Bulk Materials Handling Grab Unloaders. metso. minerals

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1 Bulk Materials Handling Grab Unloaders metso minerals

Grab Unloaders Water transportation has long been the first choice for economical delivery of bulk materials, and grab bucket unloaders have traditionally served as the most viable means of unloading

2 Grab Unloaders Water transportation has long been the first choice for economical delivery of bulk materials, and grab bucket unloaders have traditionally served as the most viable means of unloading ships and barges. Maximizing these economies involves careful evaluation of many elements: physical constraints of the unloading site; types of bulk materials handled; size and configuration of vessels to be unloaded; fluctuation in water levels; environmental control requirements; and, most importantly, the total capital and operating costs. For over half a century, the Metso family of grab unloaders has offered versatility and dependability in matching unloading capacity with facility operating requirements. Handling a broad range of products at rates up to 3,400 tph, Metso traveling and fixed grab unloaders service ports throughout the world, unloading barges and ocean bulk carriers. Metso Grab Unloaders Offer: Dependability For minimized capital investment, Metso equipment provides years of dependable service with design and technology that meets the most demanding unloading facility requirements. Versatility Metso grab unloaders are designed to unload various size vessels at the same station, and our system for changing grabs makes handling different types of bulk materials simple. Further, our equipment provides unloading capabilities unaffected by fluctuation of water levels. Low Operating Costs Metso bucket control facilitates unloading of vessels with hatches and coaming. With the help of a front end loader, virtually all material in the vessel is recovered. Diverse Material Handling Capability Metso grab unloaders handle a wide range of materials, including: Coal and coke Iron ore and other ores Fertilizers Wood chips Sugar Limestone Bauxite Sulfur Phosphate Other bulk materials A Tradition of Excellence Metso s family of grab unloaders includes those of our predecessor companies: Svedala Industries McNally Wellman Dravo - Engineering Works Division McDowell Wellman Dravo Wellman Products Engineering (PECO) Mead Morrison/McKiernan Terry (MKT) Lakeside Bridge & Steel

3 Product Presentation

Proven, reliable hoists feature rugged DC motors with fast-acting, low inertia floating caliper disc brakes that adjust automatically for pad wear.

Reeving Type Features Benefits Direct Ropes terminate at grab Minimized rope wear Utilizes an auxiliary trolley in grab Easy grab changeouts for Less rope angle multiple commodities from drums In

4 Proven, reliable hoists feature rugged DC motors with fast-acting, low inertia floating caliper disc brakes that adjust automatically for pad wear. Brakes are designed with readily available components. Rope Life: A Consideration in Day-to-Day Operation Compact trolleys with low inertia provide energy savings in constant start/stop operations. Reeving Type Features Benefits Direct Ropes terminate at grab Minimized rope wear Utilizes an auxiliary trolley in grab Easy grab changeouts for Less rope angle multiple commodities from drums In Bight of Line Single ropes from drums Economical hoist Utilizes an auxiliary trolley components Economical trolley ropes and winch Fleet Thru No auxiliary trolley Reduced rear runaway Economical hoist components Economical trolley ropes and winch Recognizing rope replacement as an operating expense for grab unloaders, Metso expertly designs reeving systems that maximize rope life and minimize replacement time. Design Features Include: Hardened drum and sheave grooves that reduce wear and extend rope life Minimal rope angle from drums and sheaves Controlled acceleration that minimizes surges in rope tension and prevents sudden snatching of the bucket upon closure Rope pattern between bucket and trolley that protects rope at stress points and helps ensure bucket stability Hold and close drums with ample spare rope capacity for economic and efficient rope advancement In addition, Metso provides unloader operator training, maintenance training, and inspection to promote longer service life of the unloader.

Features and Benefits Metso Grab Unloaders are Built for Service Structural Features The cyclic operation and dynamic action of the grab unloader subjects the supporting structure to fatigue loading.

concentrations and structural vibrations Stringent quality control and inspection during fabrication as well as analysis of connections and materials to assure safe, reliable operation and a

5 Features and Benefits Metso Grab Unloaders are Built for Service Structural Features The cyclic operation and dynamic action of the grab unloader subjects the supporting structure to fatigue loading. To ensure long service life of the structure, Metso engineers incorporate: Comprehensive modeling and finite element analysis for development of a robust supporting structure free of harmful stress concentrations and structural vibrations Stringent quality control and inspection during fabrication as well as analysis of connections and materials to assure safe, reliable operation and a fatigue-resistant structure Cushioned rail pad and rail clips that reduce and distribute dynamic loads, extending service life of the structure and mechanical components Apron structure is framed with twin box girders utilizing a structural tee section directly under the trolley runway rail. This design eliminates a critical fatigue point and allows for uniform load transfer into the apron box girders. Safety Features Include: Safe and easy access to areas requiring routine maintenance as well as stairs and optional elevator to main areas of the unloader Spud locks, tie downs, and rail clamps for safe storage during maintenance or adverse weather conditions Operator s cab safety restraints and a redundant caliper brake on the boom hoist cable drum Metso offers a wide variety of grab types that simplify changeout for unloading multiple types of materials. Some grabs employ rubber-sealed lips to prevent dribble during unloading operations. The option of grab unloader pre-assembly is available to simplify installation. This option minimizes on-site erection time.

Metso s MMI makes all facets of operation simple. High-resolution graphics vividly illustrate machine status and provide the operator with useful system information.

Metso s ABC System: Optimum Safety and Efficiency Today s high-speed grab unloaders feature short duty cycles and large capacity buckets for greater unloading volume and efficiency.

6 Metso s MMI makes all facets of operation simple. High-resolution graphics vividly illustrate machine status and provide the operator with useful system information. Automatic Bucket Control automatically calculates the grab trajectory for each duty cycle and allows for automatic or semi-automatic modes of operation. Metso s ABC System: Optimum Safety and Efficiency Today s high-speed grab unloaders feature short duty cycles and large capacity buckets for greater unloading volume and efficiency. Because of the increased demand for speed in performing exacting, repetitive tasks, operators of manually controlled grab unloaders are subject to fatigue. Operator fatigue results in error, accidents, compromised efficiency - and higher operating costs. Metso grab unloaders offer a sophisticated but user-friendly control system that eliminates the risk of operator fatigue. By completely automating grab unloading operations, overall operations are maximized over longer periods of time with minimal operator stress. The Automatic Bucket Control (ABC) system utilizes state-of-the-art control system hardware and software with the most advanced features in grab control. The ABC System features: Man-Machine Interface (MMI) Computer-based graphics system links the operator and the PLC control system in a user-friendly, onscreen format. The MMI system gives the operator the ability to control virtually all machine functions and provides detailed messages regarding machine status. Bucket Trajectory Control Prior to each unloading cycle, the grab controller calculates the grab trajectory for the most efficient unloading cycle time. Continuous monitoring of this trajectory and modulated acceleration and deceleration rates of the hoist and trolley motions ensure trouble-free unloading and accurate delivery of material into the hopper.

Controls and Dust Containment Metso s ABC System Microprocessor Logic Control Improves overall operation and lends assistance in troubleshooting.

7 Controls and Dust Containment Metso s ABC System Microprocessor Logic Control Improves overall operation and lends assistance in troubleshooting. Working in conjunction with the MMI, the control logic program instantly pinpoints areas of the grab unloader system that require attention. Grab Return Control The Metso ABC System allows the operator to adjust the return position of the grab through predetermined increment buttons. Automatic Grab Closing Provides the control capability to automatically close the grab while in the material. Grab Fill Control This control varies the amount of torque on the hold drive during grab closing operation. The operator can easily adjust how deep the grab will sink into the material and control the bucket fill for each lift. Grab Load Monitor System This system monitors bucket load at the beginning of each cycle and alerts the operator in the event of an overfill condition. Hold and Close Drive Coordination While Hoisting In manual, semi-automatic, and automatic modes, this monitor and attendant circuitry balances the loading on the hoisting equipment, thus eliminating long term hoist damage from unbalanced drive loading. Speed synchronization prevents slack rope lines while lowering and ensures that the bucket is fully open. Absolute Position Encoders Grab drive position is constantly monitored by encoders connected to hold, close, rack, and travel drives. These feedback points are unaffected by power fluctuation or interruption. Ship Height Monitor A position sensor continuously monitors changes in the location of the ship s deck that result from material removal and/or tide changes. This information allows the control system to adjust for ship height without interrupting unloading operations. On-Board Modem Provides immediate communication with Metso service technicians for remote troubleshooting of system problems. Operator Control Cab From a spacious, ergonomically-designed operator chair with arm-mounted controls, the operator views a video monitor that displays status information for each grab unloader drive, up-to-the-minute help messages for fine tuning the unloading cycle, and ongoing equipment diagnostics that minimize the need for detailed troubleshooting. Meet environmental standards with Metso s patented dust containment system. Innovative Dust Containment Designed to capture dust and maximize cleanliness, Metso s integrated system of dust containment utilizes air curtains at the opening of the gantry enclosure to trap discharged material within the hopper enclosure upon bucket entry. Collection units draw dust-laden air from the hopper while filter cartridges capture fugitive dust for discharge directly into the hopper. Dust collection is integrated into the total system, requiring no separate collection hopper or support structure. The primary benefit is reduced operating costs while meeting clean environmental standards. Less ductwork, equipment, and instrumentation means lower installation costs, while lower horsepower demands and reduced maintenance translate to day-to-day savings.

8 Our Ranges: Equipment & Systems Railcar Dumpers & Positioners Bucketwheel Stacker/Reclaimers Scraper Reclaimers Ship and Barge Loaders Stackers (Radial/Linear) Grab Type Unloaders Continuous Barge Unloaders Cable Belt Overland Conveyors Self-Unloading Ship Systems Complete Systems Metso Minerals Bulk Materials Handling Engineered Products Apron Feeders Wobbler Feeders Rail Car & Barge Pullers Rail Car Indexers Ash Submerged Chain Conveyors Ash Dry Chain Conveyors Fly Ash Mixer Conditioners En-Masse Conveyors/Elevators Coal Preparation Equipment Throwers & Ship Trimmers Aftermarket Services Machine Upgrades/Retrofits Service Life Extension Projects Equipment Inspections Operations & Maintenance Training Start-Up Assistance/Commissioning Annual Service Agreements Troubleshooting Services Breakdown Assistance Replacement Parts Programs Metso Minerals Industries, Inc Grand Avenue Pittsburgh, PA USA Phone: Fax: Metso Minerals (Brazil) Ltda. Av Independencia, Sorocaba - SP BRAZIL Phone: /1636 Fax: Metso Minerals (UK) Ltd. 52, Ashton Vale Road Bristol BS3 2HQ UNITED KINGDOM Phone: Fax: Metso Minerals (Mumbai) Pvt. Ltd. Jinja Apartments Opp. Naupada P.O. Thane (West), Maharashtra INDIA Phone: /2755 Fax: Metso South Africa (Pty) Ltd. 64 Jet Park Road Jet Park, Johannesburg, 1459 SOUTH AFRICA Phone: Fax: Metso Minerals (Australia) Limited 18 Lidco Street Arndell Park NSW 2148 AUSTRALIA Phone: Fax: bulk.info@metso.com metso minerals linking innovations Subject to alteration without prior notice Brochure No MP/Pittsburgh 2002 Metso Minerals Printed in USA

Bulk Materials Handling Bucketwheel Stacker Reclaimers. metso. minerals

Bulk Materials Handling Bucketwheel Stacker Reclaimers. metso. minerals Bulk Materials Handling www.metsominerals.com Bucketwheel Stacker Reclaimers metso minerals Bucketwheel Stacker Reclaimers Metso stacker reclaimers offer the most technologically-advanced list of standard