Lower costs, increased capacities: recommissioned road-mobile unloaders deliver on all counts

2 Sep 2024

Headquartered in Muscat, Oman, Pioneer Cement LLC, is among the leading suppliers of construction materials in the region. With dynamic business operations located in Oman, the United Arab Emirates (UAE), Kuwait, Turkey, and Tajikistan, its responsiveness to the changing market demands of the cement industry is key. 

Noticing the need for greater capacity, but also flexibility, efficiency, and environment-friendly dry bulk handling, Pioneer Cement required a new cement ship unloading solution. This came in the form of a pair of previously-owned Siwertell road-mobile ship unloaders, one 5 000 S and one 10 000 S.

Strategic unloading lowers costs

The road-mobile units offer the company a unique combination of asset agility and market-leading through-ship efficiency, and are capable of deploying within an hour of arriving at the quayside. They move between the ports of Suwaiq, Sultan Qaboos, and Sur in Oman, directly discharging cement to bulk trucks. The longest distance covered is around 350km, between the ports of Suwaiq and Sur.

“Siwertell technology provides several operational advantages for Pioneer Cement,” explains Saeed Taghdisi, Technical Manager, Pioneer Cement. “One of the key benefits lies in its ability to significantly reduce the logistics costs associated with cement unloading. 

“With the Siwertell road-mobile unloaders, we have the flexibility to seamlessly relocate them between different ports, optimizing our operations to accommodate varying vessel sizes and the proximity of our customers to these ports. This flexibility allows us to strategically select the most efficient port for delivering cement to specific customers, ultimately leading to a reduction in the product’s final price,” Taghdisi notes.

“The acquisition of the Siwertell ship unloaders aimed to transform the transfer of cement from cement carrier vessels to general cargo ships,” he adds. “Cement carriers have transportation capacity limitations and incur high costs. Thanks to the utilization of these road-mobile unloaders, bulk cement can now be transported with increased capacity and at lower costs.”

Good fit for cruise ports

Regulations at regional, national and international levels rightly seek to ensure more environment-friendly dry bulk transfers, while port-specific requirements for clean and quiet procedures can place direct pressure on operators to improve their environmental performance. 

A Siwertell ship unloader is totally enclosed, offering spillage-free dry bulk cargo handling, with virtually no dust creation. They are also quiet, making them ideal for operations in close proximity to residential, business and leisure areas, while their high efficiency makes them market leaders in terms of energy consumption per ton of material handled.

The road-mobile systems are an excellent fit for Pioneer Cement’s port locations. Taghdisi notes the particular benefits of this technology for one specific location. “Sultan Qaboos Port, situated in the Muttrah district near the center of Muscat, is primarily a passenger port with frequent cruise ship traffic. This poses a unique challenge for dry bulk handling activities, which we were able to address seamlessly.”

Positive early feedback

“I am excited to share more about our operational success,” continues Taghdisi. “With the Siwertell 10 000 S road-mobile unloader, the efficiency and smooth operation of this equipment has been truly remarkable. We have successfully utilized it to unload cement vessels at the Sultan Qaboos Port.”

Pioneer Cement’s process is tailored to the size of the vessels it receives. “For smaller vessels, we utilize the 5 000 S unloader, which efficiently handles the unloading process, and the larger unloader solely handles larger vessels,” he adds.

“We find that the optimal unloading performance of the 5 000 S unloader is when it unloads cement from vessels weighing less than 5,000 tons. Its smaller size makes maneuvering during the unloading process much more convenient,” Taghdisi explains.

“Our cement transportation system is intricately tied to the price of cement in export ports and destinations. To enhance our market presence, we are actively studying the development of new ports in Oman, such as Sohar and Duqm, where high deadweight tonnage (DWT) vessels can unload cement efficiently. In these ports, we anticipate the need for unloaders with higher capacities, such as the 15 000 S, to handle the increased volume effectively.

“Furthermore, we are exploring new opportunities in several other ports in the UAE and Qatar, and foresee potential expansion into African markets in the near future. By leveraging these strategic acquisitions and expansions, we aim to fortify our position in the region and capitalize on emerging opportunities for growth,” highlights Taghdisi.

Running like new

Road-mobile unloaders offer flexibility and efficiency, and along with small footprints, low quayside weights and quality builds, meaning that they retain their value and are prized on the second-hand market.

Pioneer Cement could see this opportunity and made the decision to purchase and recommission the previously-owned units, turning to expert original equipment manufacturer (OEM) input from Bruks Siwertell to ensure that they were operating at peak efficiency. 

“When the road-mobile unloaders were initially inspected, I saw that there were some wear parts in need of replacement, as well as a number of other improvements required for long-term operational performance,” says Jonas Hansen, Senior Surveyor, Bruks Siwertell. 

For example, one of the systems had been running without the counter-rotating inlet feeder for some months. This is not recommended, as this component optimizes the draw of material into the conveyor for faster, more efficient dry bulk unloading.

“On the 10 000 S, we also found hardened cement inside the inlet and encasing part of the screw conveyor,” says Hansen. “This is not unexpected for a cement unloader operated over a long interval without maintenance. Fortunately, the crew and I were able to remove the inlet and clean the cement off, restoring it to working order on site without having to order a replacement. We recommend that the bottom bearing is changed for this operation every 300 hours and we actually pushed through about 15kg of grease to clean the top bearing of the inlet.”

Pioneer Cement values proactive equipment service. It is embarking on a regular, thorough maintenance regime to keep the ship unloaders performing well and understands how good service impacts performance. “Thanks to the well-designed Siwertell ship unloader and Pioneer Cement’s rigorous maintenance program, we have achieved a commendable level of efficiency in cement unloading, with minimal dust emissions,” says Taghdisi.

“Additionally, we have invested in new technology from Bruks Siwertell, enabling us to use augmented reality (AR) glasses for maintenance tasks under the supervision of Siwertell experts at its service center. This ensures the quality of our maintenance work,” he highlights.

Resilient, reliable design

Siwertell ship unloaders are renowned for their market-leading longevity, reliability, low maintenance costs, and replaceable wear parts. 

“The robust and heavy-duty design of Siwertell unloaders plays a crucial role in minimizing maintenance costs,” says Taghdisi. “This durability ensures that the unloading systems operate efficiently over an extended period, thereby reducing the need for frequent repairs and maintenance, which can otherwise incur substantial expenses.

“In summary, Siwertell technology not only streamlines our logistical operations, but also contributes to cost savings through its resilient design, ultimately enhancing our competitiveness in the market,” he concludes.