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Mobile conveyors - An alternative and cost effective way to handle bulk material in Ports and Inland terminals. By: Philip Waddell. Common Misconceptions of Mobile conveying equipment. 1 - Dust Containment and Extraction not possible on mobile Equipment

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slide1

Mobile conveyors - An alternative and cost effective way to handle bulk material in Ports and Inland terminals.

  • By: Philip Waddell
slide2

Common Misconceptions of

Mobile conveying equipment.

1 - Dust Containment and Extraction

not possible on mobile Equipment

2 - Spillages at transfer points and under belts

slide3

1 + 2 = Dust Containment and Suppression

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

slide4

Common Misconceptions of

Mobile conveying equipment

3 - Limited Mobility Options Available.

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

slide5

3. Complete Site Mobility Options Available

Track Mounted

Wheel Mounted

Rail Mounted

Wheels and Rails

Tracks

Wheels

slide6

4. All Travel Mobile Ship-loader

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

Parallel

Radial

Steering

In-Line

slide7

Common Misconceptions of

Mobile conveying equipment.

5 - Limited Options Available for Discharge chutes and trimming.

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

slide8

5. Telescopic Cascade Chutes

Telescopic Cascade Chute

  • Up to 20 metres Long with Optional Trimmer.
  • Chute blocked load of 10 Tonnes material.
  • Customised to suit the particular material characteristics.
slide9

5. Telescopic Freefall Chutes

Telescopic Free-fall Chute

  • Typically Up to 10 metres Long
  • Customised to suit the particular material characteristics.
  • Optional Dust Extraction Units.
slide10

6. Vessel Sizes

  • River Barges and Coasters

Direct feed by Trucks to wheel mounted unit

Direct feed by Trucks to Track mounted unit

Fed by FELs to Track mounted unit

Fed by FELs to Track and wheel mounted unit

slide11

6. Vessel Sizes

  • Panamax / Baby Cape Vessels

Direct feed by Trucks to Ship loader

Direct feed by Trucks to Ship loader

Fed by FELs to Hopper and Ship loader

Fed by gravity reclaim to Ship loader

slide13

Telescopic and Luffing Abilities

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

Telescopic fully raised and extended c/w 360 degree trimmer chute

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

Telescopic fully lowered and retracted c/w 360 degree trimmer chute

slide14

Radial Trimming Abilities

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

Driven radial wheels for left/right travel

>3 x Hatches from single feed-in point

slide16

CASE STUDY 1 - AFRICA

MOBILE SHIP LOADING

Model - TS 2058 and HF 2020

Peak Capacity - 2000Tph Iron Ore

System Fed by - CAT 988 FELs.

slide17

HATCH TO HATCH IN 2 x MINUTES

  • System: All Travel Mobile Ship loader and
  • Hopper feeder
  • Material:Iron Ore – 2.4 t/m3 – 2000TPH
  • Application: Loading iron ore to Baby Capesize
  • vessels from wheel loaders
slide18

Africa

Up to 43 metre Beam Widths

Up to 25 metre Outreach

Up to 16 metre Freeboard Heights

HATCH TO HATCH IN 2 x MINUTES

slide19

Loading Sequence and Hatch Change

Calculations /Timings.

  • Typically 16 Number of Hatch Changes
  • Typically Hatch Distance of 1810 Metres
  • TS 2058 Parallel Travel speed of 1 km per hour.
  • Single Hatch Change travel period in 2 minutes
slide20

KEY TECHNICAL CONSIDERATIONS.

  • Phase 1 of production Ramp up – up to 6 million tpa.
  • Reliability of System – Required load 1- 2 panamax vessels per week. Previous systems proved unreliable.
  • Productivity – 2000tph system and up to 500,000 T/ month.
  • Designed to cater for testing conditions –
  • Weather Conditions – high moisture and high temps.
  • Ground Conditions – Rainy season with potential for rutting
  • Material – very abrasive, claggy and sticky in rainy season
  • Skill levels of local operatives
  • Robustness to take constant feed from CAT 988
slide21

CASE STUDY 2 – LATVIA

MOBILE SHIP LOADING

Model - TS 542, TL 530 and HF 514

Peak Capacity - 500Tph Fertiliser

System Fed by - Liebherr 458 FELs.

slide22

Latvia

  • System: TS 542 Radial Telescopic ship loader, mobile links and mobile hopper
  • Material:Fertiliser (Dust extraction and covers on entire system)
  • Application:Ship-loading from warehouse
slide23

Latvia

200 metre conveying distance

slide24

KEY TECHNICAL CONSIDERATIONS.

  • Phase 1 of production Ramp up – up to 1 million tpa.
  • Dust Extraction and Containment – Required to comply with EPA standards with close proximity to Riga City.
  • Sealing of transfer points and Spillage prevention – no spillage on jetty and completely sealed transfer points.
  • Productivity – 500tph system and up to 500,000 T/ month.
  • Designed to cater for testing conditions –
  • Weather Conditions – Low sub zero winter temperatures.
  • Material – very corrosive to conveyor structures
slide25

CASE STUDY 3 - INDIA

MOBILE RAIL WAGON LOADING

Model - TU 1015 R

Peak Capacity - 1200Tph Iron Ore

System Fed by - Trucks and FELs.

slide26

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

slide28

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

slide29

KEY TECHNICAL CONSIDERATIONS.

  • Accuracy of weighing critical –
  • Penalties for overloading – 6 x Standard Cost.
  • Maximum Efficiency of weight in Each Wagon (Max 70T/ wagon)
  • Even loading of Rail wagons
  • Reliability of System –
  • Remote location
  • Heavy application (Iron Ore Material Density 2.4–2.8T/m3)
  • Multi Functionality and Mobility Criteria –
  • Stacking at Railway siding when no Rakes
  • Rail Wagon loading when rakes present.
slide30

CASE STUDY 4 - MALAYSIA

MOBILE RECLAIMING AND BLENDING

Model - TU 1015 R

Peak Capacity - 1000Tph Coal

System Fed by - Trucks and FELs.

slide31

Design suitable for typical Stockyard layout

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

slide32

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

TU Radial Unit fed from wheel loaders operating between stockpiles and reclaiming line – 3D, Side and Plan Views

slide33

KEY TECHNICAL CONSIDERATIONS.

  • Accuracy of weighing critical – Blending purposes- pre set weights and manual settings option on control panel
  • Reliability of System – Required to feed furnace during breakdowns/ maintenance of SR.
  • Communications with Central Control room – WIFI and Ethernet Connections
  • Multi Functionality and Mobility Criteria –
  • Blending – Accurate from 100Tph – 1000tph.
  • Emergency Reclaiming – SR Breakdown or Maintenance.
  • Stacking in passive areas of Stockyard.
  • Inter yard Transfer of material.
  • General Stockyard duties.
slide34

Weighing Systems Control Settings on Panel Mimic

Pre set Weights

Blend% Tph

10% 140

20% 280

30% 420

40% 560

50% 700

60% 840

70% 980

Total Reclaim

Rate: 1400Tph

Manual Settings

100 – 1000Tph

slide35

Weighing Systems – Methodology.

  • - Dual Idler Weigh Belt Scales weigh the product on incline belt.
  • Pulse Signal is sent back to PLC every 10 Seconds.
  • Based on this signal the PLC adjusts the speed of the Feeder to maintain the preset weight required for blending/ reclaiming.
  • Used in conjunction with Stacker Reclaimer to send a accurate blended coal to the furnace

Manual Settings

100 – 1000Tph

slide40

WHY USE MOBILE CONVEYOR SYSTEM?

  • Ideal for Rapid Deployment for Phase 1 and 2 of export facilities. Can be redeployed to stockyard for phase 3.
  • Enables quick revenue stream for material being exported in first year of operation.
  • Can be used in rental fleets for short term contracts and moved from site to site. (Contract loading)
  • Limited civils infrastructure required for jetties.
  • Can also be complementary to fixed installations.
  • Innovative and operating cost saving solutions.
  • Limited Planning Requirements.
  • Resale Value of the equipment.
  • Dual Functionality of the Equipment.
  • Improve Carbon Footprint.
  • Improve Health and Safety.