Self-discharging ships

• Pneumatic loading andunloading

• Rates from 100 tph to over 1,000 tph

• 100% weather-independent, fully-enclosed ship unloading

• Minimum manpowerrequirement both duringloading and unloading

• Easy to install either on shore or on board ships

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Satisfied customers

H.W. Carlsen has been a supplier of self-discharging ships for more than 30 years.During this period the Carlsen systemshave proved extremely reliable and easyto operate and maintain. Worldwide,more than 100 ships and barges havebeen equipped with H.W.Carlsen loadingand unloading systems.

To meet specific project requirementsH.W.Carlsen supplies both pneumaticand mechanical loading and unloadingsystems. The unloading capacities mayrange from 100 tph for barge unloadingsystems to over 1000 tph for large self-discharging ships.

One of H.W Carlsen’s specialities isfluidised ships with the actual unloadingsystem on shore. This has proved to bethe ideal solution when several ships orbarges deliver cargo to one terminal.The system is particularly popular inSoutheast Asia where 20 terminals areusing this kind of equipment.

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The ships built for Ta Ho Maritime Ltd. are used onshort trade routes in Asia. Due to their high loadingand unloading capacity they carry over one milliontonnes of cement per year.

Ship no. 8, 2002-03,12,600 dwt, 600 tphunloading capacity.

One customer purchases eight shipsFrom 1987 to 2002 Ta Ho Maritime Ltd. in Taiwanpurchased eight H.W.Carlsen loading and unloadingsystems in succession. These ships represent state ofthe art technology, developing from 300 tph on thefirst M.V. Jui Ho in 1987 to 1000 tph on the largestM.V. Jui Ho delivered in 1999.

M.V. Jui Ho, 1999 22,000 dwt, 1000 tph unloading capacity

M.V. Yung Ho, 19899,700 dwt, 350 tph unloading capacity

M.V. Ken Ho, 199820,000 dwt, 1000 tph unloading capacity

M.V. Jui Ho, 198717,000 dwt, 300 tph unloading capacity

M.V. Sheng Ho, 199617,000 dwt, 600 tph unloading capacity

M.V. Thai Ho, 199417,000 dwt, 600 tph unloading capacity

M.V. Shine Ho, 199217,000 dwt, 600 tph unloading capacity

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Key to success:

The fluidised bottomThe fluidised bottom is one ofthe keys to the successfulH.W.Carlsen unloading systems.The inclined steel bottom of thehold is covered with fluidisingfabric sections that are bolted tothe steel bottom. Air that isblown in underneath the fluidis-ing fabric sections passes throughthe fabric and fluidises thecement or any other powderedmaterial above it. The fluidisedmaterial then flows towards thetrench along the centreline of the hold. From the trench itcontinues to the centre of thehold, which is the pickup pointfor the pneumatic or mechanicalconveying system.

Diamond shaped bottomThe H.W. Carlsen diamond shapedbottom is a refinement of thefluidised bottom system. The inclinedbottom slopes eight degrees bothacross and along the hold. Thiscreates a diagonal slope of 13degrees towards the centre of thehold. The increased slope combinedwith separate fluidisation of eachsection provides absolutely superiorcleanout and full control over thetrim and list of the vessel duringunloading.

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Overall systems capability

Pneumatic systemsThe H.W.Carlsen pneumatic systemsvacuum the cement or otherpowdered material out of the holds.The DR type system blows thematerial through a pipeline to thestorage facility. The CSP systemmechanically discharges the materialto an onshore belt conveyor. TheCarlsen pneumatic systems aresuitable for both conversion projectsand new ships.

Screw pump systemThe Screw pump is the world’s mostcommonly used pneumatic convey-ing system. In self-discharging shipsan Screw pump is installed in a tun-nel underneath each fluidised hold.Cement or other powdered materialis then conveyed through pipelinesto the onshore storage facility.

Mechanical systemThe H.W. Carlsen mechanical systemcarries up the material by verticalscrew conveyors from the fluidisedfloor to deck level where it is pickedup by airslide conveyors or horizontalscrew conveyors. The material is thencarried on shore either mechanicallyor by a pressure tank system. TheH.W. Carlsen mechanical system issuitable for conversion projects aswell as new ships.

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H.W.Carlsen pneumatic systemsLoadingThe H.W.Carlsen single point loadingsystem enables uninterrupted high-capacity loading of self-dischargingships. The shore-based shiploader feedsinto the central receiving bin on theship. On deck, the cement or other bulkmaterial is distributed accross the holdsof the ship by a fixed airslide systemoperating at capacities up to 1200 tph.

UnloadingThe H.W.Carlsen DR system vacuums the material from the holds and thenblows it on shore through a pipelinesystem. Only a hose connection isnecessary between ship and shore.

The H.W.Carlsen CSP system vacuumsthe material from the holds and thenconveys it on shore by an outloadingboom. The material proceeds onto a beltconveyor or directly into bulk trucks.

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The DR systemThe DR (Double Reloader) system consists of two tanksthat alternate between being filled by vacuum andemptied by pressure. The cement or other powderedcargo is fluidised in one of the holds and flows towardthe pickup nozzle. The vacuum pumps create anegative pressure in the reloader tank and thematerial/air mixture is vacuumed through the suctionpiping to the reloader tank (1). Filters in the tank cleanthe conveying air before it enters the vacuum pumps.When the reloader tank is full, the vacuum valve to thetank closes and the vacuum valve to the other reloadertank opens (2). The other reloader tank is then filled byvacuum while at the same time in the first reloadertank, the cement is mixed with air from the compres-sors and blown through a pipeline to the storagefacility on shore (3). When one reloader tank is emptyand the other is full, the two tanks alternate (4). In thisway a nearly continuous conveying process is achievedof very high unloading efficiency and low operationalcosts. In the port only a pipeline to the storage facilityis necessary. All other equipment is on board the ship.

The CSP systemThe CSP (Continuous Suction Pump)system is a continuous conveying systemthat vacuums the material from thefluidised hold into the CSP unit. Filters inthe CSP unit clean the air before itenters the vacuum pumps. A vacuumlock screw conveyor conveys thematerial at high capacity to a verticalscrew conveyor which deposits thematerial into the outloading boom ofthe ship. The outloading boom withflexible bellows discharges the materialonto an onshore conveying belt ordirectly into trucks.

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H.W.Carlsen pneumatic systems

System components

1 Cement is loaded at high capacity and withoutinterruption by connecting the shore-based loaderto the loading inlet of the ship.

2 Loading screw conveyorsThe cement flows via an airslide to the loading screwconveyor and is carried up to the receiving bin.

3 Loading airslidesFrom the receiving bin the cement is distributedalong the ship by loading airslides.

4 Distribution valvesThe cement is guided by a system of distributionvalves to the holds of the ship.

5 Dust collectorsThe dusty air in the holds created during theloading and unloading process is vented andcleaned by dust collectors.

6 Machine roomBlowers, vacuum pumps and compressors for theunloading process are placed in a machine room.

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7 Fluidisation systemThe blowers provide the air for the fluidisationsystem. Piping and valves distribute the air to eachsection of the system.

8 Fluidised bottomThe inclined steel bottom is covered by fabric.Fluidising the fabric sections one by one ensures a controlled flow to the centre of the hold.

9 Suction pipeThe vacuum pumps in the machine room suck the cement from the centre of the hold to thepneumatic system.

10 The D.R. systemHaving sucked the cement from the holds, thepneumatic system conveys it under pressurethrough a pipeline to the shore-based storagefacility. The Double Reloader tanks alternatebetween being vacuumed full and blown empty.

11 Control roomThe loading and unloading operations areautomatically controlled from the control room.

12 Unloading outletOutlet pipes from the unloading system are locatedon both port and starboard side. Only a rubber hoseconnection to the shore is needed.

The inside of a fluidised hold showingthe inclined bottom, fluidising fabric

and suction pipe.

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Conversion projectsThe H.W. Carlsen system is extremely suitable forconversion projects because it requires minimumchanges to the ship structure. The fluidised bottom iseasily fitted onto the existing tank top and theremaining equipment is installed above deck level.

New shipsThe H.W. Carlsen system is also very suitable for newships. The equipment is integrated into the shipstructure resulting in shorter suction distances and lessenergy consumption. The ship’s main engines used fordriving the propeller during voyage power thegenerators for the unloading system while in port.

H.W. Carlsen pneumatic systems

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Ship conversion projectThe daily costs of a ship arehigh. So the time it takes toconvert a bulk carrier into aself-discharging ship isimportant. The H.W.Carlsen systems enableshort conversion time.

The sloped bottom isprefabricated in sections,complete with piping,valves etc. This enablesrapid installation.

All other equipment is locatedabove deck. The machine roomis prefabricated complete withpiping, appendages, etc.Shipyard work is reduced to aminimum.

The fluidising fabric is easy to install.

Within 8 weeks after arriving atthe shipyard the M.V. Thai Ho(17,000 dwt) was equipped with a1,200 tph loading system and a600 tph unloading system.

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H.W. Carlsen mechanical systemThe H.W. Carlsen mechanical systemuses screw conveyors for verticaltransport and airslides or horizontalscrew conveyors for horizontalconveying. The holds are equipped withfluidised bottoms. The material flowsfrom the fluidised bottom through aflow control gate into a vertical screwconveyor. From the vertical screwconveyors the material flows throughairslides or horizontal screw conveyorson deck to the centre of the ship. Fromhere the material is conveyed on shoreeither by a mechanical outloading boomor by a pneumatic pressure system.

H.W. Carlsen offers a wide range ofmechanical systems for self-dischargingships. All systems have the fluidisedbottom and vertical screw conveyors incommon. However, layout, individualscrew conveyor capacities and redundancymay vary depending on customerrequirements. For horizontal conveyingeither airslides or horizontal screwconveyors are used, depending on theloading and unloading characteristics.

H.W. Carlsen has builtscrew conveyors for manyyears covering a widerange of applications:Mechanical ship loadersand unloaders, fixed andmobile screw conveyors,self-discharging ships, etc.

A 1000 tph vertical screwconveyor on board the M.V.Shine Ho ensures reliable highcapacity shiploading.

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1 Loading system receiver

2 Loading airslides

3 Fluidising bottom

4 Equipment casing

5 Vertical screw conveyors

6 Unloading airslides

7 Receiving hopper

8 Pressure tank system

9 Dust collectors

10 Machine room with fluidisationblowers and conveying compressors

11 Control room

System components

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Screw pump systemThe screw pump is the world’s mostwidely used pneumatic conveyingsystem, with more than 10,000 pumpshaving been supplied. The pumps can be used for many materials andapplications. Capacities up to 700 tphand conveying distances up to 1,500metres are available.

The material is conveyed to the venthopper of the screw pump. The highspeed screw conveyor compacts thematerial (effectively forming an airlock)and pushes it through a non-return valveinto the mixing chamber. In the mixingchamber the material is mixed withcompressed air and the mixture isconveyed through a pipeline to its finaldestination.

A very high number of screw pumpshave been used for self-dischargingships and river barges. Notable examplesare cement distribution barges on thebig rivers in the USA, self-dischargingships on the Great Lakes betweenCanada and the USA and ocean goingvessels. The screw pump system is bestsuited for new ships, as the pumps haveto be positioned below the fluidisedbottom of the holds. The system issimple and reliable although its energyconsumption may be higher than othersystems.

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1 Loading receiver

2 Loading airslides

3 Fluidised bottom

4 Tunnel below and between holds

5 Vent hopper

6 Screw pumps

7 Conveying pipelines

8 Machine room with compressors

9 Dust collectors

10 Control room

System components

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H.W. Carlsen ABCarl Gustafs väg 46, S-21421 Malmö, SwedenTel: +46 40 690 33 00Fax: +46 40 690 33 99E-mail: mail@hw-carlsen.comInternet: www.hw-carlsen.com

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