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Ship Loading and – Unloading Technology made by FAM – Förderanlagen Magdeburg

Combined Shiploader for Gujarat Cement Works

This shiploader was delivered and commissioned in 1995. The shiploader is used to load bagged and bulk cement as well as clinker into ships with a maximum size of 50,000 dwt. The loader can handle 2400 bags/hour (Fig.1) or, if converted to the bulk handling line and equipped with the bulk loading head, it can handle 1650 t/h of clinker or 600 t/h of bulk cement (Fig.2).

Fig.1: Combined shiploader with the spiral chute for 50 kg cement bags, handling capacity 2400 bags/hour

One of the special task was the request to be able to change between bag loading and bulk loading arrangement in less than one hour. Thus the loader is equipped with two intermediate conveyors (one flat for bags and one troughed for bulk material). The materials can be distributed to the correct conveyor by a hydraulically driven flat curved conveyor. The bulk material is then fed through a chute in the middle of the slewing point of the boom. The bags are transported to a turntable and are then pushed onto the loading conveyor of the boom. This design avoids any need for adjustments while changing from bag to bulk loading. The loading equipment is either a spiral chute for the bags or a telescopic chute for cement and clinker supplied by FAM.

Fig. 2: Combined shiploader with the telescopic chute for bulk cement 600 t/h or clincer 1650 t/h

These chutes can be changed by a special yoke-type support design. This design allows the chute to be easily placed on the support tower after using quick disconnects for the electrical supply and control lines. After placing one chute on the resting tower the other one can be easily taken from the tower by using the same method in reverse.
FAM had not only engineered the shiploader themselves but had to manufacture the entire loader in their own workshops on special request of the customer.

Radial Quadrant Shiploader for Los Pelambres' Port Punta Chungo

The commissioning of the radial quadrant shiploader supplied by FAM at the Port of Punta Chungo (Los Villos - Chile) took place at the end of 1999. The shiploader is the final loading end of the new Los Pelambres copper mine which was taken into operation in 1999 (Fig.3).

Fig. 3: Radial quadrant shiploader for the Los Pelambres Project – Chile

The loader receives the material from the storage hall in the port area which is also equipped with FAM conveying equipment. The loading capacity is 1900 t/h of copper ore. The loader has a slewing and shuttling function by travelling drives and a luffing function of the main boom by a winch and rope system.

Fig. 4: Ship loading with FAM radial quadrant shiploader, handling capacity 1900 t/h copper ore

The radius of the main bridge is 80 m and the longest extend boom length is 135 m (Fig.4). Special design features had to be taken to cope with the severe earthquake load requirements and to avoid any copper ore spillage into the surrounding sea.
(We will introduce the entire installation in more detail in a later issue of this magazine).

Ship Loading and Unloading Terminal for Cement Works in Vietnam

In 1999 FAM – Magdeburger Förderanlagen- und Baumaschinen GmbH supplied several loading and unloading units for seagoing ships to Nghi Son Corporation in Vietnam as well as the necessary project engineering and the pertinent conveying equipment and the de-dusting systems. Nghi Son Corporation is a joint venture between Vietnam National Cement Corp., Thaiheiyo Cement Corp. and Mitsubishi Materials Corp..
The new works of Nghi Son Corp. is, with a performance in excess of 2 million tonnes of cement, currently the biggest in Vietnam. It is located around 210 km to the south of the capital Hanoi.

The equipment supplied by FAM comprises the main component of a complete harbour facility built around 1.5 km off the coast with a pier for supplying the cement works with raw material and for loading the final products onto ships (Fig.5).

Fig. 5: Ship loading and unloading installations built around 1,5 km off the coast

Various bulk materials such as coal, iron ore, bauxite and gypsum are unloaded on the pier and cement and clinker in loose form or packed into bags are loaded onto seagoing ships.
To deal with these tasks, FAM GmbH supplied a ship unloader in the form of a double-arm luffing and slewing crane, a ship loader for bags and a ship loader for loose cement. Furthermore, the delivery was supplemented by a chain breaker unit, several vibrating conveyors and an over-belt magnetic separator.

All parts of the plant are designed in compliance with the ambient conditions such as high air humidity, aggressive sea air, strong sun radiation and extreme monsoon rains. The equipment was designed taking into consideration the targets of a high level of availability and technical safety.

The pier design

The facilities consist of an offshore concrete island with a length of approx. 50 m and a width of around 19 m. At both longitudinal sides seagoing ships can be loaded and unloaded simultaneously. The ship unloader is located at a central position on the supply building of the pier in such a way that it is able to reach both longitudinal sides of the pier for unloading (Fig.6).

Fig. 6: The ship unloader with grab located at the central position, is able to reach both sides of the pier. The shiploader for bags is located at the ride along side and the bulk loader at the left side.

To the right and left alongside the building there are a ship loader for bags and a ship loader for loose cement. The ship loader for bags loads ships up to a max size of 5,000 t. The ship loader for loose cement is able to load ships of sizes up to 35,000 t. A conveyor with a length of around 2.7 km was installed by the client for transporting the raw material and the cement between the cement works and the pier. The cement and bags are conveyed to the pier on the upper strand for loading and the lower strand is employed to convey the bulk materials from the pier to the cement works.
Due to the limited space available in the building, all pieces of equipment were adjusted exactly in their dimensions to their location thus optimally exploiting the space on the pier.
Electrics using state-of-the-art regulating and control equipment ensure efficient functioning of all devices under varying demands. Safety limit switches, path limiters and other complex monitoring systems show the importance given to safety equipment on the devices during engineering.

Shiploader SL 1100.23 SXL for Cement

The steel structure of the main frame of the ship loader for cement is likewise designed in large pipe construction and with solid web box girders. The boom for taking up the Aerobelt conveyor consists of lattice construction. The device is located stationary next to the building (Fig.6).
The loose cement is conveyed over the feed belt from the cement works onto the pier. From there it is transferred into a chain bucket elevator unit with a capacity of 1100 t of cement per hour. The bucket elevator unit conveys the material to a total height of around 20 m above the level of the pier which then moves on to the Aerobelt conveyor via a central feed. In order to ensure a low level of dust during loading there is a telescopic chute at the tip of the boom with a de-dusting system. The max. reach of the device is 24.5m. The device can be used within a slewing range of +/-180°. A winch similar to the ship loader for bags is also employed here.

FAM completed the engineering in a relative short order realisation time and manufactured all technologically demanding sub-assemblies on their own production equipment. This made it possible to ensure a consistent high level of quality and to react quickly to the wishes of the customer.
The customer assembled the equipment himself in its entirety on site under the direction of supervising erection engineers from FAM. This ensured that the plant was erected on time and complying with the relevant quality standards in co-operation with the client and with the prerequisites given by the experience made by the project partners in preparation and implementation of erection work on large-scale construction sites in Asia.