Cargo Handling

Still riding the end of the boom facility, to which it is connected by a belt conveyor system for fast and easy transport of ore_

ABB developed the automation solution for this project, with the automated grab ship lmloader incor­porating an innovative ABB technol­ogy called Target Position Sensor (TPS), which detects the position of any object with centimeter accuracy and enables fast approach to target with optimum patb control and with­out collision between the grab and the sh ip. ABB modified this system for grab unloaders on behalf o f Shanghai fn tcmational Port Group (SIPG), operators of the terminal al­though Baosteel, which has a stake

S uch is the longevity of the older generation grab unloaders that the ZPMC 60t

unloader installed at the OBA Am­sterdam coal tem1inal last year re­placed a 30t crane built in 19 57 and still performing front-line duties on a 24/7 basis_ However, the terminal wanted to increase unloading capac­ity, with the new crane more than dou­bling throughput ofthe older machine.

EMO could have also opted for the same supplier when it decided to add a third 85t unloader to its exist­ing two Krupp machines which op­erate alongside two similar SOt unloaders. However, the stevedore chose a more expensive option, to or­der the same wide; span design as the two earlier 8St units, arguing that the expense and dismption caused by constructing a second landside rai l to match the shorter rai I span of con­ventional grab unloaders, out­weighed the initial cost.

Also, EMO would have lost the flexibi lity of stacking between the crane legs, normally only used in an emergency ifthe main quayside con­veyor systems fai ls, which allows ship unloading to continue.

Building up The erection of the new 85t grab unloader, the largest of its kind in the world, is underway at EMO, Rotter­dam, with the crane being assembled on the terminal in the Mississippi harbour, a longside EMO's existing unloaders. O nce commissioned , EMO, Europe's largest dry bulk ter­minal for coal and iron ore, will have access to three 85r grab unloaders, two SOt grab tmloaders and a 36t Lemniscate floati ng crane.

The unloader sections, fabricated entirely in Europe, are being trans­ported to the EMO terminal by barge from Stcttin in Po land, in a series of transports. The new 85t grab unloader and accompanying trans­port conveyor belt system are ex­pected to be put into service in the second half of 2012. The decision was also recently taken to renovate one ofthe other 85t unloaders when the new crane is commissioned. Such is the structural strength of Krupp unloaders, that thi s refurbishment programme will extend the useful life of this crane by a futther 15 to 20 years.

The investment in th is new crane represents the final stage in EMO's current expansion programme, with the crane alone accounting for an increase in the tem1inal 's un loading capacity of some 10 mtpa.

Break in Konecranes has now delivered its 3000t/h unloader to Nippon Steel's Yawata mill as part of the plant's upgrade.The crane was constmcted in China and shipped fully erect to Japan, where it was offloaded and placed directly on existing crane rails using Nippon Steel's floating crane.

It is particularly difficult for Eu­ropean manufacturers to break into the Japanese market, as in addition to the competition of the local crane builders, such as Sumitomo, II-II, Mitsui and MHl, the Japanese pro­curement procedures arc particularly complex and expensive to overcome. However, Konecranes is confident that now it has one reference in Ja­pan and has successfully mastered the procurement policies, other or­ders will follow.

The main reason Konecranes was able to beat the competition was that

BMI September/October 2012

High throughput grab unloaders serve a specific and relatively small market, focusing more on expansion and new terminal proiects than replacement, but automation may change this approach it could offer something they could not - its AGT reeving and drive sys­tem. This feature reduces weight, particularly on the boom, which in turn a llows a higher capacity w hile still keeping within the weight lim­its on the seaward and landside rails.

The 65t capaci ty unloadcr has a hoist and closing speed of 180m/min while trolley speed is also 180m/min.

Automated response Surprisingly, there has been little progress in grab unloader automa-

tion, despite the fact that the tech­no logy is readi ly avai lable and proven.The world's first automated bulk cargo terminal comprising a SOt grab ship unloader, stacker/reclaimer ship loader, all operated remotely from a central control room was commissioned in 2009/2010 at the pott ofLuojing, Shanghai, but since then there has been little enthusiasm on the part of terminal operators to incorporate this feature. Luojing port serves several major steelworks in­cluding Baosteel's nearby Luojing

TEREX® FUCHS PORT SOLUTIONS The future of bulk handling A quick and strong grip, dynamic maneuvering and exact positioning: these are what make handling

cargo in ports profitable. And the materials handling

[W TER

specialists at Terex"" Fuchs make It happen with convenient handling, impressive performance data, legendary reliability and high lifting capacities

throughout the entire working range as well as ergonomic, safe work at an eye level of up to 12 meters- as is the case for the RHL380 XL. Your

individual needs are our blueprint. At Terex"" Fuchs, your machine is equipped on request with the special features you require. www.terex-fuchs.com

The Terex® Fuchs programme:

., Material handlers from 19 to 90 tons weight and up

to 22 meters reach

., Complete solutions honed for your specific purpose

- we cover scrap, recycling, timber and port applications ., Special equipment: We equip each machine according

to your specific requirements

15

Cargo Handling

in thi s facility and is its main customer, is believed to have prompted SIPG to investigate the automated approach.

first container cranes not fitted with a cab and instead operated remotely.

Metso method The TPS technology was adapted from the system em­ployed by ABB to enable ship profiling, chassis alignment and obstacle surveillance dm­ing loading and unloading op­erations at container terminals. ll is installed in more than l SO ship-to-shore and rail-mounted gantry cranes worldwide and will be employed in the world's

Metso has also developed an automated system for its grab unloadcrs oiTcring a sophisti­cated but user-friendly control automated system that mini­mises operator fatigue. By completely automating grab unloading operations, overall performance is maximised over longer periods of time

with minimal operator stress. The Automatic Bucket Con­trol (ABC) system utilises state-of-the-art control system hardware and software wi th advanced features in grab con­trol and features a Man-Ma­chine Interface (MMI), where a computer-based ~rraphics sys­tem links the operator and the PLC control system in a user­friendly, on-screen format.

The MMI system gives the operator the ability to control virtually all machine functions

En route from its fabrication site in China to Japan, Konecrane's 3000tph unloader is the largest it has built to date

16

THE JOURNAL OF THE INTERNATIONAL CARGO INDUSTRY

As the sector's leading international monthly journal, WorldCargo News carries regular, in-depth news & feature coverage of ICT products and services for the Port/Terminal/Cargo Handling and Logistics communities worldwide, focussing on the following areas:

• Terminal operating systems • Automation technology

• Positioning and real-time locating systems • Radio data transfer • Simulation packages • Asset tracking • Security systems

• Gate OCR and automatic equipment identlflcstlon • Container interchange systems • ERP and admin systems

To access WCN's archive of ICT coverage go to http://www. worldcargonews.coml lndex page.htm and click on ICT- Information and Communication Technology

For further details of print/online advertising opportunities,

upcoming editor/sf features, article reprints, or subscription information, please contact: info @wcnpubllshing.com

WCN Publishing, Northbank House, 5 Bridge Street, Leatherhead, Surrey. KT22 BBL, UK Tal: +44 (0)1372 37 55 11 Fax: +44 (0)1372 37 01 11 Web: www.worldcargonews.com

and provides detailed messages regarding machine status.

Bucket control Prior to each tmloading cycle, the grab controller calculates the grab trajectory for the most efficient unloading cycle time. Continuous monitoring of this trajectory and modulated ac­celeration and deceleration rates of the hoist and trolley motions enables accurate un­loading and delivery of mate­rial into the hopper while making use of the swing mo­mennun of the grab.

The microprocessor logic control improves overall op­eration and lends assistance in troubleshooting. Working in conjunction with theM M I, the control logic programme in­stantly pinpoints areas of the grab unloadcr system that re­quire attention.

Automatic Grab Closing provides the control capabil­ity to automatically close the grab while in the cargo, while the Grab Fill Control function varies the amount of torque on the grab closing drive during grab closing operation.

Overfill alert A Grab Load Monitor System monitors bucket load at the beginning of each cycle and alerts the operator in the event of an overfill condition. While hoisting in manual, semi-au­tomatic, and automatic modes, the Hold and Close Drive Co­ordination system and related circuitry, balances the loading on the hoisting equipment, thus eliminating long term rope and hoist damage from unbalanced drive loading.

ROPE GRABS MOTOR GRABS

HYDRAULIC GRABS

We proauce a top-quality ful. range of four

rope grabs for 'Tledium and large h t1 g

capac1t1es 'or the lowest costs per ton of

caryo Mndled.

nemag ~handles your bulk

www.nemag.com

in all executions for each handling The perfect gr:Jb$ with unbeatable handling.

The mos1 econornc solution In grab c•~on~s~tru~c~tio~n:_· --;;-;;-..::::::::::::::::::::..,

MRS Greifer GmbH Talweg 15-17 • 74921 Helmstadt/Germany

Tel. +49-72 63-91 29·0 ·Fax +49-72 63-91 29 12 email: info@rnrs-greifer.de · www.mrs-greifer.de

A position sensor continu­ously monitors changes in the location ofthe ship's deck that result from cargo removal and/or tide changes, allow­ing the contro l system to adjust for sh ip height with­out interrupting unloading operations.

Coastal migration Despite the current downturn in Chinese iron ore and coal imports due to a fall in steel output, its handling market re­mains relatively strong, par­ticularly as the central govern­ment has been encouraging large state-owned mills to shift operations to the coast to reduce logistics costs and im­prove the environment in ur­ban areas. ll aims to move 40% of total steel capacity to the coast by 20 15.

However, it is un likely that European manufacturers will be able to penetrate this sec­tor, despite successful con­tracts in the past, as domestic manufacturers such as ZPMC now have sufficient expertise in crane design and produc­tion and are eager to diversify away from the container crane market.

In April, ZPMC announced it had won the handling equip­ment co ntract fo r the Zhanjiang Port project includ­ing five quaysidc cranes plus three bucket wheel stacker/ reclaimers, which will be de­livered 12 months after the sale contract becomes effective.

Shanghai-based Baosteel Group, the second-largest steel producer in the world measured by cmde steel out­put, plans to invest 63.SB yuan (US$9.98) to build a major iron and steel mill in Zhanjiang. Baosteel began construction in May, although reports that the project has been halted have been denied.

The overall approved project, which also involves the construction of power plants and port facilities, will require a total investment of 69.688 yuan (US$ 1 0.988).

More capacity The pmt of Huanghua, some II Okm from Tianjin in Hebci Province, is also upgrading its faci lities with the constmction of a new iron ore terminal and deepening its access channel to al low 200,000dwt bulkers access to the port. Work is underway to construct four l OO,OOOdwt berths in the first phase, which can be upgraded to handle 200,000dwt bulkers once the main dredging work is completed. The second phase will see the addition of four similar berths which will take the capacity of the termi­nal to 80- l 00 mtpa.

No cranes have yet been

ordered, a lthough ZPMC looks to be in a strong posi­tion as it has recently won the contract for two 65t cranes for H uanghua 's multi-purpose ter­minal development.

Replacement market At the other end of the mar­ket, there is a significant re­placement market potential for fixed ann grab cranes as older jib type level luffing cranes age and reach a stage where maintenance costs to keep them up to regulation standards start to become pro­hibitively high.

While cranes based on ex­cavator components are prov­ing popular, they are limited in outreach and capacity. The E-crane design, however, does not have such restrictions with the larger machines able to handle Panamax bulkers.

The E-Cranc des ign is based on a para ll elogram boom configuration that pro­vides a direct mechanical con­nection between the counter­weight and the load. This four bar mechanism system, which is similar in principle to a level luffing crane design, ensures that the E-Crane remains in near perfect balance through­out its workjng range.

Compared to conventional hydraulic arm cranes that re­quire as much as 80% of their available energy to move the boom, stick, and grab, the E­Crane employs gravity to re­duce horsepower require­ments and power consump­tion by up ro 50% and signifi­cantly reducing maintenance and operating costs.

The E-Crane series offers models with up to SOt duty cycle capacity due to their movable counterweight and fixed parallelogram linkage as well as up to 1 SOfl:JSOm ofhori­zontal and up to 100ft/30m reach below grade. Its modu­lar design allows each E-Crane to be tai lor made to the client's specific requirements.

In and out The Port of Kokkola has ac­quired a rail-mounted 2000 Se­ries E-Crane for unloading iron ore, zinc concentrate, and coal. The crane has a maximum outreach of 35m and a duty cycle capacity of 21 t and can reach capacities of up to l ,300tph with a cycle time of 40sec.

Equipped with a 7.Sm hy­draulic clamshell bucket grab, it has a net payload between 14t to l6t, and peak offloading ca­pacities in the l, 150- l ,300tph range (zinc concentrate).

Strategic expansion The E-Cranc Group of Com­panies has acquired the Polish company Famaba, whi ch gives it a strategic supplier of high l:,rradc steel constmctions for the crane industry.

The existing co-operation between E-Crane and Famaba wi ll be intensified and it is thought that in the short-term this will result in a substantial increase in the capacity for as­sembling harbour cranes at its main plant in Adcgem, Bel­gium, as well as important savings in several logistics processes. Cl

BMI September/October 2012