Dust Control and Loading Systems IncHigh Capacity Dust-Free Barge Loading

at Port Safaga, Egypt

Leaders in Innovative Bulk Loading Systems Design

P.O. Box 125 Tele: 800-748-0563Fax: 231-547-3343

Dust Control and Loading Systems IncCharlevoix, Michigan 49720

www.dclinc.com or info@dclinc.comPUBc-0714-CH04

CASE HISTORY

DUST-FREE LOADING

Port Safaga located on the Red Sea in Egypt is 53 km south of Hurghada. The port is owned and operated by Egypt’s Ministry of Transportation and is an vital export for the country’s economy.

In 2012 the Ministry of Transportation concluded that the current ship loader configuration no longer met the environmental needs that were required. This in large part was due to archaic telescopic loading spout with no dust collection. The result of this configuration led to the entire port being engulfed in a phosphate dust cloud.

DCL was awarded the project in 2013 to supply new load out equipment to Port Safaga. Our experience in ship loading and local representative Tech Trade guaranteed they would be able to provide the Ministry of Transportation the equipment that was needed to meet there goals. Tech Trade acted as the general contractor for the project and acquired an experienced crew to remove the existing loading spout and install the new equipment.

The key requirements for the project were;

• Load pulverized phosphate rock with fines at 1000 MTPH in to open ships.

• Keep new equipment weight at a minimum so that existing mounting structure did not need to be modified.

• Maintain EPA type compliance with little to no visible dust emissions.

• The new load out equipment would need to interface with existing controls system.

To construct the load out, four pieces of equipment were custom designed and engineered for the Port Safaga application – a pivoting gimbal, in line compact filter module and retractable loading spout.

Pivoting GimbalThe single direction pivoting gimbal mounts below the head chute of the belt conveyor and directly above the compact fil-ter module. The purpose of the gimbal is to provide a articu-lating point between the boom and the load out equipment. The gimbal allows the load out equipment to remain vertical when the boom is luffed.

Compact Filter ModuleThe model CFM1618 in line compact filter module which was designed specifically for this project was constructed from alu-minum in order to keep the overall weight of the equipment to a minimum. The compact filter module was sized at 6,000 CFM with a 5.68:1 air/cloth ratio. Installing the compact filter module directly above the loading spout eliminated all duct work and the dust that is collected by the filter module is rein-troduced back into the product flow.

Removal of existing unsatisfactory loading spout.

Pre-installation assembly of compact filter module cartridges.

Retractable Loading SpoutThe OV66HD-45 designation refers to “open vehicle” specific loading with a heavy duty structural steel frame drive assem-bly. There is 45 feet of vertical travel with an outer sleeve diameter of approximately 66”. The OV66HD-45 features a three cable design that runs from three lifting pulleys through a series of transfer sheaves. Safety features of the OV66HD-45 include two over-travel limit switches and three strain switches that are located at the lifting cable ends. If the safe working load is exceeded, then an alarm will alert the operator and power will be cut from the lifting spout hoist circuit. For example, if the discharge of the spout is caught under a barge lid as it is being retracted, the additional weight of the lid would trigger the alarm. The spout is designed to load at 1000 MTPH, the internal components that control the flowing column of material were sized to handle the high volume and the outer flexible sleeve was sized to limit the carrying velocities.

The OV66HD-45 is equipped with a “Deadfall” dust suppressor at the discharge of the spout. The “Deadfall” is a unique DCL design that allows dusty materials to be loaded into open barges and ships. The design involves no mechanical or electrical components eliminating maintenance and points of failure.

Compact filter module being hoisted into position. Loading out equipment installation complete.