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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Today  new steel, power and cement plants are being set up in India and the capacity of existing plants is being expanded. In a steel plant we need to unload approx. 3 tons of raw materials like coal, iron ore, dolomite, limestone etc. for producing one ton of steel. Since all the above raw materials are transported by railway wagons, the tandem tippler is an ideal solution to unload rakes at the high rate of more than 3500 tons per hour making effective use of limited railstock, smaller rail yard area and limited rail lines connecting to the main railway network.

This is a special constraint for landlocked steel plants which want to expand the steel production. For their new three million ton steel plant project at Kalinganagar, Odisha, Tata Steel have incorporated two tandem and two single C-type rotary tipplers in the scheme to unload about nine million tons of the above mentioned raw materials. This will be the first installation of tandem tipplers in Indi­a.

The new tandem tipplers will unload two 140 ton (gross weight) wagons at a time at the rate of 25 tips per hour. The supplied tipplers are designed as per the latest RDSO guidelines and can tipple all types of existing box type wagons as well as the proposed DFC and feeder route wagons, to be introduced in the near future for coal and iron ore transportation. For a bulk export terminal, where we have to load ships in the minimum possible time, tandem tipplers can play a pivotal role for unloading trains carrying coal, iron ore etc. at higher rates and make effective use of limited railstock, smaller rail yard area and limited rail lines connecting to main railway network.

Recent trend of installing mega and ultra mega power plants, has increased daily coal requirement of power plants substantially. For a 4000 MW power plant, the typical coal requirement may be up to 40 000 or 45 000 tons per day. To cater for such high requirements, again rotary tandem tipplers will satisfy this requirement by unloading at rates of approx. 3500 to 5000 tons per hour in eight to twelve hours. One can achieve a capacity between 10 and 15 million tons per year with a single rotary C-frame type tandem tippler.

2.    Tandem Tippler Installation and Operation

There are two types of tandem rotary tipplers: ”O”-type and “C”-type tipplers.

The C-type tandem tipplers are more popular nowadays due to its C-shaped frame - open at one side which allows side arm charger to travel through the tippler and place loaded wagons on the tippler platform while pushing empty wagons out of the platform where they help to form the empty rake on outhaul side.

O-type tipplers are more popular in the countries where railstock is provided with rotary coupling – here it is not necessary to decouple the wagons during tippling. These tipplers can achieve very high tippling cycles of up to 45 tips per hour. Wagon placement on O-type tipplers is done using rope driven side arm chargers.

As rotary couplings on wagons do not require de-coupling higher tip rates are feasible. This advantage can be derived only in rotary tipplers. Wagons with rotary couplers, however, are not actually not utilized in India. Hence the O-type tippler is not popular.

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