Originally Posted by nugie.forume

Dear Experts;

My company dealing with solid handling either in raw materials and finished product.

Raw materials imported from abroad are unload from our jetty using a Continuous Ship Unloader

and a Kangaroo Crane (grab type), transported by integrated conveying system or truck to our

raw materials storage.

The raw materials we are using namely Phosphate Rock, Potassium Chloride (MOP); Sulphur.

We are producing many type of fertilizer such as Ammonium Sulphate, NPK, DAP, and

Double/Triple Superphosphate, Urea.

We sell our product also in bulk from our jetty to the customer.

Formerly we are selling our product in bag (@50 kg bag or @1 tonn bag).

Due to the increasing demand, we start to sell our product intensivelly in bulk form.

Unfortunatelly, we face and realize many losses during handling in bulky form.

We plan to improve our performance in bulk handling, but in the other hand

we do not have any "accepted" figures or references as a best practice related

with losses in bulk handling; e.g. how many percentage acceptable losses allowed

(best practice) bulk handling from cargo to storage?; how many percentage acceptable

losses allowed (best practice) bulk handling during in-bound logistic (transfer from

one storage to another storage)?; etc.

Therefore; we'd like to have the information related with our problems from the Experts.

Thank you

Nugroho Christijanto

Production GM

PT Petrokimia Gresik, Indonesia

nugie.forume@gmail.com or nugrohochris@petrokimia-gresik.com

Like football its a matter of meters and centimeters.

Your Cost accounting department and your weight slips/lading

are what are going to tell you how much money you are making and how

much you may be losing from fugitive dust,

The issue is more of what your delivery system consists of as

well as what your inbound reclaim system also consists of.

The issue is either control of or capture of fugitive dusts and the

total amount of loss from fugitive dusts from ingredients and then

from the finished product.

If your handling methods are creating a lot of fugitive dust you

need to hire a consultant to design and implement a vacuum system that

will capture the fugitive dust and reclaim it for you to place it back in the

product streams. The other issue is pollution of the water and land nearby

due to the raw material stream inbound and the dust created by the chemical

conversion and the packaging systems.

If you are using open mouth bagging systems they will create fugitive dust that

is usually carried away by a vacuum system in the weigh in loss bins or

bagging/sacking bins.In our old plant the salt dust was blown into and piped into the basement

of the mill and later removed with a fire hose before the mill plant was changed.

the only way to detemine the losses is to back track and detemine the two differences of weights and then

examine the return on investment as well as the internal rate of return after the consultant examines your systems. ■

Well, bulk material handling operations are present in most places where loose unpackaged commodities are shipped, stored or transferred between modes of transportation. Losses can result in damage to both the material and the handling equipment, which includes ship, barge, rail car, and trailer loaders and unloaders, silos, bucket elevators, conveyors, augers, weighing systems and environmental controls. These losses are often further complicated by costly business interruptions.... ■

Originally Posted by silliker

Well, bulk material handling operations are present in most places where loose unpackaged commodities are shipped, stored or transferred between modes of transportation. Losses can result in damage to both the material and the handling equipment, which includes ship, barge, rail car, and trailer loaders and unloaders, silos, bucket elevators, conveyors, augers, weighing systems and environmental controls. These losses are often further complicated by costly business interruptions....

Dear Friend,

In bulk material handling some loss of material is inevitable due to various reasons.

The loses depends on the mode of handling. This loss is termed as handling loss,which goes up to 5% depending on the type of cargo and mode of handling.

A large portion of spilled material can be salvaged.

While handling by grab type unloaders/wharf cranes there is a large spillage from grab.By providing spill plate the spilled material is salvaged.

Continuous unloaders with totally covered conveyors (Screw type unloader),loses are minimized.

The yard conveyors which cannot be covered and open Stacking and Reclaiming operations results in losses due to wind.

When the material is costly one, all operations are done in covered shed with opening for entry and exit conveyors and all out side conveyors are covered.

Rgds,

Narayanan Nalinakshan. ■

Airborne losses are quite low in Jatim so you can leave those till last.

Do you have spillage from conveyors?

Do you have a mobile hopper to receive grab discharge?

Is there access for mechanised spillage clean up?

Is you process machinery adequately sealed?

Do you have to close the ship hatches when it rains? This gives an insight into the dust collection regime which I purposely postponed.

As for the requested mathematics you have to rely on figures and observations within your pupuk competition. These forums cannot advise what are the acceptable loss levels for fertiliser production. One man's plant is another man's weed, botanically speaking.

Bulk handling engineers design for a no spillage operation and then should also design for acceptable spillage recovery. All salesman will tell you they can provide a clean plant, it's their job. ■

Originally Posted by johngateley

Airborne losses are quite low in Jatim so you can leave those till last.

As for the requested mathematics you have to rely on figures and observations within your pupuk competition. These forums cannot advise what are the acceptable loss levels for fertiliser production. One man's plant is another man's weed, botanically speaking.

Bulk handling engineers design for a no spillage operation and then should also design for acceptable spillage recovery. All salesman will tell you they can provide a clean plant, it's their job.

Agree completely with the comment! I depends much on the company and the crew, although conditions in the contract still matter. ■

Adhering to some general recommended practices for the storage and handling of bulk lubricants can greatly improve the chances of having healthy machines with long service lives. .. ■