capacity) and longest (for greatest stockpiles) mobile radial telescopic conveyors in the world. Both units are operating at ports along the Atlantic Coast in Florida, the US.

Conclusion

Figure 2. This record-breaking stacker (a 210 ft-long model shown next to a 136) will be used to unload dry bulk ships along the Atlantic Coast in Florida.

Why invest in mobile conveyors?

Superior’s Telestacker Conveyor uses hydraulics to shift these tyres into new positions within seconds. Unlimited angles of the radial tyres allow the shiploader to quickly move from one

n ● Quality of material maintained throughout conveyor handling process.

n ● Faster lead times compared to fixed systems requiring excessive engineering.

From port to port, mobile conveyors are increasing the efficiency of maritime logistics.

Ship sizes often vary, so it is important that a portable shiploading solution has the flexibility to not only be mobile, but also be equipped with the ability to telescope for different lengths and raise and lower to reach varying heights. The customer is being given an advantage if they can load and unload a number of different size ships in the same installation.

● Telescopic technology reaches multiple targets from one feed point.

● Highly mobile conveyors rapidly move in and out of position.

n ● Significantly lower capital investment than highly-engineered, fixed systems.

hold to another during material handling or to relocate the equipment entirely for other activities on the dock.

The widest unit is a 72 in. wide by 190 ft long (1830 mm x 58 m) TeleStacker Conveyor, which is capable of handling material at rates up to 5000 tph. Meanwhile, the longest unit is a 48 in. by 210 ft model (5335 mm x 64 m), which is able to stockpile up to 425 000 t (315 000 yd3) of material on a single footprint. Both conveyors are operating in shipunloading applications, though it is not uncommon for a single TeleStacker Conveyor to perform both shiploading and unloading functions at the same port.

Mutual advantages

As an alternative to the use of labour-intensive cranes and clamshell buckets, cable stackers and other more costly stationary shiploading systems – the company’s offering delivers a lower capital investment, shorter lead times and quick on site assembly.

Traditional permanent structures can take years to install and require multi-million-dollar investments. Portable conveying solutions are known for fast lead times from the factory, installation within days of delivery, and require a significantly smaller investment than bulky stationary equipment. Faster lead times means getting products out to market quicker and expediting cash flow throughout the supply chain.

n ● New machinery install times measure in hours or days, rather than weeks or months.

● Some mobile conveyors, such as the multi-functional TeleStacker® Conveyor, can load, unload and stockpile.

46 . DRY BULK . AUTUMN 2022

n ● Portable conveyors have high resale value and can even increase in value.

SYSTEMSCLEANINGBELTRICHWOODEven in severe environments, Richwood belt cleaners provide a real return on investment through increased belt uptime, decreased clean-up costs, low maintenance and longer component life. What would it mean for your productivity if carryback issues were eliminated? Contact Richwood today for an on-site evaluation (304) 525-5436. www.richwood.com +1(304) 525-5436 | info@richwood.com ©Richwood 2022 Rely on Eliminate Carryback. Richwood Belt Cleaners Provide Immediate Return on Investment. DryBulk Cleaners 22.indd 1 8/24/22 12:51 PM Rope-, Motor-, Hydraulic-GrabsOUREXPERIENCE –YOUR ADVANTAGE The economical.expedientandeﬃciencyleadingreliability,unbeatablegrabsperfectwithinquality,and MRS GREIFER GmbH Talweg 15-17 • 74921 Helmstadt • Germany Tel: +49 7263 912 90 • Fax: +49 7263 912 912 export@mrs-greifer.de • www.mrs-greifer.de

Products, such as urea, potash, ammonia sulfate, monoammonium phosphate (MAP), diammonium phosphate (DAP) and others, are often manufactured

In addition to product expansion, Paul Van den Broeck, Director at Vlaeynatie, says the company is increasingly focused on giving its activities an additional dimension and adding value to stored products, explaining that bagging is its speciality and main activity.

ertilizers are essential to feed the planet's growing population. Every year, millions of tonnes are produced from natural gas and a variety of ores to create products based on the three essential plant nutrients: nitrogen, phosphorus and potassium.

as prills, 3 – 4 mm dia. spheres, which help to reduce dust and improve the physical handling characteristics. Kept dry, the products are generally relatively easy to convey, feed or pack.

48 . DRY BULK . AUTUMN 2022

n What kind of bag will the client need?

n How sensitive are the products to humidity and weather conditions?

n Are they powders or granules?

Classified as acidic, neutral, or basic depending on their pH value, hygroscopic fertilizers attract moisture which produce acids (sulfuric, phosphoric, nitric, or hydrochloric) or alkalis (ammonia, for example), all of which are highly corrosive to steel and other metals.

n What size of bag might be required?

Packaging fertilizer is not for faint hearts. It is a tough business, handling vast quantities of dusty, hygroscopic products at high speeds. Applications are ranked among the most arduous of all for both manufacturers and users of bag filling and palletising systems.

Moreover, packaging is constantly changing – packaging serves as a quantity unit and protection of the product, but is also a residual/waste product. As sustainability becomes more and more important, this needs to be limited as much as Whatpossible.was once a simple jute bag evolved into woven polypropylene (PP) and, increasingly, polyethylene

packaging installation copes with the increased corrosion risk from port side locations, as well as a wide range of products and bags, and perhaps even more importantly, potential future products and bags which need to be taken into account. Questions to consider when choosing fertilizer packaging include:

Fertilizer packaging – a tough business

Getting fertilizers from factory to farm involves a complex distribution system using warehouses and terminals strategically located to ensure the products are readily available where and when they are needed. Manufactured in large energy intensive plants, some fertilizers are traded globally in bulk and often by sea, with substantial port-side facilities for unloading and onwardVlaeynatie,distribution.aEuropean logistics company based in Westdorpe, the Netherlands, is a provider of maritime supply chain services including bulk handling and storage systems for fertilizer on behalf of major global producers. The company also has additional operations in Varna, Bulgaria, and Cádiz and Castellón, Spain.

Moisture in any quantity, unavoidable in the world's temperate zones and particularly prevalent in coastal areas in winter, presents huge challenges to fertilizer operations due to this ever-present risk of corrosion. Without detailed attention to mitigate it, any exposed surfaces are soon little more than Vlaeynatie'srust.fertilizer

It reduces the useful life of equipment, raises maintenance costs and can lead to excessive downtime, and even environmental issues. The control, prevention and ongoing management of corrosion has become an engineering discipline in itself.

A 2013 study put the global cost of corrosion at US$2.5 trillion/yr.

(PE) bags, which bring issues around waste and recycling. Can recyclable packaging or biodegradable plastic be used, and are there specific requirements that the bagging machines need to be adapted to in order to handle?

Choosing a supplier

n The type and size of bags foreseen.

n The capacity needed.

After an initial request for bids was submitted to four possible suppliers, Concetti SpA, an Italian manufacturer based in Perugia, was selected because it provided a total solution (from bagging machine to stretch hood including roller conveyors and communication) with good support from the start, and in the period afterwards. This meant Vlaeynatie only needed to talk to one company in order to solve any bagging problems.

To make the right choice of bagging machine, it is important to have a good knowledge of the products that need to be bagged: What is the density? Granulate/powder? Free flowing? Are they weather sensitive? Disadvantages of humid weather conditions?

Above all, Vlaeynatie did not lose sight of the fact that an automatic bagging and palletising line is not just about the bag filler, it is a ‘chain of machines’ that must work together seamlessly. A chain is only as strong as the weakest link, and output is always limited by the slowest unit.

AUTUMN 2022 . DRY BULK . 49

Much is known about preventing corrosion in building structures and storage facilities for fertilizer, but there is no globally-agreed standard for complex bag filling lines. User and supplier must learn by experience based on the product and the application to jointly develop and implement practical and cost-effective solutions which help to manage corrosion

Corrosion is costly

n Should it use a robot or a layer machine?

Graham Concetti,Rawlings,UK,details how companies can manage the challenges of packing fertilizer.

n Should pallets be wrapped with spiral stretch film or a weatherproof hood?

The company’s main customers are producers of fertilizers who stock their products with it and entrust it with the entire aftercare of their product handling.

Case study

Before selecting a supplier, Vlaeynatie had to consider many factors including:

n The palletiser best suited to the speed and duty

Following the first installation in 2015, Vlaeynatie developed a close relationship with Concetti and further lines followed. Installations now include three automatic bag-filling and palletising systems, a single automatic bag filling machine and two bulk-bag fillers, all handling various fertilizer products. The most recent was supplied in 2020.

First established in 1845, Vlaeynatie has built up an extensive knowledge base of the special requirements of the fertilizer industry, particularly with regard to designing in corrosion resistance, and adopting strict cleaning and maintenance regimes.

50 . DRY BULK . AUTUMN 2022

Control enclosures were supplied with a dry air connection to maintain a slight positive pressure, so as to avoid the entry of airborne dust. All electrical components (sensors, push-buttons, electrical terminal boxes) are suitable for a corrosive environment.

For each new project, Vlaeynatie provided a detailed and demanding specification. This not only embraced

the types of products anticipated, the output needed and the potential bag and pallet sizes, but it also covered the company’s own special corrosion prevention requirements.

Building in corrosion resistance

The Concetti lines operated by Vlaeynatie include the extensive use of stainless steel (AISI 316 and 304 grade) for material contact parts, and a special two-coat polyurethane paint over an epoxy base after careful sand blasting for all carbon steel surfaces. Proprietary components not already corrosion resistant were treated with a polyurethane enamel.

Designing systems to resist corrosion is, however, only part of the solution. Good housekeeping and maintenance is essential. Cleaning, including basic sweeping and brushing down, is a necessary discipline. Plenty of quick-release and electrically interlocked access doors are provided at key transfer points in order to allow inspection and cleaning to take place between products. This removes any residues and prevents product build-up.

In addition, facilities are also provided to thoroughly wash down internal material contact surfaces through the load hopper, feed device and weighing system with a special quick release attachment for the bag holder to entrain and direct the contaminated water to a drainage point. This internal washing with water is undertaken periodically throughout the year in combination with deep cleaning to avoid any possible cross-contamination.

Short production runs require quick changes

FigureVlaeynatie.2.Vlaeynatie warehouse.

Figure 1. Concetti IGF and FFS bagging systems at

Modern, automatic bag filling and palletising lines are complex. Packing to contract often means shorter job runs and more frequent product changes. For complex systems with a number of machines (dosing system, bag placer, closing mechanism, labelling and palletising), this can lead to costly set up errors if adjustments are made manually and left to the operator.

As standard, Concetti use programme-controlled servo mechanisms to make necessary physical adjustments (e.g. for changes in bag length) and eliminate potential operator set up errors. A serial link between control devices ensures that slave systems automatically adopt

With the combination of Concetti lines now installed, Vlaeynatie has the ability to cope with a wide range of both powder and granular products using pre-made laminated woven PP bags and pre-made PE bags, either flat or gusseted. Closing can be done by heat sealing or sewing with or without fold over. In addition, the company can fill PE bags produced from tubular reels on two independent horizontal form-fill-seal lines. Bags of both 25 kg and 50 kg (depending on the client's needs) can be handled at speeds up to 1700 bags per hour. Finished pallets are over wrapped by two stretch hood machines and single or 4-loop bulk-bags of woven PP with inner PE liners can also be filled on two separate lines in the range of 500 –1250 kg at speeds up to 180 big-bags per hour.

Geared motors were supplied with the manufacturer’s anti-corrosive treatments, and palletisers equipped with a pressurised chain lubrication system.

Cleaning and maintenance

Figure 3. Vlaeynatie terminal.

Stainless steel cable trunking and stainless steel nuts and bolts are used throughout, along with stainless steel pneumatic cylinders. Pneumatic components are located inside sealed, air-tight plastic boxes, and plastic fittings are used wherever possible. Any unnecessary aluminium or copper/zinc/brass components were avoided.

Concetti manufacture complete lines from feed hopper to pallet unloading conveyor and offer total solutions designed and manufactured in Concetti's large modern plant in Umbria. Its ISO 9001 Quality Assurance, in-house fabrication and latest state-of-the-art painting facility gives effective control over the exacting surface treatments required by Vlaeynatie.

Traceability is also starting to become more important. Vlaeynatie already provides each bag with a barcode so that in case of a calamity, it can be traced when and where the product was bagged. For some industrial fertilizers, QR codes are already printed on each bag with all relevant information.

Because of the soaring cost of energy, fertilizer prices are currently at levels not seen since the 2008 global food crisis. The work of companies providing a flexible service to major global producers, such as Vlaeynatie, is helping meet the continuing robust demand for fertilizer, ensuring crop yields are maintained and food shortages avoided.

After market support includes teleservice via modems connected to each system to allow Concetti technicians to monitor the plant operation in real time and assist with fault finding.

Teleservice

In some markets, bulk-bags are preferred to 25 or 50 kg bags. Vlaeynatie operates two Concetti high speed bulk-bag filling lines for bags of capacities between 500 – 1250 kg.The most recent line handles single loop bags of 600, 1000 or 1200 kg capacity.

the programme set on the 'master' control panel, allowing an operator to rapidly make the entire line ready for a new product or bag from a single work position – usually in under 90 secs. – and consistently. This includes both pallet layer patterns and stack height.

Big-bag filling

Factory acceptance testing

The lines are also equipped with, or were supplied predisposed for the later fitting of, label applicators or ink-jet coders to apply date/time or batch coding information. Additionally, loaded pallets can also have a label applied.

In addition, factory acceptance testing in Italy involving the clients’ own products, bags and pallets gives an opportunity for the user to check not only that the lines meet the performance figures claimed, but also that access, cleaning and corrosion prevention techniques are all satisfactory. Any last-minute unforeseen issues can then be addressed in a pre-shipment review.

Traceability

BAG PACKAGING SYSTEMS FOR CORROSIVE PRODUCTS / HEAVY DUTY ENVIRONMENTS We make your content content CONCETTI.COM T. +39 075 801561 / sales@concetti.com +200Fertilizer:lines +50Salt:lines +100Chemical:lines

The woven PP bags have an inner PE liner which is automatically heat sealed after filling and the line operates at speeds up to 180 bulk bags per hour.

Conclusion

Alfonso Garrido, SYMAGA Silos, Spain, considers silo storage as an offer-ready solution to enhance grain quality and improve food security.

AUTUMN 2022 . DRY BULK . 53

Figure 1. Ricefer, Heineken, Brazil.

ith conflict affecting some of the world’s larger food producers, rampant inflation, chaos across supply chain, scarcity and food insecurity are back to add to the woes of a fragile global recovery. Projections about tightening supplies and rising food prices fall short at every revision, and the specter of hunger haunts communities and decision makers around the world.

Temperature control

With continued improvements in design and sustained efforts in research and development, SYMAGA has rolled out new solutions to underpin efforts in the fight against these threats. Notably, the introduction of insulation applications to silos have helped to reduce the effects of extreme temperatures and sun radiation. The silo design enables the installation of a second layer of steel, thus providing an air chamber between sheets – this reduces heat conductivity by 10 times. In addition, this allows for insulator fibres to be added around the silo walls and roof, preventing condensation and high temperature shocks.

High moisture and temperature create the perfect conditions for insects, fungi and molds to thrive. Traditionally, these factors were corrected by racking the grains in and out of the silo, at a high energy cost and risk to kernels breakage (which can lead to the emergence of toxins). Today, the use of temperature control and aeration systems has automated these tasks, becoming central elements in storage management.

Another solution now available against these threats is the evolution towards tighter spaces for storage. Identifying areas where air and water leaks may occur and addressing them with gas/waterseal washers and foams is also helping advance long-term, safe grain storage.

In such a scenario, producers and operators need to renew their focus on keeping food quality and bringing food production losses to a minimum. The Food and Agricultural Organization of the United Nations estimates that roughly one-sixth of the food produced worldwide is spoiled before reaching the retail market. For all food groups, cereals and pulses represent 45% of the overall food loss and waste, for which “inadequate storage facilities and poor handling practices were identified as the main causes.”1

Key features behind the metallic silo's success are plentiful. First, its versatility, with designs available for a range of targeted capacities up to 20 000 t; second, the installation costs are way below those of concrete solutions; third, easy assembly and maintenance allows for storage operations to be up and running in a very short period of time. The integration of the silo as a key part in the most demanding, industrially-automated processes has demonstrated its ability to reduce operation expenses.

At a time when every single grain counts as much as a gold nugget, safe and reliable handling and storage is needed more than ever. Aside from bringing greater and safer access to food globally, reducing waste has a direct impact on every food industry’s bottom line, as it maximises output per factor used and reduces costs.

54 . DRY BULK . AUTUMN 2022

Inner strenghts

The round silo has become a major ally in the fight against waste. A standing icon in the landscape for farms, mills, terminals, and more, the metallic silo has earned a reputation for being the best, most-affordable, investor-friendly solution to keep grains safe.

Temperature control systems are normally composed of a set of probes that, hanging inside the silo, receives real-time readings of moisture and temperature across the different levels of stored grains. Usually, these are passive systems, with zero maintenance, and in some cases, the probes are designed to be replaced without emptying the silo. SYMAGA delivers these systems with options to automate the system, weather stations, anti-condensation devices, and portable systems operated by Bluetooth for smaller silos that require manual operation.

The readings from the temperature control system are registered by a software that detects variations. If the contents are getting too hot, it is time to aerate. On the silo base, aeration plate design allows for the ingress of the air inside the silo. The most common is the channel-type, made up of concrete-casted channels covered with galvanised, corrugated and multi-perforated boxes,

Reliable solutions

Figure 3. City Group, Bangladesh.

Perhaps the most important feature that silos can offer when keeping grains in perfect condition are inside of the silo itself. Moisture and internal temperature are the most pressing elements to balance in order to achieve safe, long-term storage. Thanks to technology, stock managers now have a set of tools that help understand the conditions of the grains inside the silo, and to react swiftly in case a threat to quality is detected.

Yet, it is as a result of its different applications that the silo has become a helpful tool in reducing waste and maintaining grain quality. Compared to warehouse and bagging storage, metallic silos have demonstrated their efficacy against weather events, rodents, or birds, the most damaging external factors affecting grain quality.

Figure 2. Bühler, Viking Malt, Finland.

To bring cool air from the outside and module the temperature, fans need to be connected to the silo. When the conditions outside the silo are optimal – low moisture and temperature in the air, for which the weather station of the temperature control gives precise measurements –fans move air inside the silo. When the silo is full, it is estimated to have the required fan capacity to blow air at an hourly rate of 3 – 5 times the volume of the silo. Therefore, the resistance the grain exerts on the flow of air has to be considered. A full system would also have a set of vents and extractors on the roof, to move the moist air outside of the silo and avoid condensation and crusting. All of the company’s fans have IE2 certification, ensuring energy

Grain chillers

covering 25 – 30% of the bottom of the silo. Channels come in different shapes, commonly known as ‘Y’, ‘H’, ‘C’ if silo has a concrete hopper, or ‘T’ if it is a steel hopper. For simpler civil works, SYMAGA also supplies prefabricated gutters. Alternatively, fully-perforated floors, supported on steel structures, cover the entire silo base and allow for a most homogeneous entry of air – which is key for some grains, such as paddy rice.

An alternative to fans, grain chillers improve grain preservation markedly as lower temperatures create a hostile environment for pests and fungi, thereby avoiding fumigation, while at the same time helping to minimise grain weight loss by keeping moisture high. While chillers come with significant investment, they also bring notable advantages in management, as their operation is independent from the weather conditions outside of the silo.

References

At a time where every grain counts, steel silos are the indispensable ally in underpinning grain quality management. SYMAGA has a contributed to this push for safer grain storage, with a combined 50 million m3 of storage in 145 countries in more than 12 000 projects. Each silo represents a step forward in the company’s quest for improved food security, the empowerment of smallholder farmers, enhancing income opportunities and job creation, and for the safeguard of agricultural ecosystems.

Ventilation

efficiency, and capacities range from 2 – 30 hp, depending on the customer’s needs.

One development that allows for aeration and easier handling is the ventilated cone. It is comprised of an elevated cone made of galvanised steel inside the silo. The system avoids contact between the ground and grain, making civil works and operations cheaper, while increasing the area of aeration.

Conclusion

1. 'A major step forward in reducing food loss and waste is critical to achieve the SDGs', Food and Agriculture Organization of the United Nations, (2019), www.fao.org/news/story/en/item/1238015/icode/

WE CONVEY QUALITY Wagon Unloading Systems Robust. Reliable. Fast. Efficient. sales@schade-lagertechnik.com • www.schade-lagertechnik.com

Keepwww.globalminingreview.comUpdated Keep up to date with the latest mining and processingmineralsnews   

Dennis MariettaBlauser,Silos/USA

Silo Service, outlines how the company restored life to an abandoned cement silo.

AUTUMN 2022 . DRY BULK . 57

ince the invention of storage silos, construction materials have gone from wood, to brick or stone, and, finally, concrete or steel, the latter of which are commonly used today in agriculture and industry. Common storage materials include ash, coal, lime, cement, aggregate, and more. After decades of

Figurewall.3.

Figure 1. An image of the silo interior that shows spalling around the roof beam pocket.

n ● Client wanted to restore silo abandoned for 17 years.

Cement silo restoration

58 . DRY BULK . AUTUMN 2022

Pneumatic, or dry-method, systems can be broken down into three categories: whip, conventional pneumatic, and enhanced pneumatic. Whip systems are the slowest silo cleaning method available and are often unable to break through hardened material buildup. Conventional pneumatic systems are the most

Cleaning

n ● Hardened material prevented interior inspection and needed removed through professional cleaning before inspection and restoration could take place.

n ● Original stored material was cement, which was left inside and had hydrated.

Marietta Group, which houses Marietta Silos and USA Silo Service, recently completed a full-service project for a cement storage facility in the Central Texas area. The project consisted of an inspection, cleaning out unusable material, and repairing the silo interior and exterior. Since Marietta Group is a full-service company that can address all aspects of silo service, it was able to expedite the coordination of each phase of the job to reduce downtime and the total project time.

The Central Texas cement storage facility had a 10 000 t cement silo that had been out of service since 2005 and showed a considerable amount of cracking on the exterior silo wall. The company originally contacted Marietta Silos for a silo inspection to determine the cause of the structural problems and evaluate whether the silo could be restored to working order. When the silo was abandoned, stored material was left inside. In order to thoroughly inspect the silo interior, the silo needed to be professionally cleaned.

A series of fully restored concrete storage silos.

Case study

n ● Some by-product material was also put in the silo and abandoned in place.

Figure 2. This image shows significant cracking on the exterior silo

industrial silo use, the benefits of concrete over steel have been clear. Not only is concrete more resistant to abrasive wear, extreme weather, and high pressures, concrete silos are also less expensive to maintain. When it comes to corrosion resistance from both moisture and abrasion from stored bulk materials, concrete silos far outperform steel. While it is true that all construction materials require maintenance and repair, ageing concrete silos are more likely to be successfully restored.

n ● Silo showed signs of obvious structural damage.

Professional silo cleaning companies employ remote, mechanical cleaning methods to remove material buildup from silo interiors safely. These remote cleaning systems allow silo technicians to clean silos more safely by reducing or eliminating the need for confined space entry. Remote, mechanical cleaning systems are typically powered by either liquid as with hydraulic systems or, in the case of pneumatic systems, air. Dry-method (air) mechanical cleaning systems are recommended for silos that store materials susceptible to hydration, as leaks in hydraulic whip systems can cause additional problems. Hydraulic systems are also not very efficient at removing the tough buildup caused by hardened cement and can cause additional cleanup issues at facilities.

commonly available mechanical cleaning method. They are faster and more efficient than whip systems and more cost-effective than hydraulic systems. They rely on compressed air and specialised cleaning heads designed to remove material build-up. Though they are more efficient than whip systems, they are still often limited. In this case, for example, the old, compacted material was so tough that conventional cleaning methods could not even break through the top layer.

In order to tackle this challenging job, USA Silo Service dropped material down from the rooftop in order to access the silo interior and begin the cleaning process. Once the top crust of hydrated cement was broken through, the cleaning technicians created a flow channel that allowed them to remove the remaining material buildup using an enhanced pneumatic system. When compared to conventional pneumatic systems, the enhanced pneumatic system uses 65% more power, making it the most powerful silo cleaning system available in the US and, therefore, the fastest system on the market. USA Silo Service pairs this system with a proprietary clean-out head, The Boss TM , which is designed to quickly and effectively remove a wide variety of material build-up in order to reduce downtime and time on site. Despite the degree of difficulty in this job, USA Silo Service’s cleaning technicians were able to complete the job a full week sooner than estimated using the system.

Once the material was broken up using The Boss cleaning head, it was dumped at the bottom of the silo before being removed by a combination of vacuum trucks and bobcats. In many cases, the removed material can often be

Over years of disuse, a roof leak caused hydration of the stored cement which had been abandoned in the silo. Moisture from leaks or ambient humidity can cause a number of problems no matter what material is stored, including corrosion of metal silo components like roof beams and rebar, material flow issues and blockages, as well as damage to the stored material itself. For stored cement, this material damage is especially problematic. When cement hydrates, it may expand and/or become hardened as it solidifies, resulting in increased and often uneven pressure on silo walls. Silos are specifically designed to ensure equal pressure on interior walls. When blockages, build-up, or other material flow issues disrupt this balance, it causes cracking and delamination and can lead to structural failure. Because the abandoned silo contained both by-product and cement, the hydration led to the creation of huge boulders encased under a hard crust of cement.

A PROVEN SOLUTION FOR TOUGH MATERIAL FLOW PROBLEMS bridging,ratholes,Prevents & sticky buildup Works with the toughest powder and bulk stickyincludingmaterialswetproducts LimestoneIronGypsumearthDiatomaceousCopperCoalBentoniteAluminiumOre Magne�te SodaShalePhosphateAsh Ac�vated carbon Adipic Aluminiumacid chloride Boric Chlorineacid Herbicide Hydrated Lime Iron ZincTitaniumPolyacylamideOxidedioxide DetergentCorkChalkCementAcetate Fer�lizer Fly ash Plas�csPharmaceu�cals WoodWaxResinsPolymerssludgeFlakesChips Animal CocoaBrewer’sFeedsgrain Coﬀee SaltHopsGrainsFlourCorn Soybeans SugarStarchesSpices Suitable for use with the following 01482 601030 sales@ﬂowstar.co.uk

ISO 9001 Via A. Colombo, 144 21055 Gorla Minore (VA) - Italy Phone +39 0331 36.51.35 Fax +39 0331www.sig.it36.52.15 E-mail: sig@sig.it ITALIAN TECHNOLOGY RUBBER CONVEYOR BELTS

To address the delamination, Marietta Silos mobilised the repair crew to provide restoration

refined and recovered. This allows companies to recoup some of the expense of silo cleaning by selling recovered material. In this case, the material was so far out of spec after years of hydration that it was deemed unusable and therefore disposed of. With the material fully cleaned from the silo interior, the next phase of the project, silo inspection, could begin.

Outcome

By project completion, the cement company had utilised the comprehensive services of Marietta Group to conduct a complete restoration project, including professional inspection, cleaning, and restoration. This allowed the customer to return the silo to safe, efficient operation shortly after the job was completed.

As with many silo services, inspections often come in the form of different levels. Basic inspections typically involve a visual inspection of the silo exterior, silo foundation walls, roof cones, and the discharge configuration. Mid-tier silo inspections add the inspection of the silo interior and may include a confined space vessel entry and onsite observations to be reviewed by a silo engineer. The highest-level silo inspection examines the complete exterior and interior and includes an engineering evaluation or inspection by a silo engineer. No matter the silo inspection a client chooses, the result is a report of the findings and necessary remediations. Basic and mid-tier inspections can even include the recommendation for a higher-level inspection if findings suggest possible structuralBecauseconcerns.thissilo had been abandoned for so long and showed clear signs of structural damage, the client had a Level III silo inspection completed by Marietta Silos. During the inspection, a silo structural engineer examined the silo exterior and, following the silo cleaning, performed a complete interior inspection. This level included inspection of all potential areas of silo failure, from roof beams to the bin floor. The silo engineer identified approximately 200 ft 2 of wall that had delamination, or concrete that is separating from itself in layers and needed repair. Though delamination is a leading cause of structural failure, and the silo had been neglected for almost two decades, the inspection findings showed that following restoration, the silo would be structurally sound.

Conclusion

Inspection and restoration

services and return the silo to proper working order. Restoration started by setting up a reusable Jumpform silo framework inside the silo that would be used to pour a concrete silo liner which would correct the delamination and spalling, restore structural integrity, and ensure the silo walls and floor were properly sealed. The Jumpform silo framework takes only a few days for setup and allows for an incremental pour schedule that provides a slow, controlled process. This improves quality control while reducing overhead costs thanks to quick setup, teardown, and the elimination of a continuous schedule. Once the liner was finished, additional restoration included exterior patching on the silo walls where there was exposed rebar, corrosion, and spalling.

Identifying restoration needs for silos, whether they are used frequently or will be returned to service after a period of disuse, can only be achieved through a professional silo inspection, conducted by a qualified company, such as Marietta Silos. Following through with long-term or immediate repairs identified in an inspection is the best way to prolong the safe, useful life of your silo, bin, or cement dome. It is also the best way to ensure the continued safety of your stored material and your workers. Addressing repairs as early as possible is the best way to keep costs low. However, even emergent repairs can be less expensive than remediating a failed silo. Restoring the existing silo this cement company had on their facility saved them millions of dollars in new design and construction costs.

Therefore, their reliability plays a key role for continuous and safe operation. Downtime can lead to very high costs – to avoid or minimise downtime, timely maintenance is of great importance.

The key to gearboxesreliable

AUTUMN 2022 . DRY BULK . 61

Dr Heinz-Peter Ehren, Kumera Getriebe GmbH, Germany, provides insight into the comprehensive service solutions offered for gearboxes.

Monitoring systems

The optimum maintenance strategy for gearboxes is condition-based maintenance. For the most critical machines, online condition monitoring provides maximum reliability and minimises service actions. In many industrial processes, gearboxes are often critical components.

n the dry bulk industry, gearboxes are used as drives for belts, crusher, mills, pumps, etc.

As a result, Kumera Getriebe GmbH has developed a condition monitoring system for gearboxes or drive systems in operations called Guard Gear 4.0©, which offers monitoring up for preventive maintenance and lifecycle management solutions. The functionality of Kumera Guard Gear 4.0 is based on measuring

A typical service job, such as those carried out by the company, usually starts with the gearbox disassembly in a workshop. Optionally, there can be an on-site

The company also offers tailor-made design and fabrication of customised gearboxes and gear components, and, if needed, can utilise the engineering department for service support, especially when it comes to the upgrading of existing designs – the company is familiar with the most advanced calculation methods within the industry as a result of its long-time membership as part of the German Research Association for Power Transmission Engineering.

n Lubrication oil quality.

On request, the company can elaborate technical optimisation proposals – with state-of-the-art methods including tooth modifications as result of finite-element-analyses and torsional vibration analyses, it is able to increase the load density and reliability of gearboxes.

n GuardTemperature.Gear4.0

Service solutions

parameters that indicate incipient failure of mechanical components and lubrication oil.

The owner of a bulk carrier informed Kumera of a tooth breakage on the pinion shaft of the propulsion gearbox.

Figure 2. Load distribution with and without tooth modifications.

Based on the calculation results for different loads, the planet carrier shape could be optimised for maximum load and extended life. The same methods are used for other parts as well, for example housings and torque arms for conveyor drive gearboxes.

inspection beforehand. After dismantling, all parts are cleaned and categorised in the groups ‘re-use’, ‘refurbish’ and ‘replace’. The repair quotation is issued based on the damage report. The spare parts are produced in-house and, if necessary, the gearbox housing can be re-worked in-house as well.

Inspections

can be customised, for example with an optical particle counter or a sensor for magnetic particles. Load and torque information from the process can also be monitored with Guard Gear 4.0. Warning and alarm limits can be set for each individual parameter, while measurement results and corresponding analyses are automatically stored in an external cloud database. This database can be securely accessed via the internet from anywhere in the world and data can be visualised on mobile devices.

n Vibration.

These parameters include:

Regular inspections by Kumera experts prevent gearboxes from damages and unplanned production downtime. A gearbox inspection starts with a visual examination during operation and standstill. All abnormal noises, leakages or vibrations are documented. Afterwards, the geared parts and bearings are inspected and a check of the drivetrain alignment can also be performed. After the inspection, the customer will receive a detailed inspection report with further recommendation by the company’s experts.

Maintenance on site

n Lubrication oil saturation level.

The company provides its customers with comprehensive and competent support on site. This support can contain maintenance work, as well as disassembly and assembly jobs, vibration analysis, shaft alignment and torque measurements. It can also provide local machining of housings with worldwide partners.

Engineering

In order to keep the ship in operation, the fracture surface was ground to remove any cracks. For crack testing, the dye penetrant method was utilised. The red penetrant is sprayed on the examined surface. The penetrant penetrates any crack by capillary forces. Afterwards, the white developer is applied to the surface. The developer then draws the penetrant out of any surface defect, which is visible as a red mark on the

Figure 1. a) Tooth damage on the pinion shaft. b) Dye penetrant testing after emergency repair.

62 . DRY BULK . AUTUMN 2022

Case study: Emergency repair and retrofit of a bulk carrier propulsion gearbox

The gearbox was neither delivered by Keller, nor by Kumera, therefore no drawings were available. Kumera sent service personnel for an inspection and an emergency repair to the ship. Figure 1a shows the damage on one tooth of the pinion shaft.

The production of the spare part kit, consisting of the pinion, the bull gear including its flange shaft and a new set of plain bearing, was set on fast track in order to keep the delivery date for a planned dry dock repair in the Caribbean Sea. Kumera personnel were sent for the exchange of the parts, which included a complete

white developer. Figure 1b shows the ground tooth after negative dye penetrant testing. There were no cracks found afterAftergrinding.theemergency

The diagrams in Figure 2 show the distribution of the Hertzian pressure across the tooth width and along the path of contact. The diagram on the left shows the pressure distribution of the unmodified gear set, whereas the diagram on the right shows the same for the modified gear set. Obviously, the modifications result in a more even load distribution, which in turn leads to a lower overall pressure level. Additionally, tooth ends are significantly relieved. In contradiction to the original gear set, the modified one will gain the specified lifetime.

After the successful repair of the gearbox with re-designed and optimised Kumera spare parts, the hull was closed again and Kumera personnel participated in the sea trial. The ship could be taken back into operation directly after completion.

After the successful emergency repair, Kumera started the preparing the gearbox retrofit. With the knowledge of all interface dimensions and the gear macro-geometry, Kumera designed a new gear set consisting of the pinion and the bull gear. With a focus on optimising the tooth load carrying capacity and uniform load distribution, company experts performed a detailed load analysis of the gear pair. The load distribution was optimised by using special tooth modifications for the spare parts.

Conclusion

With cloud-based condition monitoring software, such as the Guard Gear 4.0 developed by Kumera, customers are provided with the option to monitor their gearboxes worldwide and to receive direct support, including on-site services and retrofit solutions, which are offered by Kumera.

disassembly and re-assembly of the gearbox on board. Due to the limited working space on board, the hull had to be opened for the replacement of the pinion and the output shaft (Figure 3).

repair, the remaining tooth load capacity was calculated at the Kumera facility in Troisdorf, Germany. The results were discussed with the certification body and the ship was approved to sail with a reduced motor power of 90% until final repair. Since no single part drawings were available and the ship had to be taken in operation as fast as possible, the geared parts had to be measured on board. Additionally, the housing was measured for possible deformations. Since hard particles from the tooth fracture can damage the plain bearings of the gearbox, the oil was changed.

Getriebebau NORD GmbH & Co. KG | Fon +49 4532 289-0 | info@nord.com | www.nord.com HOIST SOLUTION ANTRIEBDER Reliable Versatile Global The MAXXDRIVEnew ® XD FromModularRobustasingle source

Figure 3. Removal of the damaged pinion shaft in the dry dock for replacement.

Global Publication Subscribe online www.worldcoal.com/subscribeat: A global industry requires a publicationglobal ® WCL_Global_Publication.indd 1 24/09/2015 15:01 ADVERTISER’S INDEX 29 ABC 11 Bedeschi S.p.A. 15 BEUMER Group 43 Conductix-Wampfler 51 Concetti SpA 36 Dry Bulk Magazine 59 Flowstar 63 Getriebebau NORD GmbH & Co. KG 56 Global Mining Review 09 Hägglunds OBC Imeca 36 Kilic Engineering 27 Kumera Getriebe GmbH IFC & 23 Liebherr-MCCtec Rostock GmbH 33 Magaldi Power SpA 19 Martin Engineering 47 MRS Greifer GmbH IBC N.M. Heilig B.V. 27 Port of Corpus Christi 07 REEL Moeller GmbH 47 Richwood 55 SCHADE Lagertechnik GmbH 60 S.I.G. SPA OFC & 25 Superior Industries 02 Van Aalst Bulk Handling 39 Verstegen Grabs 04 VIGAN 29 Vortex Valves 64 World Coal 52 World Fertilizer

...T O INSTALLATION FROM CONCEP T... For more information visit www.heiligbv.com Direct contact: info@heiligbv.com or +31 (0)72 571 66 88 THIS IS HOW WE ROLL PART OF We challenge ourselves to offer the best possible solutions by designing, developing and delivering state-of-the-art machinery for handling bulk goods.