High Capacity Dust-Free Barge Loading
Port Safaga located on the Red Sea in Egypt is 53 km south of Hurghada. The port is owned and operated by Egypt’s Ministry of Transportation and is an vital export for the country’s economy.
In 2012 the Ministry of Transportation concluded that the current ship loader configuration no longer met the environmental needs that were required. This in large part was due to archaic telescopic loading spout with no dust collection. The result of this configuration led to the entire port being engulfed in a phosphate dust cloud.
DCL was awarded the project in 2013 to supply new load out equipment to Port Safaga. Our experience in ship loading and local representative Tech Trade guaranteed they would be able to provide the Ministry of Transportation the equipment that was needed to meet their goals. Tech Trade acted as the general contractor for the project and acquired an experienced crew to remove the existing loading spout and install the new equipment.
The key requirements for the project were:
- Load pulverized phosphate rock with fines at 1000 MTPH in to open ships.
- Keep new equipment weight at a minimum so that existing mounting structure did not need to be modified.
- Maintain EPA type compliance with little to no visible dust emissions.
- The new load out equipment would need to interface with existing controls system.
The single direction pivoting gimbal mounts below the head chute of the belt conveyor and directly above the compact filter module. The purpose of the gimbal is to provide a articulating point between the boom and the load out equipment. The gimbal allows the load out equipment to remain vertical when the boom is luffed.
Compact Filter Module
The model CFM1618 in line compact filter module which was designed specifically for this project was constructed from aluminum in order to keep the overall weight of the equipment to a minimum. The compact filter module was sized at 6,000 CFM with a 5.68:1 air/cloth ratio. Installing the compact filter module directly above the loading spout eliminated all duct work and the dust that is collected by the filter module is reintroduced back into the product flow.
To construct the load out, three pieces of equipment were custom designed and engineered for the Port Safaga application – a pivoting gimbal, in line compact filter module and retractable loading spout.
Retractable Loading Spout
The OV66HD-45 designation refers to “open vehicle” specific loading with a heavy duty structural steel frame drive assembly. There is 45 feet of vertical travel with an outer sleeve diameter of approximately 66″. The OV66HD-45 features a three cable design that runs from three lifting pulleys through a series of transfer sheaves. Safety features of the OV66HD-45 include two over-travel limit switches and three strain switches that are located at the lifting cable ends. If the safe working load is exceeded, then an alarm will alert the operator and power will be cut from the lifting spout hoist circuit. For example, if the discharge of the spout is caught under a barge lid as it is being retracted, the additional weight of the lid would trigger the alarm. The spout is designed to load at 1000 MTPH, the internal components that control the flowing column of material were sized to handle the high volume and the outer flexible sleeve was sized to limit the carrying velocities.
The OV66HD-45 is equipped with a “Deadfall” dust suppressor at the discharge of the spout. The “Deadfall” is a unique DCL design that allows dusty materials to be loaded into open barges and ships. The design involves no mechanical or electrical components eliminating maintenance and points of failure.