As core hubs for the transshipment of bulk materials such as ores, coal, aggregates, and cement, ports currently still face challenges including: traditional fixed equipment’s inability to adapt to multiple types of trucks and ship models, severe dust pollution during bulk material transshipment, difficult operation and maintenance (O&M) coordination among multi-brand equipment, and long cross-border supply cycles for spare parts. With 22 years of experience as a professional manufacturer and EPC (Engineering, Procurement, Construction) general contractor deeply engaged in the bulk material conveying equipment field, Zoomry Heavy Industry has developed the “Port Bulk Material Handling Solution: truck unloader Combined with Mobile Ship Loader” based on its in-depth understanding of overseas port scenarios. This solution fundamentally solves the bulk material handling challenges of overseas ports.
Core Requirements for Port Bulk Material Handling
Adaptability to Bulk Materials and Ship Models: Overseas ports often handle bulk materials with different physical properties, such as nickel ore (moist, sticky, and prone to clogging), coal (dust-prone), and aggregates (high hardness). They also need to accommodate various ship models, ranging from Barges (100-5000 DWT – Deadweight Tonnage) and Handysize vessels (10000-35000 DWT) to Capesize vessels (80000-120000 DWT). The operating height (usually ≤10m) and handling capacity (≤800 tph – tons per hour) of traditional fixed ship loaders cannot meet the needs of large-tonnage ships, requiring additional transshipment links that increase costs.
Site and Terrain Constraints: Some ports in Southeast Asia and Africa are old-aged terminals with narrow spaces and poor ground flatness. The installation of fixed equipment requires large-scale civil engineering (e.g., concrete foundation pouring), which not only incurs high investment costs (accounting for over 40% of the total project cost) and a long construction period (6-12 months) but also fixes the equipment in place, making it unable to adjust to dynamic changes in the port’s operation areas.
Environmental Compliance Pressure: Markets such as the EU, Japan, and South Korea have strict standards for dust emissions (e.g., the EU CE certification requires a dust concentration of ≤10mg/m³) and noise control (≤55dB – decibels). Traditional open-type unloading and ship loading equipment easily cause dust dispersion and high-decibel noise, which may lead to port fines or production suspension for rectification. Meanwhile, overseas ports have high requirements for equipment safety redundancy to prevent sudden failures such as belt deviation and wire rope breakage.
Spare Parts Supply Bottlenecks: Ports using multi-brand equipment often encounter issues such as incompatible control systems and inconsistent O&M standards. Additionally, the cross-border transportation cycle for spare parts can be as long as 1-3 months. Once core components (e.g., idlers, rollers) are damaged, equipment downtime increases, directly affecting bulk material transshipment efficiency.
Integrated Equipment Solution
Zoomry’s integrated “Truck Unloader + Mobile Ship Loader” solution, centered on “seamless connection, flexible adaptation, and efficient compliance”, enables “one-stop” transshipment of bulk materials from trucks to ships through the coordinated operation of two core types of equipment. Meanwhile, it ensures long-term stable operation relying on self-developed core components.
Mobile Truck Unloader
As a key member of Zoomry’s radial stacker product line, the mobile truck unloader is specifically designed to address the connection pain points between “trucks and port conveying”. It is available in both wheeled and tracked configurations (models include wheeled ZRLS-TU1400/ZRLS-TU1800 and tracked ZRLD-TU1400/ZRLD-TU1800), with core features fully adapted to the needs of overseas ports:
High Capacity: Handling capacity ranges from 200 to 1800 tph, with a belt width of 1400-1800mm, compatible with mainstream 30-50 ton dump trucks. The hopper width supports customization from 3.5m to 5.7m, and it is equipped with a low-tail feeding design, allowing feeding without adjusting the truck’s position and adapting to auxiliary equipment such as wheel loaders and excavators.
All-Terrain Flexible Mobility: Wheeled models adopt extra-heavy-duty tires, suitable for operations on hardened roads; tracked models are equipped with high-adhesion tracks, enabling free movement on muddy terrain and steep slopes (≤15°) without the need for additional hardened road paving, significantly reducing the port’s initial transformation costs.
Sealing and Anti-Clogging Design: Rubber skirts are installed at the bottom of the hopper, reducing the material spillage rate to below 0.3%; an optimized built-in grille filters large impurities (e.g., ores with a diameter >200mm) to prevent clogging; for moist and sticky bulk materials (e.g., nickel ore in Indonesia), customized heated hopper walls can be provided to prevent material sticking to the wall and caking.
Intelligent and Convenient Control: Supports radio remote control (control distance ≤100m), enabling simultaneous operation of 2-4 truck channels; the ramp angle can be adjusted manually or hydraulically (max. 6.7°) to adapt to truck compartments of different heights, reducing manual intervention and increasing unloading efficiency by over 30%.
Mobile Ship Loader
Zoomry’s mobile ship loader (ZRSL series), focused on “full ship model coverage and intelligent compliance”, can be directly connected to the mobile truck unloader to achieve seamless transshipment of bulk materials from unloading to ship loading:
Flexible Adaptability: Compatible with ship models ranging from 100-5000 DWT Barges, 10000-35000 DWT Handysize vessels to 80000-120000 DWT Capesize vessels, with an operating clearance height ranging from 0 to 16m. It features radial rotation (max. 110°), telescoping (boom length ≤50m), and luffing functions, enabling precise material distribution according to the cargo hold position and full-hold loading without moving the ship.
Efficient Conveying: Adopts PLC (Programmable Logic Controller) fully automatic “wind-shielded stockpiling” technology, reducing material segregation and breakage rate to below 0.5% while minimizing dust dispersion. The belt adopts a sealed design, and combined with non-powered dust-collecting chutes, the dust emission concentration is ≤8mg/m³ and the noise level is controlled below 45dB, fully compliant with EU CE and Russian EAC environmental standards.
Safety and Convenience: Equipped with dual safety guarantees – mechanical self-locking within 0.01 seconds in case of wire rope breakage, and automatic shutdown when belt deviation occurs. The equipment can be disassembled into modular components and loaded into 40-foot HQ (High Cube) containers, reducing overseas transportation costs by 20%. On-site assembly takes only 10-20 days, and Zoomry provides on-site guidance by engineers to shorten the project implementation cycle.
Long Service Life: Core drive components use SEW/FLENDER gear motors (optional), with energy consumption 15% lower than that of traditional ship loaders. Rollers are made of 40Cr forged steel (diameter ≥200mm), undergoing ultrasonic flaw detection and stress relief treatment, with a service life exceeding 50,000 hours, reducing equipment downtime for maintenance.