siwertell news - january 2012

CUSTOMER BULLET IN January | 2012

Refurbishment of Sin Heng Chan ship unloader.

Siwertell

news

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5 8 10 Ship unloader for Sulphur with safety system

Unloading Biomass without dust and explosion

Taiwan PowerCorporation

2 Siwertell News | January 2012

Cargotec has developed a system, known as the 4S (Siwertell sulphur safety system), which is designed to minimise the risk of explosions and detect fires when handling sulphur. IBJ Awards judges felt that it offered the bulk-handling market the most positive impact on the industry in terms of improving safety in dry bulk handling and as a result, it won the IBJ Safety in Bulk Handling award.

“We are delighted that our 4S system has been recognised in this way,”

says Jan Karlsson, Sales Director, Bulk Handling. “The risk of explosions and fires are amongst the largest hazards when handling sulphur and they also involve the most serious consequences, which is why we developed the system.

“To ensure safe sulphur handling, Cargotec developed the 4S system with two main elements in mind: minimise the risk of fire and explosions and detect these as fast as possible.”

For a third year running Cargotec has won an International Bulk Journal (IBJ) award for the technology that it offers the bulk-handling market; this year its new Siwertell sulphur safety system has taken top prize in IBJ’s safety in bulk handling awards

Cargotec has applied the 4S to all ship unloaders aimed for sulphur unloading, both those for larger ships and road-mobile unloaders for smaller ships. “Siwertell unloaders were not previously able to handle sulphur due to the high explosion risk, but thanks to the development of 4S by Cargotec engineers, the company now receives continuous requests for sulphur handling systems worldwide.”

Siwertell technology wins IBJ’s safety in bulk handling award

Siwertell News | January 2012 3

Dear Colleagues,

Another year has passed by and I am pleased to confirm that, once again, we have had a tremendous twelve months, with very good sales results both for new equipment and also for our Service business.

For new sales we have again sold a number of coal unloaders. The biggest contract we secured will see us deliver two unloaders to Jorf Lasfar Energy Company, in Morocco. They will discharge vessels up to 120,000 dwt and have a rated capacity of up to 2,400t/h. Over the last ten years, we have sold more than 30 coal unloaders, of which, 24 have had a capacity of 2,000t/h or more. This record secures our position as number one in this field; a position which is further strengthened with the introduction of our new type of transport screws and tubes on the vertical conveyor, which has a service life of up to 10,000 hours. With an average capacity of 1,500t/h, this means 15 million tonnes of coal to be unloaded before these components need replacing.

From a market perspective, one can clearly see a tendency for the requirement of higher and higher capacity systems. As a consequence, we have decided upgrade our coal unloaders from 2,400t/h to up to 3,000t/h. We estimate that this high-capacity unloader will be available from mid-2012.

Although the coal-handling market has seen significant growth, this together with iron ore, makes up about 50% of the world market for bulk trade. Another bulk material worth mentioning is sulphur. For this market, only the Siwertell screw-type unloader has demonstrated its ability to solve the three main problems caused by unloading this material. These are: the high explosion risk; extreme corrosion; and stringent regulations for environmental protection. Over the past year, the company has sold a 1,800t/h high-capacity ship unloader to India, fitted with our innovative 4 S (Siwertell Sulphur Safety System) system, which has been specifically introduced for sulphur-handling and is proving itself in operation; the 4S is described in detail on page 5.

A number of new ports, power stations, with newly built, or extended, jetties have, over the past few years, taken full advantage of our unique design for unloaders, which have a total weight – including corner loads and wheel loads – that are much lower than our competitors. This has created benefits for our clients in terms of reduced building costs and, depending on the ship size and unloading capacities, has generated savings between $5 million and $10 million.

Finally, we have continued our strong commitment to the long-term support of our clients through a combination of quality after-sales services throughout the whole service-life of the equipment. This secures its long-term cost-effective operation and also ensures that the Siwertell ship unloader/loader has minimum down-time and a high unloading efficiency year after year.

Per Karlsson

President

About SiwertellCargotec offers well-proven, efficient and environment-friendly ship unloaders, road-mobile unloaders, ship loaders and terminal conveying/reclaiming systems under the brand name Siwertell. 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.


We would like to introduce Mr. Tony Aronsson who recently re-located to Kaohsiung, Taiwan. He will work mainly for the Bulk Handling Services department in Taiwan, in co-operation with our local representative, Wei Yu Enterprise Co. Ltd.

With his long experience of Siwertell ship loaders and unloaders, Mr. Aronsson will strengthen Bulk Handling Services’ presence in Taiwan, and customers will benefit significantly from his expert knowledge.

Mr. Aronsson is already a familiar face for many of our customers as he has worked for the New Sales department since 1996. He will be stationed in Kaohsiung, Taiwan and report to Daniel Frostberg, Operations and Sales Manager of Bulk Handling Services, Bjuv, Sweden.

Although the majority of Tony’s time will be spent in Taiwan, he will also work with customers in the Philippines, Korea and China.

Siwertell Surveyor

Cargotec has held a day-long Siwertell seminar in Busan, Korea. “Face-to-face meetings give so much in return and bring about a much better understanding of each other’s businesses,” says Per Hanson, key account manager, Cargotec Bulk Handling Services.

“The seminar was appreciated both by us and our customers.”

The day started with a presentation about Cargotec Corporation, with a brief overview of its products and organisation, as well as information about Cargotec’s service portfolio and network.

The seminar covered topics such as conversion and refurbishment projects of Siwertell machines; a special case study was highlighted. Also on the agenda were product development and upgrades for control systems and drives, and their advantages over previous versions.

They also discussed conveying system parts such as the transport screw, OD bearings and casings and chutes. Maintenance is an essential

element of operating a Siwertell machine, and the seminar discussed real life issues and solutions, alongside cost guarantees in relation to conveyor wear parts.

Cargotec’s Siwertell Korea service team was represented by sales and service engineer Mr D. S. Choi, based in Busan, key account manager, Per Hansson from Bjuv, Sweden, surveyor Per Andersson from Bangkok, Thailand, and operations and sales manager from Bulk Handling Services in Bjuv, Daniel Frostberg. Cargotec’s newest member of the Korea service team, Tony Aronsson – a senior electrical surveyor, based in Kaosiung, Taiwan – was not present this day.

“We are very pleased to have received positive feedback from participants, “quote: “thanks for the excellent seminar” and “many thanks for sharing useful information about vertical conveyor maintenance; it will help to secure safety and efficiency for future maintenance”.

“We’d like to thank you all for your participation and hope to meet you again in the near future,” Mr. Hansson concludes.

We would like to secure that we have the correct contact information to all our customers. Therefore we will shortly send you a form by email that we hope you make time to fill in. Thanks in advance.

Positive feedback from Siwertell seminar

Contact


Siwertell ship unloader for Sulphur with Safety SystemCargotec has received an order for a Siwertell ship unloader type ST 790-D from the Indian Farmers Fertiliser Cooperative Ltd (IFFCO), Paradeep Unit. The enclosed screw-type unloader will be used to discharge rock phosphate and sulphur at a rated capacity of 1,800 t/h.

“IFFCO wanted a totally enclosed system for both environmental and safety reasons,” said Anders Paulsson, Sales manager, Bulk Handling. “The company specified a screw-type unloader for high efficiency and chose a Siwertell system from Cargotec because we have by far the most knowledge and experience of this technology – the first Siwertell system designated for sulphur was delivered in 1980. Of the four main types of continuous unloaders – screw, pneumatic, chain and bucket chain – only the Siwertell screw-type has been demonstrated to solve the three main problems caused by unloading sulphur: a high explosion risk, extreme corrosion, and stringent regulations for environmental protection.”

starts, so Cargotec has designed a system that reacts immediately upon detection and extinguishes any fire,” Mr Paulsson said. “Fire detectors along the conveying line automatically stop the conveyors and start spraying water from the fire extinguishing system. To manage an explosion, the conveyor’s steel casings are reinforced with extra-thick steel, and explosion-venting valves fitted along the conveyors and dust collectors relieve pressure.”

A specially-designed conveying line with stainless steel components ensures that a Siwertell unit is protected from corrosion and it is also practically maintenance-free.

This is the third reference for Siwertell fertiliser unloaders in India: in 2003 a 400 t/h Siwertell 490-F was delivered to Coromandel Fertilizers for unloading fertilisers and sulphur from 40,000 dwt ships, and this was followed in 2005 by an order from Paradeep Phosphates for a 1,600 t/h Siwertell 640-D handling sulphur, phosphate and fertilisers.

Components for IFFCO’s system will be manufactured in Sweden and China for erection on site in Paradeep Port, Orissa, India. With a delivery time of 12 months, the unloader is expected to be in operation by early 2013.

Cargotec’s Siwertell Sulphur Safety System (‘4S’) was developed to minimise the risk of explosions and detect fires. The 4S is designed to prevent sulphur dust explosions in the conveying line and to evacuate explosion pressure in case a dust explosion does occur, without causing damage to equipment and endangering the safety of operators, personnel and other facilities. To prevent explosions and fires, the Siwertell unit is equipped with nozzles that spray water at the inlet feeder and in the conveyor transfer points. An automatic lubrication system lubricates and cools down end bearings and intermediate bearings.

“Even with preventative technology in place, there are rare occasions on which an explosion occurs or a fire


“After upgrading the unloader in 2010, several improvements were noted in the quality of the machine,” says Mr CH Quek, Factory Manager, Sin Heng Chan, Singapore. “These included elements such as: the discharging operation had improved by 20 percent; cement pick-up from the cargo holds was more efficient; and stability during discharge was improved.” “Maintenance costs were also reduced by 15 percent for products such as grease and hydraulic oils,” notes Mr Quek.

Continuing a long and successful customer relationship, Cargotec Bulk Handling Services has carried out a refurbishment contract with Sin Heng Chan comprising upgrades and modernisation of its ship unloader. The work has been performed with supervision from the Bulk Handling Services and with manpower from Cargotec in Singapore.

The recent refurbishment of Sin Heng Chan’s ship unloader included attention to the screw conveyor system, the hydraulic system, electrical slewing machinery, the radio remote system, and the operator/machine interface and PLC system for the unloader and part of the terminal.

The refurbishment work was divided into three main phases:

• Installation of operator/machine interface system terminal.

• Site installation/dismantling/transport/refurbishment/transport and erection of ship unloader.

• Commissioning and testing

Dismantling the unloader started with electrical disconnections of the slewing part. The vertical and inlet machinery was lifted down. Then the vertical arm, tension rod ar rangement , counterweights,hydraulic cylinders, horizontal arm and turret were removed in a defined order to ensure machine stability and safety. Lubrication and hydraulic connections were plugged. When all the parts had been lifted down and transported to the work site Cargotec was able to begin the refurbishment and upgrade work.

The refurbishment work on the Siwertell ship unloader was followed by commissioning and testing.

Refurbishment in Sin Heng Chan

Services


Upgrades Benefits

1 PLC application program and hardware to the latest version

2 New operating panel in the operator/machine interface system

3 New Siwertell radio remote system

4 Redesigned the existing finger reach extender with a conventional inlet arrangement

5 Replaced worn out parts and also replaced the gearbox on the horizontal conveyor

6 New electrical slewing machinery constructed to latest design

1 To simplify operation while providing more information.

2 A flat, full colour graphic operating panel. This unit communicates directly with the operating system (PLC system).

3 The new transmitter box is equipped with a panel for viewing alarms. The new system will simplify operations while also providing more information about, for example, fault tracing and alarm handling. It can also provide information about the unloading status of a hatch. A tonnage unloaded counter can also be shown.

4 The refurbished vertical element will decrease maintenance costs and deliver increased reliability and availability.

5 A more rigid gearbox and maintenance friendly unit.

6 Reduces the wear and tear on the slewing structure, thanks to reduced applied forces and the new arrangement provides a more precise motion.


The Siwertell ship unloader/loader is multipurpose and designed to handle also the material Biomass, which is a growing market both in Europe and Asia.

The development of the biomass market is driven by the need to secure new energy sources for the future and for the reduction of greenhouse gas emissions. Siwertell is the perfect solution for handling this type of material, as the well-proven screw technology ensures highly efficient, dust-free, reliable operation with low power consumption and less cargo degradation. The vertical conveyor – with its unique inlet feeder – efficiently

feeds both free-flowing and crusted materials onto the conveying system. The Siwertell machine can change from unload to load mode and from biomass to another material without any adjustment. The same Siwertell ship unloader can discharge both large vessels, up to 200,000 dwt, to smaller barges due to the small size of the inlet feeder.

Cargotec has delivered a Siwertell 5000 S ship unloader to unload biomass for Nuon Power Buggenum BV, in the Netherlands. As the full conveying line from ship to silo is enclosed, the terminal is completely dust free, and with its extra sound absorber hoods, the unloader is very quiet.

To prevent explosions, the unloader is equipped with bronze linings and low temperature bearings, while

the mechanical conveying line and silo system are pressurised with a Nitrogen distribution system. However, should an explosion occur, there are explosion pressure-release valves installed along the unloader conveyors in addition to a fire fighting system, including an O2 and CO control device. The Siwertell 5 000 S and the complete plant is CE and ATEX 95 classified.

Siwertell is the perfect solution

Biomass


Cargotec wins a large contract for Siwertell ship unloaders from Morocco

Adelaide Brighton Cement’s new enclosed Siwertell system from Cargotec will ensure minimal environmental impact when loading cement and clinker at its plant in South Australia

Cargotec has won an order to supply Adelaide Brighton Cement with a Siwertell SSL 700 screw-type shiploader. A leading supplier of cement, lime and pre-packaged dry blended products into the South Australian market, and an exporter of cement to Victoria and clinker to Queenland, Adelaide Brighton Cement, specifically requested the Siwertell unit for its environmental credentials.

“Our enclosed Siwertell system ensures minimal environmental impact for the owner,” says Bertil

News around the world

Cargotec has recently won a significant order for two Siwertell ship unloaders to handle coal at Jorf Lasfar, on Morocco’s Atlantic coast. The contract comes from the Jorf Lasfar Energy Company (JLEC) and includes repositioning two existing unloaders as well as installing the two new Siwertell units when they are delivered in 2013.

The unloaders will suit a new jetty belt conveyor system with an increased travelling length at the Jorf Lasfar coal-fired power plant, which is undergoing major expansion. Each Siwertell type ST 940-DOB unit will

have a coal-unloading capacity of 2,400t/h.

“Cargotec’s Siwertell system is technically superior to the other systems offered: it is more efficient and environmental friendly,” says Bertil Andersson, Sales Manager, Bulk Terminals. “Cargotec is the only provider of this kind of system with its performance proven by many references. In addition to technological advantages, Siwertell systems have a unique lightweight design offering weight-savings of more than 50 per cent in comparison with a corresponding bucket and chain type unloader”.

Siwertell shiploader specified to keep cement handling clean in Australia

Andersson, Sales Manager, Bulk Terminals “And it has the advantage of being able to handle both cement and clinker. Also, we are able to minimise the company’s disruption and modernisation costs by integrating our loading arm system into the customer’s existing loader structure, as well as integrating our control and power systems with the existing ones. The old arm system will be removed.”

The new Siwertell unit will be located at Adelaide Brighton Cement Birkenhead Plant in the Port of Adelaide, South Australia. It will have a rated capacity of 900t/h for cement and 600t/h for clinker.


Long-term partnerships driven by superior performanceCargotec Sweden Bulk Handling AB has worked together with the Taiwan Power Company for almost 30 years. In 1982, it invested in two Siwertell coal ship unloaders for its Hsinta Power station; these were the first ever Siwertell screw-type continuous ship unloaders that were delivered for unloading coal. About ten years ago, the power company contracted Cargotec for a turn-key renovation of its original two coal ship unloaders, which were in operation until they were replaced with two new Siwertell ship unloaders in 2009. The new unloaders were ordered in mid-2006 to meet a change in coal intake following the construction of a new jetty for discharging vessels up to 150,000 dwt. The unloaders, with a rated capacity of 2,000t/h, were taken into commercial operation at the end of 2008. In addition to these, in mid-2008, the Taiwan Power Company also bought an additional two Siwertell ship unloaders, for unloading vessels up to 150,000 dwt at a rated capacity of 2,200t/h,

which started operation at Ta-Lin Power Plant in 2010. “These repeat orders are proof that the Siwertell ship unloader is the best performing unloader on the market and that Cargotec delivers on expectations, technology and support,” says Per Karlsson, President, Cargotec Sweden Bulk Handling AB.“Since the first Siwertell units were delivered, Cargotec has continued to develop the technology further to meet today’s increasing demands for higher capacities, larger ship sizes, reliable operations, life-time on wear parts, and improvements in maintenance and operational costs. Cargotec’s mission is to improve the efficiency of cargo flows. To achieve this, it drives technological developments for the benefit of its customers. “Cargotec’s ability to lead these technology improvements and advances in the past, today and for the future, has relied on working closely with its customers to satisfy their needs. When this type of co-operation is in place, it is possible to

Coal handling

improve business for both partners and co-develop new solutions and technology, which is why most customers have chosen Cargotec as a partner,” he notes. To date, Cargotec has sold more than 25 coal unloaders with rated capacities of 2,000t/h and above. In the past 10 years, more Siwertell systems, with rated capacities in excess of 2,000t/h, have entered the coal-handling market than any other brand. Cargotec is the leading supplier of coal unloaders on the Taiwanese market, with 15 Siwertell coal unloaders – 11 of which are rated at 2,000t/h and above – and two cement unloaders delivered so far. Mr Karlsson concludes: “Cargotec’s long-term commitment to the full service life of the Siwertell systems – which can be a 30-year relationship – from the initial sales process to service agreements, support and training, spare parts, supervision services, upgrades, modernisations and refurbishments, gives us a strong position in the market.”


1982

2009

2010

Cargotec is present throughout the world.

Cargotec improves the efficiency of cargo flows by offering solutions for loading

and unloading goods on land and at sea – wherever cargo is on the move. For

handling dry bulk materials, Cargotec provides engineering solutions through its

Siwertell brand. Designed to ensure environmentally-friendly and efficient cargo

operations, Siwertell ship unloaders and loaders are based on unique screw

conveyor technology, in combination with belt conveyors and aeroslides and can

handle virtually any dry bulk cargo.

SIWERTELL IS A CARGOTEC BRAND

Cargotec SwedenBulk Handling AB

P.O. Box 566 GunnarstorpSE-267 25 Bjuv, Sweden

Tel +46 (0) 42 858 00Fax +46 (0) 42 858 99

[email protected]

siwertell news - january 2012

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