Martin Bakker, Van Aalst Bulk Handling B.V., the ... · new and very innovative cement import ... tender process and the decision-making. ... to Holderbank Switzerland to get a letter

Holcim and Van Aalst Bulk Handling are currently working together to build two new and very innovative cement import terminals in New Zealand. One is located

in Timaru on the South Island and one in Auckland on the North Island. Once the terminals are up and running, expected in 2016, Holcim will cease cement production in New Zealand. Van Aalst Bulk Handling won the order to deliver the main equipment and engineering for the terminals. This is a very important flagship project for both Holcim and

Van Aalst. This article presents an explanation of the tender process and the decision-making.

In October 2013 Van Aalst Bulk Handling received the tender documents from Holcim. ”When the first tender documents for the import terminals in New Zealand arrived at our office, we were overwhelmed by the size of the project. This is a big project!” says Sales Manager Hans van Est. “After studying the papers, we came to the conclusion that we had delivered a similar terminal in Tampa, USA, in 2006, which gave us a confident feeling about

Martin Bakker, Van Aalst Bulk Handling B.V., the Netherlands, provides some insight into the project with Holcim New Zealand

to build two new cement import terminals.

the project. We knew the ins and outs and could offer ship unloaders with the lowest weight possible, which was extremely important due to local circumstances. We realised that we had done this before.” Hans van Est continues: “With our project knowledge and the fact that Van Aalst Bulk Handling has supplied to Holcim before, we were able to offer specific solutions to make the terminal more effective in terms of quick connection of ship unloaders and dust control at the ship unloading, loading and dome storage.”

For both Holcim and Van Aalst Bulk Handling it is very important to take responsibility for the global environment and to provide clean working surroundings. Holcim is also very focused on safety for their people. The Van Aalst equipment meets this need and is particularly focused on these areas. The company is always interested in improving its environmental footprint and has spent a lot of time on innovations that lead to lower power consumption and reduced dust emissions, which is key when dealing with harbour restrictions and regulations. It is good for the planet, but of course it also benefits the total cost of ownership.

“The cement storage domes will have a capacity of 30 000 t each. Van Aalst will design and manufacture the aerated floors of the domes. The reclaim is based on ‘first in, first out’ so Holcim will always deliver their customers the highest quality cement possible,” explains Arno van Aalst, the Managing Director of Van Aalst Bulk Handling.

The storage dome will be filled with cement during ship unloading. The dome has been developed in such a way that all (with 99% reclaim guarantee) cement can be extracted fully automatically with aerated floors. This design means that the cement will flow and act like water and therefore all cement will be able to float out of the storage domes. The domes and filters that prevent dust escaping into the atmosphere are designed with the environment in mind. This is combined with a consideration for the maximum freedom of personnel and other port activities during ship unloading,

Figure 1. High capacity rail mounted equipment in Tampa, USA.

Figure 2. A 600 tph ship unloader supplied by Van Aalst Bulk Handling.

Reprinted from February 2015 \ World Cement

ship loading and truck loading activities – and of course, the entire port design meets the highest international standards. This is an important project; all eyes will be on these highly sustainable import and export terminals designed by Van Aalst Bulk Handling according to Holcim New Zealand’s logistic setup.

Van Aalst will also manufacture two pneumatic ship unloaders with nominal 600 tph unloading capacity for each terminal. The unloaders will unload the ship and then the cement will be blown through pipelines to the storage domes over a distance of 230 m in Timaru and 450 m in Auckland. The unloaders are self-propelled and can move over the jetty from manifold to manifold to connect the system within a few minutes from another location, unloading from a different hold of the ship.

The various demands of the local surroundings, the environment and the industry in the harbour have been given serious consideration. Holcim is very committed to Corporate Social Responsibility and is mindful of the impact on the local community. Therefore a pneumatic suction principle was preferred, as this way of unloading an open cement cargo carrier is efficient, effective, economical and of course will minimise emissions. The equipment will effectively eat its own dust, so there is negligible air pollution.

In March 2014 a site visit in America was planned. Holcim was accompanied by representatives from Van Aalst Bulk Handling Corp. in the US to visit the equivalent setup in Florida. “The visit to the terminal in Tampa convinced both parties that this was exactly what is needed at both locations in New Zealand. It was there and then that we decided we wanted to do this project together – of course with all technical standards from today and modifications where necessary – but the fact was that this was the kind of terminal that was needed in New Zealand,” Hans van Est explains.

The flexible solution and greater freedom to integrate the conveying discharge pipelines was preferred over conveyor belts and other open logistic solutions. Therefore Van Aalst has designed the optimum convey and air pipeline, which is integrated in both existing harbour ports. Note that the harbour port in Timaru will be completely renewed by Downer New Zealand, a large local construction contractor commissioned by Holcim.

Van Aalst Bulk Handling in the Netherlands has integrated the best optimum dimensions for the ship unloading activities as well as a ship loading facility at Timaru terminal only. The Timaru Port is therefore configured to be an optimal green import and export terminal for cement (distribution) around the South and North Island.

The biggest challenge for the Auckland terminal is the weight and wheel (rail wheel load) loads on the existing railways, which have not been used for

Figure 3. Hydraulic clamping device for quick manifolds changing.

Figure 4. Conveying from dome to truckload station.

Reprinted from February 2015 / World Cement

more than 30 years. The ship unloader will unload open cargo cement carriers of about 35 000 dwt with a capacity of over 600 tph, so meeting the restrictions of the limited rail wheel loads is a challenge.

A big advantage of these ship unloaders is the extremely economical and user-friendly operation that leads to low power consumption, low maintenance and significant operational cost savings. They are designed for the lowest weight, as well as less weight in the electrical parts, including the electrical cable wheel. They are also developed for optimum safe and user-friendly operation according to the latest innovative technology by Van Aalst.

In June the Van Aalst sales team went to Holderbank Switzerland to get a letter of intent (LOI) for this project. Holcim’s project management and procurement team attended the meeting. The scope of supply was made definite and technical details were discussed. After signing the LOI in Switzerland, Van Aalst immediately started engineering to be ready to go ahead. In August 2014 the contract was formally signed and work could begin.

In November 2014, Van Aalst Bulk Handling was invited by Holcim to attend the ground-breaking ceremony for

the new terminals in New Zealand. The technical departments met and the Van

Aalst team was introduced to all stakeholders. The whole team is enthusiastic and everyone is working together to achieve the best possible import terminals.

Figure 5. Overview of a similar terminal built in 2006.

Reprinted from February 2015 \ World Cement