Bulk material handling is an engineering field that is centered on the design of equipment used for the handling of dry materials. Bulk materials are those dry materials which are powdery, granular or lumpy in nature, and are stored in heaps. [1] Examples of bulk materials are minerals, ores, coal, cereals, woodchips, sand, gravel, clay, cement, ash, salt, chemicals, grain, sugar, flour and stone in loose bulk form. It can also relate to the handling of mixed wastes. Bulk material handling is an essential part of all industries that process bulk ingredients, including: food, beverage, confectionery, pet food, animal feed, tobacco, chemical, agricultural, polymer, plastic, rubber, ceramic, electronics, metals, minerals, paint, paper, textiles and more.
Major characteristics of bulk materials, so far as their handling is concerned, are: lump size, bulk weight (density), moisture content, flowability (particle mobility), angle of repose, abrasiveness and corrosivity, among others. [1]
Bulk material handling systems are typically composed of stationary machinery such as conveyor belts, screw conveyors, tubular drag conveyors, moving floors, toploaders, stackers, reclaimers, bucket elevators, truck dumpers, railcar dumpers or wagon tipplers, shiploaders, hoppers and diverters and various mobile equipment such as loaders, mobile hopper loaders / unloaders, various shuttles, combined with storage facilities such as stockyards, storage silos or stockpiles. Advanced bulk material handling systems feature integrated bulk storage (silos), conveying (mechanical or pneumatic [2] ), and discharge.
The purpose of a bulk material handling facility may be to transport material from one of several locations (i.e. a source) to an ultimate destination or to process material such as ore in concentrating and smelting or handling materials for manufacturing such as logs, wood chips and sawdust at sawmills and paper mills. Other industries using bulk materials handling include flour mills and coal-fired utility boilers.
Providing storage and inventory control and possibly material blending is usually part of a bulk material handling system.
In ports handling large quantities of bulk materials continuous ship unloaders are replacing gantry cranes.
Non-bulk materials handling classifications include palletization and containerization.
A hopper car (US) or hopper wagon (UIC) is a type of railroad freight car that has opening doors on the underside or on the sides to discharge its cargo. They are used to transport loose solid bulk commodities such as coal, ore, grain, and track ballast. The hopper car was developed in parallel with the development of automated handling of such commodities, with automated loading and unloading facilities.
Bulk cargo is commodity cargo that is transported unpackaged in large quantities.
A silo is a structure for storing bulk materials.
The Port of Ashdod is one of Israel's three main cargo ports. The port is located in Ashdod, about 40 kilometers south of Tel Aviv, adjoining the mouth of the Lachish River. Its establishment significantly enhanced the country's port capacity. It handles the largest volume of cargo containers annually of all Israeli ports. Ships carrying humanitarian aid for the Gaza Strip also unload their cargo at Ashdod.
A variable rate feeder is a piece of industrial control equipment used to deliver solid material at a known rate into some process.
TAKRAF Group (“TAKRAF”), is a global German industrial company. Through its brands, TAKRAF and DELKOR, the Group provides equipment, systems and services to the mining and associated industries.
Rotary feeders, also known as rotary airlocks or rotary valves, are commonly used in industrial and agricultural applications as a component in a bulk or specialty material handling system. Rotary feeders are primarily used for discharge of bulk solid material from hoppers/bins, receivers, and cyclones into a pressure or vacuum-driven pneumatic conveying system. Components of a rotary feeder include a rotor shaft, housing, head plates, and packing seals and bearings. Rotors have large vanes cast or welded on and are typically driven by small internal combustion engines or electric motors.
Material handling equipment (MHE) is mechanical equipment used for the movement, storage, control, and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption, and disposal. The different types of equipment can be classified into four major categories: transport equipment, positioning equipment, unit load formation equipment, and storage equipment.
A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transport of heavy or bulky materials. Conveyor systems allow quick and efficient transport for a wide variety of materials, which make them very popular in the material handling and packaging industries. They also have popular consumer applications, as they are often found in supermarkets and airports, constituting the final leg of item/ bag delivery to customers. Many kinds of conveying systems are available and are used according to the various needs of different industries. There are chain conveyors as well. Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys.
Transloading, also known as cross-docking, is the process of transferring a shipment from one mode of transportation to another. It is most commonly employed when one mode cannot be used for the entire trip, such as when goods must be shipped internationally from one inland point to another. Such a trip might require transport by truck to an airport, then by airplane overseas, and then by another truck to its destination; or it might involve bulk material loaded to rail at the mine and then transferred to a ship at a port. Transloading is also required at railroad break-of-gauge points, since the equipment can not pass from one track to another unless bogies are exchanged.
A concrete plant, also known as a batch plant or batching plant or a concrete batching plant, is equipment that combines various ingredients to form concrete. Some of these inputs include water, air, admixtures, sand, aggregate, fly ash, silica fume, slag, and cement. A concrete plant can have a variety of parts and accessories, including: mixers, cement batchers, aggregate batchers, conveyors, radial stackers, aggregate bins, cement bins, heaters, chillers, cement silos, batch plant controls, and dust collectors.
Heyl & Patterson Inc. is an American specialist engineering company, founded in 1887 and based in Pittsburgh, Pennsylvania.
Open wagons form a large group of railway goods wagons designed primarily for the transportation of bulk goods that are not moisture-retentive and can usually be tipped, dumped or shovelled. The International Union of Railways (UIC) distinguishes between ordinary wagons and special wagons (F/6). Open wagons often form a significant part of a railway company's goods wagon fleet; for example, forming just under 40% of the Deutsche Bahn's total goods wagon stock in Germany.
A shiploader is a large machine used for continuously loading bulk solid materials such as iron ore, coal, fertilizers, grains and/or material in bags onto ships or barges. These machines are located in ports and jetties to facilitate bulk material exportation. Generally shiploaders are engineered to suit specific project requirements. Those requirements often include: port design, material characteristics, loading capacity, vessel type, local law, and budgetary limitations. A shiploader mainly consists of a central column, an extendable arm or boom, a belt conveyor extending out of the boom structure, a slewing mechanism, and a loading chute to transfer product from a source conveyor or feeder. The boom can move front and back, up and down by separate drives so that it can fill the whole breadth of the ship hold and adapt to the ships increasing draught while it is loaded.
AUMUND Fördertechnik GmbH, commonly known as Aumund, is a German producer of conveying technology and is headquartered in Rheinberg, district of Millingen. The company was founded in 1922 by Professor Heinrich Aumund and is today managed by his grandson, Franz-Walter Aumund. Aumund nowadays has around 390 employees, 10 branches worldwide and a wide network of local representatives.
The Victorian Railways in Australia have had a vast range of hopper-type wagons over the last century, for transporting anything from grains through fuel to various powders.
Grain damage is any degradation in the quality of grain. In the current grain trade, this damage can affect price, feed quality, food product quality, and susceptibility to pest contamination. Between the field and the end use, grain may go through any number of handling operations which can each contribute to grain damage. For example, grain might encounter free fall, conveyors, spouts, grain throwers, elevators, hoppers, dryers, and many more. Overall, these handling methods can be evaluated as to what effect they have on the grain. Damaged grain can often be characterized by the extent to which it reduces storage time. For example, cracked or broken kernels are more susceptible to insect or bacteria as well as chemical degradation. The damage to the actual grain is only one example of losses incurred after harvest. In order to quantify grain damage, one must also understand grain quality. Grain quality is a very broad term and can relate to many topics such as foreign material, chemical compositions, mechanical damage, insect infestations, and many more. These references to quality are highly dependent on the end use of the grain. Certain types of damage may be acceptable to specific industries, whereas others cannot use grain with these issues.
A stabilized soil mixing plant is a combination of kinds of machines used for mixing stabilized soil, which is used for highway construction, municipal road projects, and fertile airport areas. The plant produces stabilized soil with different gradings in a continuous way. Such a plant usually contains a cement silo, measuring and conveying system, and mixing devices.
A Helix Dumper is a rail transport and unloading solution, designed for continuous rolling discharge of bulk commodities. Originally developed for the iron ore industry, the Helix Dumper system can handle many types of fine-grained and potentially sticky commodities. When the Helix Dumper wagon enters the unloading area, a wheel at the top of the wagon makes contact with the spiral-shaped rigid guide that constitutes the unloading station. As the wheel travels along the path of the guide, the wagon chassis remains on the rails while the body of the wagon is rotated 148 degrees to dump its load. After the rotation, the direction of the guide changes and the wagon body is returned to its normal position. The Helix Dumper has a discharge rate of up to 25,000 tonnes per hour.
Transmin is an Australian privately owned company specialising in bulk materials handling equipment and related products headquartered in Malaga, Western Australia, 15 kilometres north of Perth, Western Australia, that provides engineered equipment, supplies and services to the mining-resources and bulk material handling industries, in Australia and overseas.