Speeding up Wagon Unloading

Conveying & Transportation

Speeding up Wagon Unloading

C-Frame type Tandem Rotary Tippler and Transfer Platform for high capacity Wagon Unloading in India
Railway transport is one of the most important means of transport for huge amounts of dry bulk solids. Often, train unloading is a bottle neck of such systems. A solution to this problem is presented in this article.
(ed. WoMaMarcel - 13/2/2015)
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Tandem wagon tipplers have been employed extensively to achieve higher unloading rates and improve the utilisation of existing railway infrastructure.

Countries with high rate of economic growth like China, Brazil, Russia are constantly upgrading their port infrastructure to meet increasing demand for import and export of various bulk materials. Tandem wagon tipplers have been employed extensively to achieve higher unloading rates and improve the utilisation of existing railway infrastructure. In China at the Huanghua coal export terminal six tandem rotary tipplers supplied by ThyssenKrupp have been installed to achieve export figures of 80 million tons of coal per year.

Each tippler at this port simultaneously unloads two rail freight box type wagons, with a payload of 60 to 70 tons each, at a rate of up to 33 cycles per hour, thus unloading an average 4000 tons of coal per hour with a maximum capacity of 4500 tons per hour.

At the port of Tubarao in Brazil, five tandem tipplers supplied by Thyssen­Krupp are in operation - each having a   handling capacity of two 120 ton (gross weight) wagons with rotary coupler at 45 dumping tips per hour of iron ore.

Similarly at Ust Luga, one of the largest ports in Russia, two tandem tipplers are installed to unload coal at the rate of 3500 tons/hour each for export of Russian coal.

1.    Indian Scenario

In India, as per old railway guidelines (RDSO - Research Design and Standards Organisation), the dumping capacity of tipplers was limited to not more than 20 tips/hour. Hence side discharge tipplers having a maximum of 20 tips per hour were popularly used to unload material from railway wagons of 110 tons gross weight in ports, power, steel and cement plants. Rotary tipplers have been less popular in India in the past, as it calls for four to five meters deeper underground civil construction than side discharge tipplers. Especially for small scale projects, civil construction costs grew to a considerable percentage of total project cost.

The energy requirements of side discharge tipplers are much higher due to the lift and shift type operation while unloading the box wagon. They require heavy counterweights to even out the mechanical effort. In contrast, rotary tipplers are energy efficient as they rotate the wagon about its center of gravity. No counterweights are necessary in this case.

Side discharge tippler design is not suitable for more than 27 to 28 tips per hour and also is not amenable to tipple more than one wagon at a time.

As per the new RDSO guidelines effective from December 1, 2010, the number of tips has been increased to more than 25 tips per hour for both side discharge and rotary tipplers to achieve higher unloading capacity and more turnarounds of rakes per year. These new guidelines now also permit the use of single as well as tandem wagon tipplers.

Indian economy is growing at a rapid pace creating a high demand for raw materials by steel, cement and power plants. It is necessary, therefore, to improve the utilization of the available railstock and railway network as it is the main source of transport for bulk materials. Thus necessity is felt to introduce high capacity tandem tipplers in India.

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