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Rotary Railcar Dumpers & Train Positioners

Rotary Railcar Dumpers & Train Positioners

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Metso Minerals rotary railcar dumper/positioner sys-tems have set the worldwide industry standards formore than 80 years with the most technologically-advanced list of standard features for system de-pendability, efficient operation and long service life.

Versatility

With a wide choice of configurations and features, MetsoMinerals can service random car and unit trains of anylength, style and varying car size. Single, tandem or triplecar dumpers provide capacities from 500 to 10,000 tph.

Complete Systems

Metso Minerals capabilities in design, supply, installationand commissioning provide complete turnkey railcar un-loading systems including: the dumper, train positioner,train holding devices, hoppers, feeders, controls, dust col-lection, car weighing, foundations, building enclosuresand control room.

Custom Built

For each individual application, the railcar unloading sys-tem is custom-configured and built with the site specificsand customer needs in mind.

Expert Design

Designing dumper barrels with state-of-the-art finite element analysis software allows Metso Minerals engi-neers to evaluate high-stress areas prior to manufacturefor optimum fatigue life.

Variable Speed Drives

Metso Minerals offers a choice of AC variable frequency(flux vector controlled), DC adjustable voltage or hy-draulic adjustable flow variable speed drives for thedumper and train positioner to meet customer require-ments. Variable speed with controlled acceleration anddeceleration softens the impacts that occur during speedchanges, increases the life of gearing, brakes and motors,reduces maintenance, permits slow speed movement tofacilitate inspection and enhances system reliability.

Diverse Material Handling Capacity

Rotary dumper systems handle a wide variety of materi-als, including: coal, coke, metallic ores, limestone, baux-ite, phosphate, sulfur, wood chips, waste and a variety ofother bulk materials.

A Tradition of Excellence

With over 300 systems installed, Metso Minerals’ family ofdumper/positioners includes those of our predecessorcompanies:

• Svedala Industries

• McNally Wellman

• Strachan & Henshaw Bulk Division

• Dravo Wellman

• McDowell Wellman

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Product Presentation

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Double/Quad Wheel TrunnionsExcellent for heavyrailcar handling.Distributes the endring load to 8 or 16points instead of 4.Reduces fatigueloading of each cy-cle on the end ring,greatly extending

barrel life. Rail and trunnion wheel surfacewear life is improved due to reduced stress.

Blocking MechanismMaintains supportof railcar sidewallsduring rotation.Maximizes railcarside support andminimizes carshifting duringdumper operation.Prevents damage

to railcar caused by excessive side stresses.Two-position shiftable blocking can be pro-vided to accommodate wide locomotives.

Integral Platen Weigh ScaleIntegral load cellsallow railcars to beweighed beforeand after dumpingwithout the needof separate trackscale. Excellent ac-curacy of 0.1%meets strict rail-

road requirements. Platen does not interferewith dumping operation.

Shiftable PlatenA shiftable platen is available to accommo-date a wide range of car widths.

Rolled “T” End RingsReduces structuralstress and extendsservice life by uti-lizing a standard“T” shape to con-struct the flangeand portion of theweb. Promotes ex-tended barrel life.

A special five-year warranty is offered byMetso on rolled “T” end rings.

Breakaway Car Clamps with Spring Relief Feature

A vertical pivot al-lows the clamphead to rotate ifstruck on the sideby a locomotive orrailcar. Preventsdamage to loco-motive, railcar,and dumper bar-

rel. Spring relief feature prevents overload-ing of clamps, barrel frame, and structuralgirders, maximizing dumper life.

Dual Heavy-Duty Rack and PinionRotate Drive System

Eliminates extremetorsional forces inthe dumper barrel.This lengthens bar-rel life by minimiz-ing shear stressesin front and reargirders and boltedconnections. Each

drive supports half the load for longer drivelife. Redundant drive arrangements also pro-mote safer operating characteristics.

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Features, Benefits and Configurations

Rotaside dumpers for random cars lift thecar during dumping, therefore reducingthe depth of the receiving hopper andfoundation.

Metso’s basic rotary car dumper makeshandling a wide variety of materials arapid, automatic process.

Tandem barrel configurations dump two railcars simultaneously to doubletraditional unlading capacity.

This C-frame (crescent) design allows thepositioner to move through the barrel,promoting efficient handling of randomcars.

Off-Board Hydraulic Power Unit (HPU)

One main unit is lo-cated off the dumperand away from thematerial flow area.Improves fluid clean-liness, enhancestroubleshootingability, eliminatesleakage problems of

rotary breathers, and provides better systemreliability.

Rack and Pinion Style Railcar Positioner

Designed for quickand efficient han-dling of large num-ber of railcars. Aprecision over-the-coupler arm andrack and pinionstyle drive withsynchronized AC,

DC or hydraulic motors allows for fully-auto-matic indexing, return, and precise locatingof cars for dumper operation.

Wire Rope StyleRailcar PositionerAlternately, a wire rope cable and drumarrangement is used to move the positioner.

Control RoomHighest systemvisibility is main-tained at all timesin an elevated,ergonomic envi-ronment. One op-erator maintainstotal system con-trol and conducts

trouble-shooting through user-friendlyMan-Machine Interfaces and Programma-ble Logic Controllers.

Wheel ClampsSecures railcar inplace during dumperrotation. Hydraulicclamping mecha-nism pinches wheels,securing car for safedumping. Also holdstrain in positionwhile positioner is

returning to index the next railcar.

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SCAMP® Reversible hydraulic indexers can be used in two-direc-tional applications, for up to 50,000 lbs. pull or for applicationsrequiring a spotting accuracy of ±1 inch. SCAMPs are usuallyarranged to index a string of cars one car length at a time. Unitscan be arranged to traverse scale platforms or to be integratedinto rotary dumper platforms. Recommended for dumping 5 to 15 cars per hour.

Sidearm train positioners with rack and pinion drives, such as this one installed at the Los Angeles Export Terminal, advance 100+ cartrains rapidly through rotary dumpers.

Nolan Hydraulic Car Movers™ (HCMs) are used where cylindersare preferred over wire rope due to site conditions or for pulls upto 45,000 lbs. HCM’s move strings of railcars for dumping mate-rials with spotting accuracy of ±6 inches.

are available to handle 1 to 40 cars. Each completedumper/positioner system provides fast, dependabletrain turnaround requiring only one operator.

At Metso Minerals, we design systems specifically foryour particular train unloading requirements, rangingfrom 5 cars per hour to more than 90 cars per hour.

Metso Minerals train positioner systems are designed tomove individual blocks of 1-10 railcars up to unit trains inexcess of 200 railcars. Most systems are computer-moni-tored and SCR-controlled to meet exacting dumping re-quirements. For high speed, high capacity requirements,Metso Minerals offers an over-the-coupler positioningarm, holding arm, and a truck/wheel locking assembly.For lower capacity requirements, car positioning devices

Positioning Systems to Service Any Application

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Train Positioners

Wire Rope Car Pullers

Single Drum One-Way - Six size options available, from3,700 to 25,000 pounds pull, with variable rope speeds.

Single Drum Reversible - Used where cars must bemoved in both directions along one or two tracks, wherelength of travel is not in excess of the practical capacityof a single layer of rope on the drum. A closed rope cir-cuit is used.

Double Drum Reversible - Used in applications where aclosed rope circuit is required, with two-way movementgreater than 585 feet.

Capstan Puller

Vertical Capstan - Operator attaches hook to railcar andmanually snubs rope on capstan with sufficient tensionfor proper pull. Pulling distance is limited only by the op-erator’s strength in handling the rope.

Gemini® Car Positioner

Two Over-the-Coupler - positioners index cars at highrates through the dumper.One positioner moves the traininto the dumper while the second simultaneously returnsto the starting position in preparation for the next index.Significantly reduces overall train dumping time.

A complete unit train is easily and accurately moved by thisautomatic wire rope-type sidearm positioner, shown here withthe arm in the vertical disengaged position.

Metso’s train simulation program calculates speeds, loads, cycletimes, and in-train forces, and evaluates the dynamics of thetrain configurations to be handled by the facility. Adjustmentsare made by a Positioner Optimizing Control (POC) system toaccommodate site-specific requirements.

Over-the-coupler positioner arm at LAXT.

Additional Metso Minerals Positioners

Subject to alteration without prior notice Brochure No. 1625-05-03-MPR/York-English © 2003 Metso Minerals Printing in U.S.A.

linking innovations™

Our ranges: Engineered ProductsApron FeedersWobbler FeedersRail Car & Barge PullersRail Car IndexersAsh Submerged Chain ConveyorsAsh Dry Chain ConveyorsFly Ash Mixer ConditionersEn-Masse Conveyors/ElevatorsCoal Preparation EquipmentThrowers & Ship Trimmers

Aftermarket ServicesMachine Upgrades/RetrofitsService Life Extension ProjectsEquipment InspectionsOperations & Maintenance TrainingStart-Up Assistance/CommissioningAnnual Service AgreementsTroubleshooting ServicesBreakdown AssistanceReplacement Parts Programs

Equipment & SystemsRailcar Dumpers & PositionersBucketwheel Stacker/ReclaimersScraper ReclaimersShip and Barge LoadersStackers (Radial/Linear)Grab Type UnloadersContinuous Barge UnloadersCable Belt Overland ConveyorsSelf-Unloading Ship SystemsComplete Systems

Metso Minerals North and Central America240 Arch StreetYork, PA 17403USAPhone: +1-717-843 8671Fax: +1-717-845 5154

Metso Minerals South AmericaAv. Independência, 250018087-050 SorocabaBrazilPhone: +55-15-219-1300Fax: +55-15-219-1699

Metso Minerals Asia-PacificP.O. Box 399West Perth, WA 6872AustraliaPhone: +61-8-9420-5555Fax: +61-8-9320-2500

Metso Minerals Europe and MediterraneanNoorangsgatan 2P.O. Box 30273325 SalaSwedenPhone: +46-224-570-00Fax: +46-224-169-50

Metso Minerals Southern Africa64 Jet Park RoadJet Park, 1469South AfricaPhone: +27-11-967-4000Fax: +27-11-397-5090

Metso Minerals HQP.O. Box 30733101 TampereFinlandPhone: +358-20-484-140Fax: +358-20-484-141

www.metsominerals.comE-mail: minerals.info@metso.com

Metso Minerals Bulk Materials Handling