ibauhamburg marine cementterminals -...

IBAU HAMBURG

A MEMBER OF THE HAVER GROUP

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IBAU HAMBURGMarine

CementTerminals

The IBAU HAMBURG Marine cement terminals

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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 largegaps in capital chargesbe explained?

The gap between a60,000 tons flat storagewarehouse and a domestorage of equal size isapproximately 2.5 to3 million US Dollars.The gap between variousship unloading systems

can 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 also mighthave different uses: oneterminal might be usedonly for loading cementonto trucks, others alsofor loading cement furtheronto river barges, ontorailway waggons or intobags.

Even when all thesefactors are taken into con-sideration there can stillbe a large gap of capital,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 costs 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 terminal

investments are possible.In a payback calculationthe investment costs forthe required storagecapacities and shiploading/unloading ratesare essential as are timeschedules 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.

Flat storage

Dome system

Central cone silo system

Mobile mini terminal

Floating terminal

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Information

Illustration of a floating terminal

FloatingterminalsFloating 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 60,000 t.On deck of the floatingterminals ship unloadingsystems are installed.The cargo holds can bedesigned as a self dis-charging unit. Ideally thecargo holds can be usedfor the storage of differenttype of materials like fly

ash, GGBS or mixedcement. They are tied upat a dock in the entry portand can be operated with-out any shore facilitiesto handle cement andtransport it directly ontrucks/rail cars. Withintegrated packers, bothbulk and bagged cementcan be handled. With a

floating terminal it ispossible to enter a portand start operationsimmediately, without landlease or constructionpermission.

Charter costs, port feesand handling expensesmight make this optionunattractive.

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Mini terminalsIf no intermediate storage isneeded a road mobile shipunloader can be used forloading cement directly ontotanker vehicles. Theseship unloaders are used forcement carriers of up to10,000 dwt for relativelylow handling frequenciesat several locations.Trailer-mounted mobileship unloaders require ahigh degree of manoeuvra-bility. Starting from thetransport position IBAUMobile ship unloadersare ready for use in only20 minutes.

Regardless of their size theship unloaders have up tofour separate screwconveyors. Vertical screw1 picks up the materialassisted by a counter-rotating outer screw.Vertical screw 2 raises thematerial to the conveyingheight required for onwardtransport.

Screw 3 provides thehorizontal transport fromthe hold to the materialtransfer point, its highestefficiency being reachedwith a downward slope. Afourth screw (loading screw)loads the material directlyinto a silo trucks.

It is possible to traversescrew conveyors 1 to 3 sothat all areas of the hold canbe reached from a givenposition. As a result theindividual screws can betilted or rotated within fixedangles.

In conclusion, the completeunloading is made possibleby the unique IBAUHAMBURG technology.


Stationary ship unloader at Bamberg Harbour, Germany

Road-mobile ship unloader in Saudi Arabia

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Road-mobile ship unloader for Betoncem, Port of Savona, Italy

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Port-mobile ship unloader for Tong Yang Cement Corporation, Korea

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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 IBAUSilos of 18 m diameterand 42 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.


Export terminal for GOLIATH, PORTLAND CEMENT, Devonport, Australia

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Information

Marine Cement Terminal for Cement Industries (Sabah) Lahad Datu, Malaysia

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Marine Cement Terminal for Cementa A.B /

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HeidelbergCement Group, Malm, Sweden

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Cement carrier during loading at the Brunsbttel terminal, HOLCIM, Germany

Terminal with steel silos for SACIMA, Port of Longoni, Mayotte Island, France

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Information

Cement import terminal for CEMEX, Pichilingue, Mexico

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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 kWh/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


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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.

Information

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Flat storageFlat storage terminals arebest suited for medium to long-term service.

This is a low cost solu-tion, especially whenan existing warehousecan be converted into amaterial storage installa-tion or if the buildingsneed to be used later forother purposes.

The short time required tobring about the necessaryapprovals and the shortbuilding times alsofavour this concept.

The technology that hasto be integrated is themost sensible part of flatstorage systems. The mostcommon method is to usefront end loaders insidethe dust- tight building.

The front end loaderreclaims the cementmechanically and trans-ports it to a collectinghopper.

From the collecting hop-per a vertical transport toa separate building fortruck or railcar reloadingis usually 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, IBAUHAMBURG has installeda fully automated cementdischarge system for thereloading of 200 t/hcement, 24 hours a dayand 7 days a week.


Illustration of a

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Information

flat storage terminal

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Ship unloader feeding a flat storage hall, DECIROM, Constanza, Rumania

Flat storage hall for BUZZI UNICEM spa., Ravenna, Italy

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Information

BUZZI UNICEM SPACasale, Italy

CEMENT TERMINALWITH 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

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View of the tunnel between the compartments of the flat storage hall

Compartment with fluidslides installed on the bottom

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The flat storage terminalis designed for 30,000 tonsof cement in a 4,750 m3building. The partitionwalls for the cement hallare made of prefabricatedconcrete, the storageheight is about 6-7m.

The floor is fullyequipped with standard-ized fluidslides anddivided into 18 sections,6 of which alwaystransport the cement toa horizontal screwconveyor, located in a45 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 sectionscan be fluidised and emp-tied one after the other.Pressure switches and

level indicators over thecomplete area ensure fullyautomated feeding anddischarge. A similar flatstorage terminal wasbuilt for BUZZI Cementin Ravenna, Italy.

Flat storage hall, Golden Bay Cement, Auckland, New Zealand

ConclusionTerminal concepts byIBAU HAMBURGare based on a varietyof advanced andreliable mechanicaland pneumaticsystem components.Existing equipmentcan mostly be tied-in.

Technical compe-tence and engineeringfrom a single sourcecontribute tofinding the mostcost-effectivetechnical solutionfor each project andto ensure thesubsequent function-ing of the entireterminal system.

Information

Flat storage

Dome system

Central cone silo system

Mobile mini terminal

Floating terminal

short construction timelow cost solution

no shore facilitiesattractive for boomingmarkets

minimum footprintlow operation and labor cost

less foundation work

minimum of investment

06/12/MarineCem

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

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