Flexible Rail transport of Fly Ash

AshTrans 2013 Copenhagen
HT5 a successful application of
intermodal supply chains for
flyash
Dean Reilly
September 2013
The challenge
The ISO-Veyor
Intermodal logistics
Flexibility/Quality
Drivers for
substitution
towards
intermodal
containers
Cost
Environment
• Ensure JIT deliveries
• Containers allow “floating” stock and flexibility in supply chain
• Via alternative routes or local storage service/cost balance
can be tailored to specific customer needs
•
•
•
•
More cost effective than road (long distance) or bags/drums
Higher payloads possible
Storage in containers can be more effective than silos/tanks
Unstable factors in road transport (fuel costs, driver shortage,
congestion)
• Reduces road transportation (CO2 emissions)
• Taking loads from roads creates public and customer goodwill
Intermodal Supply – Capital Costs
Capital
employed
( € / t)
100
Dedicated Equipment
and Silos
80
60
40
7 8
ISO-Veyors
20
4 5 6
0
1 2
3
20
40
60
Cost base for infrastructure
80
100
# days
Economics during global recession
As producers of materials cut costs and
close plants
•Increased substitution from bag to bulk
•Material moving further to market –
intermodal efficiencies
•Increasing focus on sustainable supply
chains and reduced environmental impact
of transport
•Increasing trend for outsourcing
•Reduced investment in fixed silos
ISO-Veyors
First contract award based on 3 way
trial between the following intermodal
pneumatic tank manufacturers
InBulk had the biggest payload
InBulk discharged in the shortest time
ISO-Veyor had least residue left
behind
Types of pneumatic conveying
Rugby - T5 Project
ISO-Veyor launch
Heathrow Terminal
5 Project
The largest construction
project in Europe at the
time. T5 was an innovative
and extremely complex
multi-modal
transport
interchange designed to
meet the challenges of the
21st century and handle up
to 30 million passengers a
year.
Laing O’Rourke
Programme manager and
principle contractor
The scale of the project
Fly Ash coming from 200 miles
away in Nottingham
Overall build project was 1.2
m3 of concrete
135,000 tonnes of fly ash was
required
Project lasted for over 2 years
Rugby - T5 Project
Reachstacker transfer empty
units from storage to rail
Train with empty
ISO-Veyors arrives
at West Burton to
be filled
Rugby - T5 Project
Train load of empty
ISO-Veyors positions
itself under the 2500
tonne silo at the power
station rail head
Dustless loading system
provides rapid filling of
ISO-Veyors with each
container taking less than
10 minutes to fill.
Rugby - T5 Project
Train departs on 200
mile journey to London
Train arrives into the
Colnbrook logistics hub
Rugby - T5 Project
Full units are lifted from
rail
On site - full units can
be delivered to the silos
at the batching plant or
stacked and used for
buffer storage
Rugby - T5 Project
Discharge into batching
silos
ISO-Veyors stacked 2
high – Flexible
weatherproof storage
Rugby - T5 Project
Driver controlled
deliveries – fast
effective discharge
Empty units transferred from
skeletal raod trailer back to
rail using sidelifting trailers
Rugby - T5 Project
Transfer of empties from
rail to road using side
lifting trailer for return
journey
Stacked storage option using ISOVeyors
Rugby - T5 Project
Key figures:- 4000 discharges (0ver 120 trips per unit)
135,000 tonnes of fly ash
Road Miles saved: 4000 trips x 330 miles = 1,320,000 miles
Rugby Cement won the UK Supply Chain Good Citizen award
A tremendous springboard to launch InBulk
Cemex
Original Rugby units used by Cemex for special projects
Cemex
Lafarge
Contracts with Lafarge
in UK and North
America
Further discussions
taking place for:
Fly Ash
Cement
Ferrous Sulphate
GGBS
White Cement
Holcim
•
ISO-Veyors working in the heart of the Swiss Alps for Holcim AG
Heidelberg
• Successful trials
• Ferrous Sulphate business going
to Castle Cement in the UK
• New project beginning with
Hansons in the UK for fly ash
going from Drax to Oxfordshire
Oilfield Projects
• Strong global partner in MI SWACO
• For onshore and Offshore
opportunities for barite, bentonite
and cement transfers
• Projects include Tukey, Trinidad,
Greenland, South Korea
• Global agreement signed with MI
SWACO and parent company
Schlumberger
• DNV unit being developed for 2014,
meeting needs for offshore
segregation of specialist products
Product Developments
• Use of plastic membranes to
reduce weight, enable the
unit to handle very fine
powders and use for food
products.
• Rubber discharge pipes to
handle very fine powders
such as micro-silica
• Construction in stainless steel
for chemicals and food.
• Pneumatically loaded manlid
option
Patents
InBulk Technologies has taken
steps to protect Intellectual
property via patents
21 Patents applied for
World wide approvals and
certification
ASME
Worksafe
DOSH
Summary
•InBulk is a recognised brand and we have secured business with the top
cement companies in the world
•Strong economic drivers to intermodal prevail
•Strong environmental and Sustainability drivers prevail
•Supply Chain issues caused by consolidation will be solved by logistics
and greater distances to market
•ISO-Veyor proven to be robust and durable
•No other intermodal unit available that matches performance and is non
tipping.
Thank you!
www.interbulkgroup.com