The Hitachi ZW250 wheel loader has proved to be a reliable and highly productive performer at a pulp mill in Norway. After three years of operation at So¨dra Cell Folla, the machine has 15,500 working hours and 86,000km on the clock. It has helped the company, based in Verran, to reduce fuel consumption by up to 25 per cent.
Fitted with a 15 cubic metre bucket, the wheel loader transports wood pellets and sawdust around the mill in three shifts per day, seven days a week, and can travel up to 180km in 24 hours. The mill produces chemi-thermomechanical pulp for manufacturing milk cartons, tissue and printing paper. It is
distributed to customers around the world, including Europe and the Far East.
So¨dra Cell Folla took delivery of the ZW250, its first Hitachi machine, after testing four leading brands. It was supplied by NASTA, the official Hitachi dealer in Norway, in February 2009 and is supported by the dealer’s service contract.
Kjell Sørensen, who is responsible for wheel loader sales at NASTA, says: “The most important benefit of the ZW250 wheel loader for this customer is the 20–25% reduction in fuel consumption, compared to its previous model. Another
significant benefit is the optional limited slip differential, which delivers effective driving force to both wheels for greater traction on snow-covered roads.”
Tore Andreas Norum, a supervisor and operator at So¨dra Cell Folla, adds: “We use studded tyres and chains during winter — we can’t sprinkle sand on the ground because it might contaminate the production process. The limited slip differential is important because it enhances traction and ensures the wheel loader keeps working in difficult conditions. The ZW250’s tyres are also extremely durable.
“We are delighted with the performance of the ZW250 — it’s a powerful, fast machine and it never stops. After three years, it seems as good as new, which is a good indicator of its excellent build quality.”
North Killingholme Storage (NKS) provides one-stop storage and logistical solutions, including Customs-approved warehousing for bulk products. Based in the UK in North Lincolnshire, near Immingham docks, NKS receives a wide variety of products from across the world, which are stored and then screened to the customer’s requirements before being sent out again.
The total capacity of the NKS site is over 250,000ft and around a million tonnes of different product is turned around each year. To help speed up this operation, NKS has invested in two Loadmaster 9000i onboard weighing systems from RDS North Eastern Ltd for use on its two Volvo L120F wheeled loaders.
RDS Technology manufactures a wide range of weighing systems suitable for all types of loader in the material handling industry including for use on wheeled loaders used in open cast mining. The Loadmaster 9000i is trade-approved for the commercial sale of goods to MID Class Y(b) and OIML Class R51 & R76 standards and at NKS is currently used in conjunction with a weighbridge, to ensure accurate loading, reducing the time trucks spend on site, increasing accountability and to speed up the complete operation.
Through use of the telemetry link option in the Loadmaster, NKS is looking to phase out the weighbridge and simply send load data direct from the loader to the office where a printed ticket will be automatically produced, further improving operational productivity.
NKS has used RDS weighing systems for over 20 years as Shaun Dannatt,Warehouse Manager at NKS explains,“We have received nothing but excellent service and product support from RDS North Eastern, who have always responded quickly and effectively to any question or support issue. The loader operators get on well with the RDS system and in such an operation as we have here it certainly helps our aim of achieving a quick vehicle turn around.”
Mobile Sennebogen equipment widely used in today’s ports
Since it was founded in 1952, the family company Sennebogen has been developing and producing cranes, telescopic cranes, special machinery, materials loaders and hydraulic earth moving machinery, including mobile equipment for use in harbours.
Numerous technical innovations and continuous product improvements have ensured that the company has a solid reputation in many of today’s market sectors in the construction industry and industrial material loading.
The name of Sennebogen stands for reliable, finely engineered equipment. Sennebogen produces machinery to the highest quality level at its Straubing and Wackersdorf sites in Germany. Products are distributed worldwide through an extensive dealer network. The broad product range encompasses complete series of rope excavators, cranes, telescopic cranes, mobile telescopic cranes, material loaders and special carrying machinery. The development and design of all this machinery is focused on the needs of the customer. Sennebogen supplies flexible standard models as well as individual customized and specialist machinery, which it develops in conjunction with its customers.
Sennebogen supports its customers with a comprehensive service package to ensure that the machinery is used optimally and efficiently.
ON THE ROAD WITH THE SENNEBOGEN 835 E-SERIESA machine only really shows what it can do when used in practice. Long development and testing processes culminate in the start of series production and the machine has to prove its worth to the customer. Hardly any other working environment
is more demanding than the high requirements in port material handling. A new Sennebogen 835 E was one of the first machines to begin operation at Elzinga in Holland in the middle of 2012.
With 12 Sennebogen machines currently in operation, the Elzinga Group is not only one of the biggest customers in Holland, but has also been a partner for several new innovations at Sennebogen. The very first port materials handling machine delivered to Holland, a 835 B-series with crawler chassis, was supplied to Elzinga and it still running reliably today with over 16,000 operating hours on the clock. The new Sennebogen
835 E, which has been proving its worth at Elzinga since April 2012, has worked significantly fewer operating hours. Drivers and managers at Elzinga were some of the first customers to drive the machine. Elzinga handles around three million tonnes of scrap and piece goods each year at Eemshaven, north-east Holland. Mainly sand and gravel, as well as round timber, grain and waste are unloaded from and loaded onto the incoming ships each day.
‘Time is money’ has never been truer than at the port. In Eemshaven, the hull of the ship lies up to 6 metres below the quay wall at low tide — a major challenge for any machine driver. High loads and long ranges are required, combined with quick handling speeds. The potential afforded by the new machine is highlighted once again when unloading goods on trucks. The drivers describe their first impressions of the machine as ‘impressively fast’ and ‘extremely quiet’. “With the new Sennebogen 835 E, we can achieve three cycles per minute in ship materials handling. This makes the machine significantly faster than its predecessor,” highlights manager Eke Elzinga. According to Elzinga, between two and 2.5 cycles were previously possible depending on the situation — a direct increase in performance of at least 20%. In Eemshaven, there is now a direct comparison — the predecessor model and the new 835 E. It is the simple things that make a difference and are noticeable immediately without elaborate measuring equipment. Driver Andries Vriezema confirms: “You notice the change in noise immediately. The machine is much quieter both inside and outside.” The running costs are important to every operator, and Elzinga is extremely satisfied in this respect too. It reports lower consumption with increased performance. The Green Efficiency Technology also guarantees increased efficiency and efficient technology. After many years of experience, the company is completely convinced of the reliability and high quality of the Sennebogen machines. A further benefit while on the move: the Sennebogen 835 and be transported easily on a low-loader thanks to its compact dimensions. So it doesn’t take long for the new machines to reach customers all over the world. Elzinga is just one of many interested companies.
A SENNEBOGEN 860 M DOES ITS JOB AT TLCA new Sennebogen 860M recently began unloading incoming ships at the port in Tiel, Holland. Located on the Amsterdam–Rhine canal,Tielse Loswal Combinat, a subsidiary of Gebru¨der Hartemann Holding B.V. and K3 Industriezand B.V. carries out bulk goods handling at the site.
As the ships increase in size, ever more powerful and high- performance machines are needed. That was why a material handling machine from Sennebogen was chosen for the Tiel site. Sand and gravel in particular are handled there. The 860M is equipped with a 364hp Cummins diesel engine, a triple-circuit fan system and is particularly easy to service thanks to the centrally accessible measuring and lubrication points. Particularly important for port operations, the 860 is also equipped with a 2.7-metre hydraulic elevating maXcab comfort cab. This cab offers optimal overview when unloading the ships, combined with cameras for improved all-round visibility and a rail all around the upper carriage guaranteeing the highest possible safety. The responsible Sennebogen sales partner Kuiken N.V recently supplied the machine and acts as a competent contact partner on-site.
Caterpillar partners with Demlone to create high-lift log handler
Caterpillar and Demlone have partnered to create a high-lift log handler based on the Cat® 980 wheel loader and a log grapple and front designed and built by Demlone. The new log handler complements the extensive line of Cat Forestry machines and enables Cat dealers to offer a total solution for material handling needs around the wood yard and in port situations. The Demlone DLH100k Log Handler will be commercially available this month (September) this year.
Demlone has extensive design experience in engineering steel fabrications and hydraulic systems. As a result, Demlone, a wholly owned subsidiary of the Vensys Group, has partnered with Caterpillar since 2010 in the design and development of ultra high demolition machines based on Cat excavators. For the new log handler, Caterpillar will produce the carrier, based on the proven 980 wheel loader platform, and Demlone will provide the lift structures, work tool and lift controls for this purpose-built machine.
Both Caterpillar and Demlone warranties cover the DLH100k Log Handler. The carrier is covered by a Caterpillar warranty with the same terms as a standard Cat machine. The front parts of the machine are covered by a Demlone warranty offering similar terms. The Demlone DLH100k is fully supported by Cat dealers.
When innovation meets performance
The development of Liebherr mobile harbour cranes not only follows industry related matters like increased turnover, but also reflects prevailing political guidelines concerning health and environment. Around the globe, an increasing number of ports are focusing on environmental issues. One of the major environmental concerns is noise pollution. Noise is one of the most common occupational health hazards in heavy industrial and manufacturing environments, as well as in ports. To prevent adverse outcomes of noise exposure, noise levels should be reduced to acceptable levels. The best method of noise reduction is to use engineering modifications to the noise source itself. In 2011, the LHM Noise-Control Initiative was implemented and is a major step in this direction.
To seek the greatest environmental benefit with its product range the design process is co-determined by fundamental thoughts on how to achieve a notable noise reduction.
For the first time the concept of elastic suspension of components was realized in port cranes with two times up to 104-tonne heavy duty winches, withstanding the daily tasks of dedicated bulk handling.
In order to minimize structure- borne noise level, the number of bulkhead plates in the LHM 550 is kept to a minimum. Isolated pipes and hoses ensure further noise reduction.
In fact, all these measures more than halve the noise level of new generation Liebherr mobile harbour cranes, in other words two LHM 550 make less noise than a single crane of their predecessor model. Even further noise reduction is possible if the cranes are equipped with an optional ‘Attenuation Package’. This option includes the additional isolation of the slewing platform, which results in further reduction of noise pollution by approximately 50%. In close proximity to the customer, Liebherr will continue to explore new ways to enhance
its noise abatement programmes for the entire mobile harbour crane range.
In the first six months of the year, twenty-two LHM 550 were delivered worldwide, quickly catching up with 28 deliveries achieved throughout 2011. In addition to such remarkable delivery figures, well-filled order books emphasize high demand and market acceptance of this innovative multipurpose crane.
Regarding geographical distribution Africa takes the pole position, accounting for eleven LHM 550. This underlines the on-going economic development in several African countries, which stimulates demand for highly competitive and top quality products. 2012 supplies also include Liebherr’s one hundredth mobile harbour crane delivery to Africa. The crane is now part of APM Terminals Apapa’s fleet which already comprises nine heavy-duty LHMs.
Five LHM 550 were destined for the European market, including a crane for Nova & Hesse-Noord Natie Stevedoring (NHS). NHS is a Belgian stevedoring company specialized in conventional cargo handling which also operates the predecessor model LHM 500. The new crane provides an additional economical solution for handling coils, slabs and all kind of steel.
Three cranes were delivered to customers in Latin America. Amongst others,Terminal Za´rate in Argentina opted for one LHM 550 for container handling supporting and backing up the existing STS gantry cranes. Two LHM 550 boost cargo handling in India and one crane was supplied to North America.
The majority of the LHM 550s delivered this year are equipped with two winches and are dedicated to bulk operation. Similar to 2011, the first and very successful year after market introduction, the LHM 550 is again the most popular model.
This highlights the competitiveness of Liebherr’s new generation of mobile harbour cranes.
Regarding bulk handling, Liebherr mobile harbour cranes are mighty tools. In July 2011, Indian Krishnapatnam Port set a record for unloading coal with mobile harbour cranes. Liebherr’s state-of-the-art machines discharged 106,171 tonnes of steam coal in just 24 hours. This record surpassed Krishnapatnam’s previous record of discharging 95,528 tonnes in 24 hours.
In April 2012 Adani Petronet Dahej Port Pvt. Ltd. (APPPL) broke their old record for coal discharging as well. A total of 60,077 tonnes of coal were unloaded in just 24 hours with two LPS 600, the award winning
model in the category ‘Crane of the Year’ at the IBJ Awards 2011.
Eren Enerji is a thermal power plant in Zonguldak,Turkey, which started operation in July 2010. In order to handle the large amount of coal required, a new harbour has been built at the Black Sea coast, where four Liebherr portal cranes are in operation. Two of them are type LPS 600 and are able to unload up to 2,000 tonnes of coal per hour. Harbour director Ali Ko¨lemenoglu states that “Liebherr cranes are very efficient and reliable for our port availability. In conclusion, we are very satisfied with the overall performance of this equipment.”
To minimize exhaust gas pollution, all high performance bulk handling cranes mentioned above are equipped with Liebherr’s E-Drive. This alternative drive system allows for eco-friendly land-based power supply.
VIGAN’s on the move
Since 1967,VIGAN Engineering S.A. has been designing and manufacturing portable pneumatic unloaders, commonly called ‘mobiles’ or ‘grain pumps’: y Model T100 or T120: working in ‘suck only’, ‘suck & blow’ or
‘blow only’ mode, their capacity ranges from 100tph (tonnes per hour) to 170tph, depending on configuration and product transported; and
y the high-capacity model T200 is able to unload at rates of up to 250tph in sucking-only mode, without producing any dust emissions. Products are discharged by gravity, optionally through an integrated belt conveyor. It is equipped with an automatic self-cleaning filter with air-compressor.
These mobile portable unloaders are particularly adaptable, as they can be put on a ship’s deck (see picture above) or on quay: directly on the ground (see picture, right), on a frame (see pxx) or on hopper (see p107). With a wide range of accessories available, they can be customized to meet customer’s needs for cargo handling in many different
working configurations: from vessels to trucks/railcars/ conveyors/silos or warehouses and inversely to load ships, but also for transshipment for instance.
Their compact dimensions (≈ 4 x 4m without booms) and low weight (≈ from 5 to 15 tonnes depending on the model and accessories) make them among the most flexible of all grain handling equipment.
For higher capacity requirements (from 200tph up to 800tph) and annual throughput (over 250,000 tonnes per year),VIGAN designs and manufactures pneumatic continuous ship unloaders (CSUs) on gantries, called ‘NIV’ models (see p109). Self- propelled on tyres or rails, they can be powered by diesel engine or electrical motors with cable reels. The most frequent combinations found are either rail-mounted/electrical/discharging into quay conveyors to ensure a regular movement parallel to the quay conveyor, or on tires/diesel/into trucks for ports which are not equipped with rails and conveyors. Each gantry is designed bespoke according to the port requirements (dimensions, wheel load and/or rail span, etc.). Boom length, piping system diameter and length, airlock size volume, filter size and number of turbo blowers all determine the expected unloading rate. Many optional devices are available.
The mobility on the dock alongside the boat allows highly efficient unloading of vessels up to Panamax size, following the typical required unloading chart of the holds.
Furthermore,VIGAN’s range of equipment also includes a mobile mechanical continuous ship unloader called ‘SIMPORTER’ designed to meet very high discharging rates up to 1,500tph (metric). It is particularly suitable for large bulk carriers up to post-Panamax. The twin- belt SIMPORTER technology offers major
benefits: efficiency, cost-effectiveness (minimum energy consumption, reduced operational and maintenance cost) and environment-friendly qualities (minimum noise, dust control...).
Beside the variety of mobile unloading equipment,VIGAN’s ship loaders (see picture, bottom), designed for almost any kind of products in bulk with a density from 0.2 to 1.8, are suitable for all size of barges or vessels.
The loading is achieved mechanically: for example, cargo can be transported into the loading boom by integrated belt (eventually with a travelling movement) or chain conveyor and discharged by gravity into the ship hold thanks to a telescopic loading chute.The loading boom is usually mounted on a slewing ring. The loading structure can be mounted on a self-propelled gantry on rails or on rubber wheels.
VIGAN has also gained significant expertise in other mobile harbour equipment design such as mobile hoppers/ bagging lines, like for the grain port terminal of Djibouti (see pictures left).
Originally, all VIGAN equipment was designed to convey dry agribulk cargo such as: all types of
cereals, beans, seeds, and most of the raw materials for animal feeding. The company’s units have also proved to be suitable for handling fragile products (malt, cocoa beans etc.), certain chemicals (dense soda ash, alumina, urea, etc.), as well as many products in pellet form, such as wood pellets for instance.
Page Macrae Engineering supplies hoppers and grabs to Australian stevedore
Innovative New Zealand bulk cargo handling equipment designer and manufacturer, Page Macrae Engineering, has completed an order for two dust-controlled hoppers and two diesel hydraulic grabs for Qube Ports & Bulk.
Qube, previously known as POAGS, is a renowned supplier of stevedoring logistics and port management services in Australia. The $1.5 million package has been commissioned at the Western Australian port of Bunbury, a hub for worldwide distribution of products from the country’s south-west.
Cargo Handling Equipment manager Bruce Ennis says the order package is the second from Qube and reflects the success of a previous order for three grabs and two discharge hoppers supplied two years ago to Qube’s East Arm Wharf operation in Darwin, Northern Australia.
The Darwin bulk materials handling facility can cater for Panamax-size vessels and is used to export iron ore, manganese, copper concentrate and phosphate rock. The grab and hopper acquisition has enabled the operation to further improve handling efficiencies and ship turnaround times, meeting ever increasing environmental compliance standards for dust emission.
Ennis recently completed a two-year follow up to check on the equipment supplied to Darwin, and says it is working extremely well. “The owners are very happy with its performance.”
Page Macrae’s PMGrabs, a division of the company’s cargo
handling department, has experienced strong bulk grab sales growth over the past few years. Grabs have been supplied to Southern Cross Stevedoring, New Zealand (repeat order), ISO International Stevedoring Operations, New Zealand (repeat order), Northern Stevedoring Services, Australia (repeat order) and to the Koniambo nickel mine project in New Caledonia. In August 2012 PMGrabs supplied three of its latest designed chain bulk grabs to Qube’s South Australia operation, along with an order for a bulk grab being confirmed by new customer Nyrstar, Hobart, Australia.
With exports of iron ore, bauxite and coal and other minerals enjoying a massive boom, Australia has become the major focus for the Tauranga, Bay of Plenty company, whose versatile grabs can be used to handle a large range of products including fertilizers, clinker, palm kernel, grains, soda ash, mineral concentrates and sand.
Page Macrae’s aptitude for innovation in the bulk cargo equipment field and the market-leading quality and durability of its products was underlined in 2010 when the company won a premium award in a major Australian competition.
The 55-year-old company took the Innovative Technology category at the annual Australian Bulk Handling Awards in Brisbane for its diesel-hydraulic grabs, amid stiff competition from the world’s leading manufacturers.
Operated via remote control by a crane operator, these grabs are designed to discharge large volumes of bulk material from ships’ holds. They can carry up to 20 tonnes of material at a time, discharging hundreds of tonnes per hour and enabling stevedores and shipping companies to make significant savings in time and money, says Ennis.
Key to their success is the fact that they incorporate special features to control spillage, noise and dust emissions, while still providing operators with significant gains in productivity.
The company’s range of wire or chain mechanical grabs provides advantages including low operating costs, exceptional productivity and high digging capacity, also featuring a unique overlapping blade seal that seals the material being transported, preventing leakage.
Page Macrae’s diesel/hydraulic grabs excel in situations demanding low operating height and minimum noise emissions, and can be an ideal solution for working in difficult discharge situations. Like the wire and chain grabs, they contain features designed to reduce the risk of environmental impact from product spills, while producing low dust emissions.
Ennis says the busy division works closely with clients in coming up with the right cargo handling solution for their needs. That innovative ‘can do’ approach also helps Page Macrae Engineering stay competitive in a fiercely contested global market.
Cargo handling equipment designed and manufactured entirely at the company’s premises includes log lifters, container spreaders, container loading equipment, over-height spreaders,
spreader beams, remote and manual release multilifters, lifting cages and lifting beams.
Highly efficient dust emission control is also a feature of the company’s range of discharge hoppers, which offer ship-to- hopper spillage recovery, dust controlled inflow chutes and a choice of onboard or separate dust collection.
With strict environmental controls now in place at ports in New Zealand, Australia and around the world, Page Macrae Engineering has refined its hopper design with a totally new product that integrates the dust collection system with the hopper. Until now, the two units have been separate, with the dust collection system having to be moved to wherever the hopper was positioned on the wharf.
“It’s a new evolution in the line of equipment we produce and it completes our dust controlled hopper package,” Ennis says. The operation is particularly adept at tailoring equipment to suit specific needs, which sometimes means designing and manufacturing custom discharge systems, he says.
“Our clients don’t always know what they want, but they certainly do know what outcome they require. We tailor-make solutions for the outcomes they’re after and provide any advice or technical support they might need along the way.
“We are particularly proud of the strong relationships we have built with all of our clients, including providing a 24 hour service and can dispatch service personnel as required.”