siwertell news - autumn 2013

CUSTOMER MAGAZINE Autumn | 2013

Bulk capacity doubled at Baltic hub

terminal

Siwertell

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6 16 24 Forecast: Biomass sector offers global opportunities

Australian iron ore port expands with new ship loader

Hands-on training delivers optimum results

2 Siwertell News | Autumn 2013

Contents 4-5 News

6-10 Biomass forecast

12-14 Major Baltic Sea port expands with new terminal

15 Siwertell Maintenance Centre in Taiwan

16-19 Iron ore ship loader for busy Australian port

20-23 Hong Kong Electrics: horizontal & vertical screw conveyors

24 Hands-on training

25 Screw conveyors: continuous improvement

25 Events

27 Contacts

New grain terminal for

Baltic Sea bulk port12

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Siwertell News is one of Cargotec’s customers magazines. Distribution: 1200 copies Publisher: Cargotec Sweden Bulk Handling AB, P.O. Box 566, SE-26725 Bjuv, Sweden. Editors: Malin Pekberg / Emily B. Cueva. Layout: Emily B. Cueva. Proofing: Shipwrite Editorial, UK Printed: Tryckaren Engelholm AB. The opinions expressed by the authors or individuals interviewed do not necessarily represent the views of Cargotec. The content of the magazine (with the exception of photos) may be reproduced provided that the source is mentioned.

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Siwertell

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Siwertell News | Autumn 2013 3

Dear reader,

Welcome to another exciting issue of our magazine. It contains the latest information about how we are defending our worldwide No 1 position in the dry bulk handling market as well as highlighting our new products and improvements to existing ones. You can read about new deliveries such as the advanced loader that we delivered to Australia and the state-of-the-art terminal for Bega in the Baltic. Both are very good examples of what you can achieve with a Siwertell product. Solutions like these, combined with our expertise, make for satisfied clients all over the world.

The issue also includes interesting information about biofuel forecasts. We are very well positioned in this important market with a number of references and an ongoing contract. One of our latest deliveries for the Avedøre multi-fuel power station near Copenhagen in Denmark demonstrates the flexibility of Siwertell technology. At this power station both coal and biomass are handled using the same unloader. The power plant is close to our offices and to Copenhagen International airport, so it will be a great showcasing asset for us.

Then of course there are always markets where you feel you could do better. Today, pneumatic and grab unloaders seem to be the technology of choice for alumina unloading, however, we know for a fact that the Siwertell screw-type unloader will deliver enormous cost savings, from reduced spillage, in comparison to a grab crane and reduced power consumption in comparison to a pneumatic unloading system. We already have a number of references for alumina loading technology and aim to become the first choice also for alumina unloading. Therefore, so that you can see what I’m talking about, for anyone who is interested, we are happy to conduct a full scale test free of charge using one of our mobile unloaders. I’m hoping that you, as a reader, can come up with some potential leads and be part of a lasting industry change that takes alumina unloading up to the level that it deserves.

Have a pleasant read.

Per KarlssonPresident

This is SiwertellSiwertell is a global market-leading brand in dry bulk handling. Customer-driven Siwertell engineering and service solutions for the dry bulk handling industry are used in import and export terminals worldwide. Siwertell dry bulk handling equipment consists of environment-friendly and efficient ship unloaders, road-mobile unloaders, ship loaders and complete bulk terminal solutions. All conveying systems are totally enclosed, reducing dust emission to a minimum and eliminating spillage completely. Virtually any dry bulk material can be handled by Siwertell systems.

Ship unloaders

Cover photoLocationBega grain terminal, Klaipeda, LithuaniaPhotographer Teddy Strandqvist, Studio e

Road-mobile ship unloaders

Ship loaders Bulk terminal solutions



In-service performance secures

new Siwertell road-mobile unloader contract

UK company TAD Enterprises Ltd has recently signed a contract with Cargotec for the delivery of a Siwertell 5 000 S mobile unloader for cement-handling operations in the Black Sea port of Yeysk, south of Rostov, in Russia. Delivery is planned for February 2014 from Cargotec’s production plant in Bjuv, Sweden.

“The new Siwertell unit will offer the company a flexible, low cost cement handling operation,” says Jörgen Ojeda, Sales Director for Siwertell mobile unloaders. “TAD Enterprises currently

A combination of proven Siwertell reliability and low maintenance requirements secured a new mobile unloader contract to a UK customer for flexible and low cost cement handling operation in the Black Sea port of Yeysk

employs a pneumatic mobile unloader, but is not happy with its performance. The company also expressed concerns about the level of maintenance that this type of unloading system demands.

“The new Siwertell unit will offer the company a flexible, low cost cement handling operation”- Jörgen Ojeda

“With more than 400 units put on the market since 1992, Siwertell unloading

News

systems have proven themselves in service. This market-leading reputation for reliability and the support offered by Cargotec were essential elements in securing this new contract,” explains Mr Ojeda.

The diesel-powered, trailer-based Siwertell 5 000 S system will be used to load trucks alongside the berth, for further transport by road. It will be fitted with a double-bellows system for handling cement continuously at a rated capacity of 300t/h. The unit will also have a dust filter system to ensure a low environmental impact.


News

Siwertell wins

‘Best Ship Loading/Unloading System’ industry awardSiwertell has just won the International Bulk Journal’s ‘Best Ship Loading/Unloading System’ award for a second time. The award was announced at this year’s IBJ Awards event on 18th November, in Paris.

“IBJ Awards highlight achievements in the maritime bulk industry, and to win this category, Siwertell has been judged to offer the most efficient, safe and innovative dry bulk cargo flow systems,” says Per Karlsson, President, Cargotec Sweden Bulk Handling. “Siwertell systems have excellent environmental credentials and winning the award for a second time further demonstrates all these excellent qualities.“At the same time, we are always exploring ways to develop new markets,” adds Mr

Karlsson. “For example, the versatility of Siwertell screw type unloaders means they are ideally suited to the rapidly expanding biomass market. This year Dong Energy, one of Northern Europe’s largest energy groups, took delivery of a Siwertell type ST 790-D ship unloader for unloading wood pellets and coal, at a rated capacity of 800t/h, at its highly efficient combined heat and power station at Avedøre in Denmark. Handling coal and biomass with the same unloader delivers major operational and economic benefits, including reduced capital investment.

Image: From left to right, Nigel Herdman, Director, Noble Group (sponsor of this particular award); Emily B. Cueva, Communications Manager, Siwertell; Juha Huovilainen, Sales Director, Siwertell, and Ray Girvan, Publisher, IBJ.

Breakthrough Siwertell order for Black Sea grain terminal Cargotec has secured an important order to deliver three stationary Siwertell SBL 1600 loaders for installation at a grain terminal in the Ukrainian port of Illichevsk. The belt-type loaders, which are designed to handle vessels of up to 100,000 dwt, each have a grain loading capacity of 2,000t/h. It will be possible to use two loaders simultaneously to provide efficient, environmentally friendly grain loading services.

Ola Jeppsson, Siwertell Sales Manager at Cargotec, says this is an important breakthrough into the Ukrainian grain market for Cargotec. “The Black Sea region

in general and Ukraine in particular is a hub for grain export; this will be the first grain terminal in the region using Siwertell equipment.

“Illichevsk Grain Port chose the Siwertell system because the company considered that it represents an excellent technical solution at a reasonable price,” notes Mr Jeppsson. “The region has many new bulk export facilities at the planning stage; the Illichevsk terminal improves our chances of winning further contracts.

“The system will be designed to minimise dust and eliminate spillages,” he explains.

“Cargotec offers a wide range of Siwertell grain handling products; loaders, unloaders and bulk terminal solutions. All of these are tailor-made to address customers’ particular needs and all offer exemplary levels of efficiency and safety with minimal environmental impact.”

The new loaders will be delivered in pre-assembled sections suitable for shipping. Delivery is scheduled for the end of 2014. The final mechanical construction work, electrical installation, testing and commissioning will be carried out on site under the supervision of Siwertell engineers.


Forecast



Booming biomass sector offers global opportunities


As global biomass demand is expected to quadruple in the coming years and the UK has contracted out almost all existing biomass capacity in the US and Canada for the next 15 years, Siwertell Sales Director, Juha Huovilainen, explains the growing role that Siwertell technology has in the expanding biomass market

text JUHA HUOVILAINEN photos OLA JOHANSSON


Biomass demand is expected to increase dramatically from the current level of around 15 million tonnes to 37 million tonnes by 2015 and by 2020 global consumption is predicted to rise to 60 million tonnes with Europe taking the lion’s share at 80 percent. These predictions make certain assumptions including a sustained level of demand from Europe and the belief that South Korea and Japan will convert their existing power stations from co-firing to 100 percent biomass firing. Despite such uncertainties, the trend is for a worldwide rise in demand for bulk biomass, driven by the need to secure new energy sources via a carbon neutral cycle.

Biomass is typically about half the density of coal with two-thirds of its caloric value. Therefore, a much greater volume is required to deliver the same energy output. Questions remain regarding how, and indeed if, this demand can be met, and how much will countries have to pay to secure their supplies.

Industrial biomass pellets are produced from a range of energy crops and other sources; the principle producer is the US, closely followed by Canada. Russia has potential to increase production; the same is true for some South American

countries, but investment has been limited and economic policy does not necessarily support biomass production.

From April 2015 the UK biomass industry, which is worth around Euro 1.2 billion in new investment and supports over 3,000 jobs, must show that the fuel it uses is sustainable or it will lose government financial support

UK corners North American productionTo meet rising energy demands, impending environmental impact targets and strict sustainability regulations due to be implemented in 2015, the UK leads global biomass demand and has contracted almost all existing biomass capacity in the US and Canada, along with its planned capacity growth over the next 10 to 15 years.

In 2012, Drax Power Ltd, operators of the UK’s largest power plant, announced plans to switch to predominantly burning biomass. The 4GW plant has already converted the first of its six boilers to burning pure biomass.

When a second converted boiler starts operations in 2014, Drax will become the biggest biomass power plant in Europe. By 2015 a third boiler should have been converted, at this point the plant will have halved its coal consumption to five million tonnes a year, burning about 7.5 million tonnes of imported biomass instead. In addition to wood pellets from managed forests in the US and Canada, Drax receives biomass from Russia, the Baltic and Africa. It is also considering Latin America, where nutritionally depleted soils in deforested areas offer fuel crop potential.

Switching fuel at this plant, and others like it in the UK, would not be possible without substantial UK government subsidies secured under the Renewables Obligation scheme. However, the rules for securing funding from this scheme are changing. From April 2015 the UK biomass industry, which is worth around €1.2 billion in new investment and supports over 3,000 jobs, must show that the fuel it uses is sustainable or it will lose this financial support.

The new criteria for sustainable forest management include sustainable harvesting rates, biodiversity protection and land use rights for indigenous populations.

Increasing demand for biomass requiresoptimum transport solutions supportedby effective, efficient port infrastructure



The regulations apply to all generators of 1 Megawatt (MW) capacity or more using solid biomass or biogas feedstock; around 98 percent of all biomass power generation in the UK.

There will be no changes to the sustainability criteria before April 2027; this provides the level of certainty that investors and developers need.

Uncertainty in AsiaAsian markets are witnessing a profound shift in biomass trade, with South Korea and Japan setting the pace for China, Thailand, Indonesia and Malaysia. The Korean Renewable Portfolio Standard, implemented last year, states that South Korea’s thirteen power utilities must deliver two percent of their energy from renewables, rising progressively to ten percent by 2022. Japanese feed-in tariffs for biomass have been important enablers of biomass trade in the region. The common understanding is that pellet consumption in China will increase over the next five years, burning both domestically produced and imported pellets.

The realistic biomass production potential for Asia is about 58 million tonnes, of which 41 million tonnes is wood-based. Despite this potential, the Asian biomass market

still faces an uncertain future because of challenges in cultivation, sub-optimal pellet capacities, price volatilities and cross border trade shifts. Korean and Japanese demands for bio-energy depend on competitive sourcing of pellets from global sources. Global and regional Asian pellet suppliers will have to come up with novel supply models to remain competitive.

Freight costs have a crucial impact on the final selling price, naturally favouring nearby producers, which is why the East Coast of the US and Canada has a cost benefit for European markets. The Canadian West Coast and the East Coast of Russia share the same cost benefit with relation to Asian markets.

South Korea and Japan are both interested in switching to biomass-firing power plants, but local pellet production is limited. For Japan, this is mainly because forest in the north of the country is unsuitable for pellet production because of the soil’s high Caesium content following the 2011 Tsunami and the energy accident at Fukushima Power Plant.

Unlike the UK, governments in Asian countries such as Korea and Japan have not taken long-term biomass contracts; they are buying today’s low volume biomass from spot markets, and are aware that supply capacity is extremely limited. Furthermore, today’s spot price is 150-160 US$/tonne, which Asian consumers would like to continue with, but the price for manufactured pellets from the US and Canada is 200-250 US$/tonne. The issue is that the US and Canada have the capacity, but cannot afford to reduce their price and the Asian (and other nearby) producers

Siwertell’s role in the biomass sectorIncreasing demand for biomass requires optimum transport solutions supported by effective, efficient port infrastructure. New pellet import and export terminals equipped with high-capacity loaders and unloaders will be needed to handle the volume of trade anticipated over the coming decades.

Siwertell has a market leading position in the biomass sector, reinforced by the ability of its unloaders to handle biomass and coal without any adjustment; a unique attribute in this market and particularly important during the transitional phase.

Dual-fuel capabilities will soon be used to advantage by Denmark’s leading power company, Dong Energy, when its new Siwertell ship unloader comes on line in autumn 2013. Ordered from Cargotec in 2012, the unloader will be used to supply wood pellets and coal to the company’s combined heat and power station at Avedøre.

Siwertell’s totally enclosed, continuous conveyor system extends from the cargo pick up in the ship’s hold all the way to the receiving facility ashore. The screw technology results in a remarkably low level of cargo damage at the same time as it reduces dust creation to a minimum and completely eliminates ground spillage.

Biomass is derived from a wide range of materials and comes in many different physical shapes and sizes and. Siwertell unloaders handle all types efficiently and safely.

Siwertell systems can discharge the most common varieties of wood pellets at between 800 and 2,000t/h, depending on the density.

Juha Huovilainen, Sales Director for Siwertell proudcts and solutions at Cargotec

Dong Energy, Denmark



Specialist expertise delivers safe operationsBiomass handling and storage involves significant risks, including fire and dust explosions. Siwertell has unrivalled experience of handling hazardous bulk cargoes. Siwertell produces the only mechanical, continuous unloaders used for handling hazardous cargoes such as sulphur on a large scale.

These systems are equipped with its 4S system, designed to both minimise the risk of fire or explosion and to detect, contain and deal with any such incidents, such as hot spots, when they do occur. Siwertell’s biomass systems take advantage of this expertise to deliver safe operations.

could accept the lower spot price, but they do not have the capacity. Pellet price and China’s unwillingness to commit to long-term supply contracts with North American producers might become limiting factors for short to medium-term growth.

Increased demand in Asia and lack of capacity will increase pellet prices in the future. When volumes in Asia become significant, the sourcing decision will be between the high-priced, good quality North American pellets and cheaper, local (South East Asian) pellets with greater risk levels regarding supply security.


This demonstrates how much spillage you get with a Siwertell ship unloader.

www.siwertell.com Siwertell is a Cargotec brand


Klaipeda is Lithuania’s third largest city and its port is one of the busiest cargo handling facilities in the region, playing a significant role in Baltic seaborne trade as it develops to deal with ever increasing cargo volumes.

Bega is a major stevedoring company operating in Klaipeda. Its terminal handles more than five million tonnes of cargo each year and specialises in the handling and storage of liquid and dry bulk cargo, such as agricultural products and fertilisers.

Dry fertilisers account for the greatest volumes; Bega’s main clients are fertiliser producers from Russia, Belarus and Lithuania.

“This new bulk import/export terminal allows Bega to provide the most efficient bulk transfer services available in the Baltic region”- Laimonas Rimkus

Klaipeda, Lithuania

Bulk capacity doubled at Baltic terminal

Bega has increased its cargo handling capacity by two and a half million tonnes per year; its new bulk import/export facility features an integrated Siwertell solution and provides the most efficient bulk transfer services in the Baltic region

Import/export

text JÖRGEN OJEDA photos TEDDY STRANDQVIST


Bega implemented a Siwertell solution when the company needed a new transfer terminal to allow the simultaneous import and export of all types of agribulk commodities and fertilisers. The upgraded terminal – which features a second Siwertell ship loader to supplement the existing unit – allows for the simultaneous handling of incoming and outgoing cargo.

“This new bulk import/export terminal allows Bega to provide the most efficient

bulk transfer services available in the Baltic region,” says Bega’s Technical Director, Laimonas Rimkus. ““The new terminal has increased Bega’s cargo handling capacity by two and a half million tonnes per year and significantly improved its potential for handling agricultural products, which is exactly in line with our expectations and the design brief for our Siwertell terminal solution.”

Previously, it was not possible to store agricultural products at Klaipeda, so grain was exported through other Baltic ports. Now, Bega can handle both the export and transit flow of agricultural produce. The new terminal offers many operational advantages, says Mr Rimkus.

“Another great advantage with this terminal is that we don’t have to limit our agricultural operations to a particular season, which is generally the case for grain export”- Laimonas Rimkus

“Thanks to the terminal’s rail loading and unloading station, we no longer have to store bulk material for export in railway wagons, as we were forced to do in the past. The powerful new Siwertell cargo handling equipment means we can load large vessels directly from rail wagons and from the warehouses.

“Another great advantage with this terminal is that we don’t have to limit our agricultural operations to a particular season, which is generally the case for grain export. Now that we have the capacity to store agricultural products in our warehouses, the terminal will be in active use throughout the year, meeting the fluctuating market demands for grain, soybean meal and other feed derivatives.” He says it is also very important that the terminal’s capacity and technical capabilities allows Bega to deliver

Laimonas Rimkus, Technology Director, Bega

all the expected functions of a hub-port. “We can re-distribute large quantities of bulk material from vessels such as Post-Panamax type bulk carriers, not only by road and rail, but also by smaller vessels covering the Eastern Baltic region.”

“The Bega terminal is a fine example of the way in which Siwertell combines its unrivalled understanding of cargo flow solutions and its market leading hardware to deliver a solution that really meets a client’s needs,” says Jörgen Ojeda, Siwertell acting Contract Manager at Cargotec. “Our customers need to get it right first time; we put in an enormous amount of work before any ground is broken to ensure that we produce a design with the reliability and flexibility to maximise a terminal’s operational capabilities and efficiency.”


Bega’s Siwertell solution

The design of the Bega terminal allows a very high level of flexibility in cargo handling and storage. It can handle the export and import of multiple bulk cargoes carried by sea, road and rail.

The Siwertell design for the new complex comprises two linked warehouses with a total floor area of 20,000m² and a storage capacity of 160,000m³. To segregate the different types of cargo, the warehouses are divided into eight compartments. A covered loading and unloading station for rail wagons and road transport is linked to the warehouses. Cargo for export is delivered to the terminal by bulk rail wagons or trucks and is tipped into four underground receiving hoppers. Weighbridges are installed at all the cargo intakes.

The four hoppers are served by two separate intake lines, so two different types of cargo can be received at the same time. Each conveying line has a capacity of 500t/h, delivering a total intake

capacity of 1,000t/h. From the intake site, material is conveyed to any one of the eight compartments in the two warehouses.

Fully automatic overhead belt conveyors transfer cargo to the individual storage compartments, according to a sequence set by the operator in the control room.

It is also possible to transfer cargo directly from the intake to a ship. This capability is useful for small quantities of special materials that do not need intermediate storage; it can also be used if the warehouses are full. From the warehouse the cargo can be conveyed to the ship loader on the jetty or to the combined loading station for transfer to rail wagons or trucks.

Payloaders operating inside the warehouse feed the material onto two underground conveyor systems with capacities of 1,200t/h and 500t/h. The larger system is used for loading ships; the smaller one is used for loading rail wagons and trucks via overhead buffer bins installed in the loading station.

Belt conveyors transfer material to the ship loader on the jetty. En route, it is weighed by a hopper scale installed in a separate

weighing tower. Ships of up to about 70,000 dwt can be loaded at a rate of 1,200t/h by the rail-mounted ship loader. A system of mobile conveyors serves the ship loader, allowing loading at any position along the length of the vessel. A travelling belt conveyor transfers material from the pier conveyors to the loader.

An additional Siwertell ship loader, capable of handling Panamax vessels at 1,200t/h, has been installed on a new jetty, where vessels can also be unloaded using a mobile harbour crane.

The terminal is also designed to receive many types of bulk cargoes arriving by sea. Bulk material is transferred, via a rail-mounted travelling hopper, to an underground conveying line with a capacity of 1,000t/h. It can be conveyed directly to the two warehouses at full capacity. Alternatively, part of the cargo can be conveyed to one of the warehouses while, at the same time, the remainder is sent to the rail wagon and truck loading station.



as gantry transport screws, along with alignment work. “Taking advantage of the competence and professionalism of the Siwertell Maintenance Centre, we soon took the opportunity to expand our service portfolio in Taiwan to offer our total commitment to all types of maintenance work and repairs,” he notes. “This includes our planned service arrangement, Siwertell Terminal Care (STC) which has different levels of service, designated as Inspection, Enhanced and Total, designed to suit the varying individual requirements of our customers. In addition we can undertake a wide range of refurbishments and conversion projects for our customers in Taiwan.

“Through this dedicated service centre, we are able to deliver very competitive, professional services, which we believe are unrivalled in Taiwan. This gives our customers a proper sense of security and the guarantee that the work we carry out meets our consistently high standards. As part of a global organisation, we also benefit from the availability of Cargotec’s worldwide service network,” says Mr Aronsson.

Cargotec’s recently opened Siwertell Maintenance Centre in Taiwan has been expanding its business offerings so that customers can take full advantage of its expertise and experience.

Cargotec has been building new Siwertell equipment in Taiwan for many years and in 2011 it identified an opportunity to develop local, certified service provision. Siwertell specialist Tony Aronsson was relocated to Taiwan to set up the local Siwertell Maintenance Centre and ensure the quality of its services. In February 2012 a long-term agreement was signed with a trusted local engineering company to carry out work to the high standards required.

Right from its formation last year under Mr Aronsson’s supervision, the Siwertell Maintenance Centre has been delivering on demand, planned and emergency services to its customers. “Over the past year, we have undertaken a variety of projects, often on a turn-key basis,” says Mr Aronsson.

“Major contracts have included work at Goldsun Cement and CHC Taipei Port, and have involved changing vertical conveyors and feeding conveyor as well

Siwertell Maintenance Centre goes fromstrength to strengthtext/photos TONY ARONSSON



Customised solutions deliver winning combination in Australia

Saliba, Strategic Sourcing Manager for Arrium Mining and Materials. “The project was successfully completed on time and on budget, despite a short lead-time, which was critical to meeting Arrium’s business objectives.

“Arrium would not hesitate to recommend Cargotec or the Siwertell product to any company looking to source marine bulk material handling equipment,” Mr Saliba adds.

“Cargotec’s measures to limit dust and spillage were very important in complying with our environmental operating licence and protecting the local community”- Paul Saliba, Arrium

He explains that the company had no in-house expertise with shiploaders, so it began the procurement process by searching the internet and talking to informed contacts before inviting potential suppliers to tender for the contract.

“We chose Cargotec for a number of reasons; the price was competitive and cost effective compared to tenders from other primary players. Cargotec offered a technical solution that met all our performance specification requirements and also committed to completing the project in a reasonably short and tight timeframe,” says Mr Saliba. “Furthermore, Cargotec was

In 2012 the international mining and materials company Arrium committed to a major port expansion project with the primary aim of doubling its iron ore export sales to 12 million tonnes per annum. In addition to the construction of a new rail facility at its Whyalla Port to receive iron ore from its South Australian mining operations,

the project called for a new storage facility and berth equipped with a new high capacity Siwertell shiploader.

“The shiploader has now been in operation since July 2012 and is meeting all of Arrium’s performance specifications,” reports Paul

Expansion

Robust proven technology, good environmental credentials, market leading service and industry recommendation proved a potent mix in the tendering process for Arrium Mining and Materials’ new shiploader

Arrium’s new 4,500t/h capacity Siwertell loader is designed to load directly into bulk vessels of up to 45,000 dwt

text BERTIL ANDERSSON photos BENGT SVENSSON


recommended to us by Flinders Ports, South Australia’s ports authority; Cargotec was in the final stages of commissioning a project in the port of Adelaide at the time.

“It was vital that Cargotec worked closely with the contractor responsible for construction of the new permanent berth, as there were significant ties between the two projects,” he says. “Cargotec’s dealings with our Corporate Sourcing team and the Whyalla Port Expansion team were very professional throughout the process; the local representatives and the Sweden-based team were more than accommodating regarding any of our requests throughout contract negotiations and the project delivery phase.”

Proven performance and service support

Arrium’s new 4,500t/h capacity loader is designed to load directly into bulk vessels of up to 45,000 dwt, the largest that the Whayalla terminal can accommodate. It is also used to load iron ore into two self-unloading transfer barges that take the ore out to a transhipment vessel located in deeper water. From here the iron ore is loaded onto Capesize vessels, primarily for export to China. The floating transfer terminal and the selfunloading transfer barges were supplied by sister company MacGregor, entering into service in 2007.

“The new travelling, telescoping, luffing arm loader suits Arrium’s quay configuration very well,” says Bertil Andersson, Sales Manager for Siwertell at Cargotec. “It is also a standard Siwertell model for the requested capacity. The loader has only one belt conveyor; its shuttling motion combined with the loader’s travelling capability means it can reach all corners of a vessel’s holds so there is no need to move a vessel during loading.”

Mr Saliba says Arrium was influenced by Cargotec’s proven design expertise for

Arrium: a leading mining and materials specialist Arrium is an international mining and materials company with 11,000 employees, listed on the Australian Securities Exchange. Sales revenue for the 2013 financial year was around AUS$ 7 billion.

The company has three key businesses: mining, mining consumables, and steel and iron recycling. Arrium is a significant iron ore producer and the global leader in grinding media for the resources sector.

Arrium Mining is an exporter of hematite iron ore and also supplies iron ore to Arrium’s integrated steelworks at Whyalla, South Australia. Arrium’s mining operations are located in South Australia and include its Middleback Ranges and Southern Iron operations which together produce approximately 12 million tonnes per annum for export to China.


dry bulk material handling equipment, particularly for higher capacities supported by extensive references. “We were impressed by the proven technical and customer support, including the extensive fault diagnostic system. Cargotec’s measures to limit dust and spillage were very important in complying with our environmental operating licence and protecting the local community.”

“The project was successfully completed on time and on budget, despite a short lead-time, which was critical to meeting Arrium’s business objectives”- Paul Saliba, Arrium

Siwertell is respected within the bulk handling community for its determination to deliver environmentally-friendly equipment that minimises dust creation and spillage. The greater part of Arrium’s loader’s boom conveyor is covered to prevent dust problems in windy conditions. The absence of transfer points between different belts on the loader helps to minimise dust creation and spillage and there is a water spray system around the loading chute; all this contributes to a bulk loading system that delivers both on efficiency and environmental considerations.

Bespoke service extends beyond design

“The ability to manufacture and assemble the shiploader offsite for shipment as a fully constructed piece of equipment was yet another important factor in deciding to award the contract to Cargotec,” says Mr Saliba, “as this minimised the risk of over running on the time schedule.”

It was agreed that the loader, with a total weight of 400 tonnes, would be transported as a fully assembled, tested and commissioned unit on board a heavy lift vessel for delivery directly to the new berth

at Whayalla. The main steel structure for the loader was manufactured by Cargotec’s strategic supplier in China, incorporating components and systems supplied by well- known Swedish and European brands.

“Delivery arrangements are a very important element of any contract; determining the optimum solution requires careful calculation and will inevitably contain some variables,” explains Mr Andersson. “Heavy lift freight rates depend very much on the vessels available at the time of delivery, but the plan has to be settled when the proposal is sent to the customer more than a year before the actual work is to be carried out. Calculating labour hours and crane hire costs in a new location can be tricky. Nevertheless, we have a great deal of experience in these matters and we are confident of our ability to arrive at the best possible solutions for our customers.

“Normally, Siwertell delivers its machinery as component parts; often from a number of different sources, for construction and installation on site, but we tailor our manufacturing, delivery, testing and commissioning processes to take account of factors including local economic conditions and time constraints imposed by on site operational schedules.

“In some cases, delivery of a complete machine, tested and ready to commence work, is the best solution; and this is becoming more common. In Arrium’s case, Cargotec had to limit the time spent on site to a minimum and consider the high cost of labour in Australia,” adds Mr Andersson.

To further facilitate rapid onsite installation, Cargotec delivered the tripper car for the new feed belt – which was supplied by Leighton Construction – some months before the loader. “Therefore, this element of the loading equipment was installed and tested before the loader arrived, helping to ensure that the overall project proceeded smoothly and the unloader was in operation ahead of schedule,” notes Mr Andersson.


The Siwertell loader, with a total weight of 400 tonnes, was transported as a fully assembled, tested and commissioned unit on board the heavy lift vessel Happy River



Successful terminal operations

rely on smoothbulk transferSiwertell screw technology delivers compact, clean and efficient terminal conveying systems with lifetimes measured in decades; a notable example includes Hong Kong Electric Group’s Siwertell system, which has been successfully operating for 20 years with no upgrades

Conveying


text CONNY JOHANSON photos EMILY B. CUEVA

Siwertell News | Autumn 2013 21Siwertell News | Autumn 2013 21


To the casual observer of bulk cargo activity in port, the loading and unloading processes may attract the most attention, but there is far more to successful terminal operations. Transporting bulk materials smoothly and efficiently around the terminal is vitally important and demands versatile, reliable, environmentally-friendly conveying equipment that requires little routine maintenance.

Siwertell puts its long experience in screw conveyor technology to good use in this field, offering systems that can cope with the most demanding terminal installations, says Conny Johanson, Sales Manager for the Siwertell brand at Cargotec.

“We offer horizontal, vertical and inclined screw conveyors; with these we can design and install highly efficient, totally enclosed bulk material transfer systems for virtually any terminal, including those with complex conveying requirements.

Tailored solutions for fewer costs“Generally speaking, our vertical screw conveyors involve less capital

investment than systems employing other technologies,” says Mr Johanson. “A single screw conveyor can elevate material up to 40m depending on size and capacity; combining two or more conveyors in series, one feeding into the other, allows material to be raised to whatever height a customer requires. The same principle holds for horizontal and inclined conveyors.

“For very high capacity situations, we can increase the amount of material that can be handled per hour simply by installing several screw conveyors alongside each other, served by the same loading box. A vertical screw conveyor takes up much less space than, for example, a bucket elevator, so we can design effective systems even when space is very limited. The highest capacity Siwertell vertical screw conveyor currently available is the VSC 700 with a capacity of 1,500t/h.

“While some terminals have very straightforward operational requirements, others need complex bulk conveying arrangements to meet the demands of a variety of bulk trades. Our horizontal and

inclined conveyors are reversible and can be supplied with multiple inlets and outlets, providing the potential for very flexible cargo distribution arrangements.”

When a Siwertell screw-type conveying system is used in conjunction with a Siwertell screw-type unloader, the entire system can be totally enclosed, delivering exceptionally clean performance. Furthermore, noise levels are kept very low, so the impact on those working and living close to the terminal is minimal.

Efficiency over a long life spanThese qualities were very important when the Hong Kong Electric Group invested in a flue gas desulphurisation plant for its power station on Lamma Island. The project called for an environmentally friendly, fully enclosed limestone discharge and transfer system with a guaranteed noise level of less than 75dBA, consuming less than 1kWh/tonne from ship to silo.

Cargotec supplied a Siwertell continuous, screw-type ship unloader feeding into a screw conveyor system employing


horizontal, inclined and vertical conveyors. A coverbelt with a belt lifter is used to, in a dust-free manner, continuously load material onto the jetty converyor. The system is designed to handle limestone powder from ships of up to 10,000 dwt at a rate of 400t/h, elevating the material by 32m up to the top of the two silos.

The Lamma Island system has a rail-mounted ST 490-F Siwertell screw-type unloader with a rated unloading capacity of 350t/h. The conveying system employs Siwertell HSC 800, HSC 800S and SEC 601D horizontal, inclined and vertical screw conveyors. The equipment was designed to allow for the installation of an additional unloader if required in the future.

Hong Kong Electric Group says the design, construction, delivery and commissioning was carried out to its satisfaction and the system has been reliable and durable in operation with no serious problems, displaying acceptable wear rates.

Clean operations reply on good serviceCustomer care from Cargotec has been good. It is worth noting that this is not a new installation; it has been in use for over 20 years now, without any upgrades. Hong Kong Electric Group says periodic planned maintenance has been carried out without any problems and it expects to continue operating the system for as long as the desulphurisation plant remains in service.

Siwertell horizontal, vertical and inclined screw conveyors - as shown in blue in the examples below - deliver highly efficient, totally enclosed bulk material transfer systems for virtually any terminal, including those with complex conveying requirements


and improving the efficiency and reliability of the system. The training is also intended to improve the company’s in-house skills at trouble-shooting and repairs. This minimises downtime, repair costs and the need for Siwertell engineers on site,” Mr Jönsson says.

“We can offer all kinds of training, tailored to your particular needs. While proper training has a positive impact on productivity, we can go a stage further by undertaking an on-site unloading efficiency study. With this report in its hands, a company can identify any bottlenecks in the unloading facility. The study provides the opportunity to increase the performance of the unloading process, minimise costs and reduce the turnaround time for vessels. If this sounds interesting, please feel free to contact us.”

“The best part of the training was that we could do the training in the field on our own Siwertell unloader,” says Rahmah Rohani, from Tripoli Cement Company.

In addition to introducing the technical specifications and drawings, the main training elements included explanations of the unit’s main functions, operation, maintenance and trouble-shooting, along with overviews of the diesel engine and the hydraulic and electrical systems. It also involved general guidance for inspections and safety protection systems. “The aim of the training is to enable personnel to operate and maintain the Siwertell machine in a safe, well qualified way, thereby extending the lifetime of the components,

In preparation for taking delivery of its mobile Siwertell 15 000S unloader, Tripoli Cement Company sent key operative and maintenance personnel for training at Cargotec’s Siwertell headquarters in Bjuv, Sweden. The four-day course involved practical sessions on Tripoli’s actual unloader, which will be employed in the company’s cement handling operations in Libya.

“We offered the company the opportunity to come to our site to see its own Siwertell unloader and participate in operator and maintenance training,” says Mats Jönsson, Supervisor. “The training involved theoretical classroom-based sessions and practical training sessions with the unloader.”

Hands-on training delivers optimum results

Service

text/photos MALIN PEKBERG


Siwertell technology continues to push the limits of capacity and service life. With original Siwertell wear parts, you will always have the lowest cost per tonne unloaded – it’s a fact.

Today’s technology for tomorrow’s needs

3-5 February, The Netherlands23-24 January, Mauritius

6-7 March, India 6-7 February, USA

EventsSiwertell representatives will be present at all these events in Q1 of 2014.

Find more events later in the year on www.siwertell.com

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A graph illustrating the service life of one set of Siwertell vertical screws/tubes for coal

Years

11-12 February, UAE


NEWVIDEO OUTSOONMajor bulk terminal in Baltic Sea regionWATCH OUT FOR IT ON www.siwertell.com



For contact details of a Siwertell representative near you, please send an email to either of these addresses:

SALES [email protected] SPARE PARTS & [email protected]

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Siwertell representatives

You’ll get a lot of this when you invest in a reliable and low maintenance Siwertell ship unloader.

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www.siwertell.com Siwertell is a Cargotec brand

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