Marine Cement Terminals Englisch

0406

I BAU HAMBURG · Rödingsmarkt 35 · D-20459 Hamburg · PHONE +49 (0) 40 36 13 090FAX +49 (0) 40 36 39 83 · Email: [email protected] · Internet: www.ibauhamburg.de

Information

Marine Cement Terminals

I BAU HAMBURG

Ship loading station for

CIMENTS CALCIA, Rouen, France

Distribution terminal at Glasgow Port for

CALEDONIAN SLAG CEMENT, UK

Cement Carrier M.V. BIG ONE for WINDSTOR

HOLDING INC., Panama City, Panama

High-capacity ship unloader for CONTINENTAL

FLORIDA MATERIALS, Port Canaveral, USA

I BAU HAMBURG

Marine Terminals, Ship Loaders and Unloaders,

Cement Carriers, Equipment for Power Plants,

Special Applications


2 3

Information

Illustration of a Floating Terminal

TerminalProjectionAlthough cement termi-nals have been built forover 30 years, cement ter-minal design has still notreached a point of maturi-ty. This is most clearlyseen at large cement ter-minals with high capabili-ties, where capital chargescan range between 12 and35 million US Dollars.How can such large gapsin capital charges beexplained? The gapbetween a 60,000 tons flatstorage warehouse and adome storage of equalsize is approximately 2.5to 3 million US Dollars.The gap between variousship unloading systemscan be in some cases upto 1 million US Dollars,however, in most cases itis much smaller. One casemight be restrictions to aspecific terminal site thathave to be overcome, forexample a poor dockingsituation that has to beimproved. Terminals alsomight have different uses:one terminal might beused only for loading

cement onto trucks, othersalso for loading cementfurther onto river barges,onto railway waggons orinto bags. Even when allthese factors are takeninto consideration therecan still be a large gap ofcapital, which can only beexplained by differencesin terminal design.

For terminals with rela-tively low throughput andexpected short life-timethe focus should be onlow capital investments.

For terminals with highthroughput and longlife-time larger invest-ments and a focus onkeeping operational andshipping cost low shouldbe considered. As amatter of fact the appliedtechnical solution arisesfrom an evaluation of thespecific handling costsper tonne of cement.

Operational and capitalcharges of a cementimport terminal compriseapproximately 15% of thecement price. Dependingon the terminal conceptand local market condi-

tions, payback times of2-5 years on the terminalinvestments are possible.In a payback calculationthe investment costs forthe required storagecapacities and shiploading/unloading ratesare essential as are timeschedule and terminallogistics.

There is no terminaldesign applicable to allsituations. Each concepthas its advantages anddisadvantages, whichhave to be weighed upcarefully against oneanother.

First of all it is necessaryto consider the questionof the anticipated servicelife.

• For a rapidly available,short-term utilisation ofonly a few months thefloating terminal is themost suitable technicalsolution.

• For medium – to long –term use with low han-dling capacities a mobilemini terminal can beadvantageous.

• For medium – to long –term concepts with highhandling capacitiestraditional silo plants,dome systems and flatstorage systems comeinto consideration.

Each design can integratemechanical andpneumatic equipment.

The best options have tobe selected by knowingindividual customerrequirements and evaluat-ing the specific handlingcosts per tonne of cement.

Floating terminals requireno shore-based buildings.The floating terminalsare chartered for a shortperiod of time, to handletemporary peak cementdemand, with storage

capacities of typically5,000 to 50,000 t. Theyare tied up at a dock inthe entry port and can beoperated without anyshore facilities to handlecement and transport

it directly on trucks/railcars. With integratedpackers, both bulk andbagged cement can behandled. With a floatingterminal it is possible toenter a port and start

operations immediately,without land lease or con-struction permission.Charter costs, port feesand handling expensesmight make this optionunattractive.

Floating Terminals

4

Mini TerminalsIf no intermediate storageis needed a road mobileship unloader can beused for loading cementdirectly onto tankervehicles. These shipunloaders are used forcement carriers of up to10,000 dwt for relativelylow handling frequenciesat several locations.

Trailer – mounted mobileship unloaders require ahigh degree of manoeu-vrability. Starting fromthe transport positionIBAU mobile shipunloaders are ready foruse in only 20 minutes.

Regardless of their sizethe ship unloaders haveup to four separate screwconveyors. Verticalscrew 1 picks up thematerial assisted bya counter – rotating outerscrew. Vertical screw2 raises the material to theconveying height requiredfor onward transport.Screw 3 provides thehorizontal transport fromthe hold to the materialtransfer point, its highestefficiency being reachedwith a downward slope.A fourth screw (loadingscrew) loads the materialdirectly into a silo trucks.It is possible to traversescrew conveyors 1 to 3 sothat all areas of the holdcan be reached from agiven position. As a resultthe individual screwscan be tilted or rotatedwithin fixed angles.In conclusion, thecomplete unloadingis made possible by theunique IBAU HAMBURG

technology.

Information

5

mechanical ship unloader as a mini terminalRoad mobile


7

Information

6

Export terminal for GOLIATH, PORTLAND CEMENT, Devonport, Australia


Silo SystemsImport and exportterminals with centralcone silos of 20,000 tcapacity or more are builtfor long – term service.

Their great advantage liesin the fact that theyrequire little space. Inmulti-compartment silosit is also possible to storedifferent types of cementon a very small groundarea. Loading equipmentfor vehicles – as well asmixers and packing plants– can be integrated withinthe silos.

Limitations to thisconcept are higher invest-ments and a permanentstructure.

An example is theDavenport cement exportterminal of GoliathCement in Australia witha 20,000 tons storagecapacity. The installationcomprises two IBAU silosof 18 m diameter and42 m height.

From these silos a cementcarrier is loaded via4 IBAU Pumps at a rateof 1,200 t/h. In combi-nation with IBAU self-unloading ships, the lowoperating costs and a highdegree of automationmake this terminal designparticularly interesting forlong-term capital projects.

For storage capacities ofup to 2,000 tons the trendis to use steel silos, as forexample in Bamberg,Germany and on MayotteIsland for Sacima Port deLongoni.

Cement storage silos forthe harbour terminal ofGOLIATH PORTLANDin Devonport Tasmania.

Silo feeding by railway.Silo discharge via IBAU

Screw pumps in seagoingvessel M.V. Goliath.

Technical data:2 Pneumatic dischargesystems for cement silossilo diameter 18,0 msilo height 42,0 msilo capacity 10,000 tdischarge 4 x 350 t/h

Silo with raised bottomfor direct feeding ofscrew pumps4 IBAU Pumps IB-D 350

conveying cement intocement carrierconveyingcapacity 4 x 350 t/hconveyingdistance 190 m

8 9

Information

Stationary ship unloader at Bamberg harbour terminal, Germany Sacima Port de Longoni on Mayotte Island


Information

10 11


Ship loading station at Port Talbot, UK A 30,000 t cement silo for ADELAIDE BRIGHTON CEMENT LTD., Adelaide harbour, Australia

Civil & Marine Slag grinding plant for GGBS, Port Talbot, UK

Civil & Marine grinding plant at Port Talbot / Wales for GGBS

Information

12 13


View of ROSTOCK TERMINAL, Germany, during a ship unloading process

HOLCIM, Hamburg,GermanyTerminal Rostock

CEMENT TERMINAL

New cement terminal in thebaltic sea harbour of Rostock,Germany: Terminal tostore 13 different types ofpulverized material,(mechanical) mixing plant,rotopacker and bulk loadingonto trucks.

Technical data:

1 Silo feeding systemfrom a vessel 150 t/h

1 Silo feeding systemfrom rail cars 2 x 55 t/h

1 Silo feeding systemfrom trucks 30 t/h

13 Pneumatic dischargesystems 50 – 250 t/h

2 Weighingsystems 200 t/h

1 IBAU Batch type mixer

1 IBAU Pump IB-D 300capacity 130 t/h

2 IBAU Simplexloaders, loadingcapacity 250 t/h

14 15

InformationMarine Cement Terminals

Dome SystemsDome silos have becomepopular for storinga single type of cement.The ground area used andthe required constructiontime for dome silos liebetween those for conesilos and flat storagesystems. Separate build-ings are required both forcement loading andcement packing. At somesites converted oil tankshave also proved to beuseful as cement stores.

Nowadays, instead ofmechanical systems, panelaeration systems are usedfor cement discharge.

The silo bottom consistsof three aeration levelswith different sectors toallow a material dischargeof 400 t/h.Only 0.16 kW h/t arerequired for the fullyautomated and nearlymaintenance – free silodischarge.

This storage has thefollowing benefits:

• Low civil-buildingcosts with regard to thefoundation soil

• Short construction time

• Low energyrequirement for the silodischarge system

• Low maintenance costs

• High availability of silovolume

• Material reclaimingaccording to the first-in/first-out system

• Dust free feeding anddischarge

Illustration of a dome silo

Dome silo station and rail waggon loading at LEHIGH CEMENT COMPANY

GLENS FALLS LEHIGHCEMENT COMPANYAllentown, PA, U.S.A.

Terminal ProvidenceU.S.A.

CEMENT TERMINAL

New dome storage silo in theProvidence Cement Terminal

1 Pneumatic discharge systemfor a cement dome storage siloType IB-L/MR/HR

silo diameter 42 msilo height 34 msilo capacity 40,000 m3

External ring –first aeration level

The external ring is divided upinto 10 aeration sectors, eachsector consisting of two aera-tion surfaces inclined towardseach other and two radiallyaligned discharge fluidslidesinbetween. This results in atotal of 20 aeration surfaces and10 discharge fluidslides. Formaterial discharge the surfacesare aerated sequentially.

Second aeration ring

The second aerating ring(second level) is aerated usingthe same method as for theexternal ring.

Interior of silo –third aeration level

This level consists of twelveaeration sectors which are alsoaerated in sequence.

16 17


with aeration fluidslidesDome silo bottom

19

Information

18


Flat StorageFlat storage terminals arebest suited for medium –to long-term service.This is a low cost solu-tion, especially when anexisting warehouse can beconverted into a materialstorage installation or ifthe buildings later need tobe used for other purposeslater.

The short time required tobring about the necessaryapprovals and the shortbuilding times also favourthis concept. The technol-ogy that has to be inte-grated is the most sensiblepart of flat storage sys-tems.

The most commonmethod is to use front endloaders inside the dusttight building. The frontend loader reclaims thecement mechanically andtransports it to a collec-tion hopper. From thecollection hopper avertical transport to aseparate building for truckor railcar reloading isusually necessary.

The other very interestingreclaiming technologywhich also complies withthe standards is dischargeby panel aeration, suchas it is used in floatingterminals or dome silos.

For Antilles Cement,Puerto Rico,IBAU HAMBURG hasinstalled a fully automat-ed cement discharge sys-tem for the reloading of200 t/h cement, 24 hoursa day and 7 days a week.

of a flat storage terminalIllustration

21

Information

20


Picture above:Truck loading station atthe flat storage hall forT.C.B.M., Myanmar

Picture on the right:Flat hall for BUZZI

UNICEM SPA, Ravenna,Italy

Picture below:Aeration panels in a flatstorage hall

BUZZI UNICEM SPACasale, Italy

CEMENT TERMINAL

WITH FLAT HALL

1 Flat hallwith 4 compartmentsstorage capacity 22,000 thall length 60 mhall width 38 mhall height 12 mcement fillingheight 8 m

2 compartmentsstorage capacity 2 x 3,600 tdimension 10 x 38 m

2 compartmentsstorage capacity 2 x 7,400 tdimension 20 x 38 m

Flat hall dischargecapacity 80-200 t/heach compartment

22 23


The flat storage terminalis designed for 30,000 tonsof cement in a 4,750 m3

building. The partitionwalls for the cement hallare made of prefabricatedconcrete, the storageheight is about 6-7m.

The floor is fullyequipped with standard-ized fluidslides and divid-ed into 18 sections,6 of which always trans-port the cement to a hori-zontal screw conveyor,located in a 45 m tunnel.

From the total 3 horizon-tal screw conveyors thecement is lifted via verti-cal screws to a combinedfluidslides conveyor,which transports thecement from the storageto the reloading station.

The reloading stationincludes 3 bulk loadinglines with IBAU Simplexloaders. The floor sec-tions can be fluidised andemptied one after theother. Pressure switchesand level indicators overthe complete area ensure

fully automated feedingand discharge. A similarflat storage terminal wasbuilt for BUZZI Cementin Ravenna, Italy.

ConclusionTerminal concepts byIBAU HAMBURG arebased on a variety ofadvanced and reliablemechanical and pneumat-ic system components.Existing equipment canmostly be tied-in.

Technical competenceand engineering from asingle source contribute tofinding the most cost-effective technicalsolution for each projectand to ensure thesubsequent functioningof the entire terminalsystem.

for ANTILLES CEMENT CORPORATION at San Juan harbour, Puerto RicoFlat storage hall

Documents

Marine Cement Terminals Englisch