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Bulk Materials Handling

www.metsominerals.com

Grab Unloaders

metso
minerals
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Grab Unloaders
Water transportation has long been the first choice Low Operating Costs
for economical delivery of bulk materials, and grab Metso bucket control facilitates unloading of vessels
bucket unloaders have traditionally served as the with hatches and coaming. With the help of a front
most viable means of unloading ships and barges. end loader, virtually all material in the vessel is
Maximizing these economies involves careful recovered.
evaluation of many elements: physical constraints of
the unloading site; types of bulk materials handled; Diverse Material Handling Capability
size and configuration of vessels to be unloaded; Metso grab unloaders handle a wide range of materi-
fluctuation in water levels; environmental control als, including:
requirements; and, most importantly, the total capital
and operating costs. • Coal and coke
For over half a century, the Metso family of grab • Iron ore and other ores
unloaders has offered versatility and dependability in • Fertilizers
matching unloading capacity with facility operating • Wood chips
requirements. Handling a broad range of products at • Sugar
rates up to 3,400 tph, Metso traveling and fixed grab • Limestone
unloaders service ports throughout the world, • Bauxite
unloading barges and ocean bulk carriers. • Sulfur
• Phosphate
Metso Grab Unloaders Offer: • Other bulk materials
Dependability A Tradition of Excellence
For minimized capital investment, Metso equipment Metso’s family of grab unloaders includes those of our
provides years of dependable service with design and predecessor companies:
technology that meets the most demanding unloading
facility requirements. • Svedala Industries
• McNally Wellman
Versatility • Dravo - Engineering Works Division
Metso grab unloaders are designed to unload various • McDowell Wellman
size vessels at the same station, and our system for • Dravo Wellman
changing grabs makes handling different types of bulk • Products Engineering (PECO)
materials simple. Further, our equipment provides • Mead Morrison/McKiernan Terry (MKT)
unloading capabilities unaffected by fluctuation of • Lakeside Bridge & Steel
water levels.
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Product Presentation
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Proven, reliable hoists feature rugged DC motors with fast-acting, low inertia floating caliper disc brakes that adjust automatically for pad wear.
Brakes are designed with readily available components.
Compact trolleys with low inertia provide energy savings in constant
start/stop operations.
Reeving Type Features
Direct • Ropes terminate at grab
• Utilizes an auxiliary trolley
• Easy grab changeouts for
multiple commodities
In Bight of Line • Single ropes from drums
• Utilizes an auxiliary trolley
Fleet Thru • No auxiliary trolley
Rope Life: A Consideration in
Day-to-Day Operation
Recognizing rope replacement as an operating
expense for grab unloaders, Metso expertly designs
reeving systems that maximize rope life and minimize
replacement time.
Design Features Include:
• Hardened drum and sheave grooves that reduce
wear and extend rope life
• Minimal rope angle from drums and sheaves
• Controlled acceleration that minimizes surges in
rope tension and prevents sudden “snatching”of the
bucket upon closure
Benefits • Rope pattern between bucket and trolley that
protects rope at stress points and helps ensure
bucket stability
• Minimized rope wear
in grab • Hold and close drums with ample spare rope
• Less rope angle capacity for economic and efficient rope
from drums advancement
• Economical hoist In addition, Metso provides unloader operator training,
components maintenance training, and inspection to promote
• Economical trolley longer service life of the unloader.
ropes and winch
• Reduced rear runaway
• Economical hoist
components
• Economical trolley
ropes and winch
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Features and Benefits

Metso Grab Unloaders are Built for Service

Structural Features
The cyclic operation and dynamic action of the grab
unloader subjects the supporting structure to fatigue
loading. To ensure long service life of the structure,
Metso engineers incorporate:
• Comprehensive modeling and finite element
analysis for development of a robust supporting
structure free of harmful stress concentrations and
structural vibrations
• Stringent quality control and inspection during
fabrication as well as analysis of connections and
materials to assure safe, reliable operation and a
fatigue-resistant structure
• Cushioned rail pad and rail clips that reduce and
distribute dynamic loads, extending service life of
Metso offers a wide variety of grab types that simplify changeout for
the structure and mechanical components unloading multiple types of materials. Some grabs employ rubber-sealed
• Apron structure is framed with twin box girders lips to prevent dribble during unloading operations.
utilizing a structural tee section directly under the
trolley runway rail. This design eliminates a critical
fatigue point and allows for uniform load transfer
into the apron box girders.

Safety Features Include:

• Safe and easy access to areas requiring routine
maintenance as well as stairs and optional elevator
to main areas of the unloader
• Spud locks, tie downs, and rail clamps for safe
storage during maintenance or adverse weather
conditions
• Operator’s cab safety restraints and a redundant
caliper brake on the boom hoist cable drum

The option of grab unloader pre-assembly is available to simplify

installation. This option minimizes on-site erection time.
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Metso’s MMI makes all facets of operation
simple. High-resolution graphics vividly
illustrate machine status and provide
the operator with useful system
information.
Automatic Bucket Control automatically calculates the grab trajectory for each duty cycle and allows for automatic or semi-automatic modes of operation.
Metso’s ABC System: Optimum Safety and Efficiency
Today’s high-speed grab unloaders feature short duty
cycles and large capacity buckets for greater unloading
volume and efficiency. Because of the increased
demand for speed in performing exacting, repetitive
tasks, operators of manually controlled grab unloaders
are subject to fatigue. Operator fatigue results in error,
accidents, compromised efficiency - and higher
operating costs. Metso grab unloaders offer a
sophisticated but user-friendly control system that
eliminates the risk of operator fatigue. By completely
automating grab unloading operations, overall
operations are maximized over longer periods of time
with minimal operator stress.
The Automatic Bucket Control (ABC) system utilizes
state-of-the-art control system hardware and software
with the most advanced features in grab control.
The ABC System features:
Man-Machine Interface (MMI)
Computer-based graphics system links the operator
and the PLC control system in a user-friendly, on-
screen format. The MMI system gives the operator the
ability to control virtually all machine functions and
provides detailed messages regarding machine status.
Bucket Trajectory Control
Prior to each unloading cycle, the grab controller
calculates the grab trajectory for the most efficient
unloading cycle time. Continuous monitoring of this
trajectory and modulated acceleration and decelera-
tion rates of the hoist and trolley motions ensure trou-
ble-free unloading and accurate delivery of material
into the hopper.
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Controls and Dust Containment

Metso’s ABC System Operator Control Cab

From a spacious, ergonomically-designed operator
Microprocessor Logic Control chair with arm-mounted controls, the operator views a
Improves overall operation and lends assistance in video monitor that displays status information for
troubleshooting. Working in conjunction with the MMI, each grab unloader drive, up-to-the-minute help
the control logic program instantly pinpoints areas of messages for fine tuning the unloading cycle, and
the grab unloader system that require attention. ongoing equipment diagnostics that minimize the
need for detailed troubleshooting.
Grab Return Control
The Metso ABC System allows the operator to adjust
the return position of the grab through predeter-
mined increment buttons.
Automatic Grab Closing
Provides the control capability to automatically close
the grab while in the material.
Grab Fill Control
This control varies the amount of torque on the hold
drive during grab closing operation. The operator can
easily adjust how deep the grab will sink into the
material and control the bucket fill for each lift.
Grab Load Monitor System
This system monitors bucket load at the beginning of
each cycle and alerts the operator in the event of an
overfill condition.
Hold and Close Drive Coordination While
Hoisting
Meet environmental standards with Metso’s patented dust
In manual, semi-automatic, and automatic modes, this containment system.
monitor and attendant circuitry balances the loading
on the hoisting equipment, thus eliminating long term Innovative Dust Containment
hoist damage from unbalanced drive loading. Speed
synchronization prevents slack rope lines while Designed to capture dust and maximize cleanliness,
lowering and ensures that the bucket is fully open. Metso’s integrated system of dust containment utilizes
air curtains at the opening of the gantry enclosure to
Absolute Position Encoders
trap discharged material within the hopper enclosure
Grab drive position is constantly monitored by upon bucket entry. Collection units draw dust-laden
encoders connected to hold, close, rack, and travel air from the hopper while filter cartridges capture fugi-
drives. These feedback points are unaffected by power tive dust for discharge directly into the hopper. Dust
fluctuation or interruption. collection is integrated into the total system, requiring
Ship Height Monitor no separate collection hopper or support structure.
A position sensor continuously monitors changes in
The primary benefit is reduced operating costs while
the location of the ship’s deck that result from material
meeting clean environmental standards. Less duct-
removal and/or tide changes. This information allows
work, equipment, and instrumentation means lower
the control system to adjust for ship height without
installation costs, while lower horsepower demands
interrupting unloading operations.
and reduced maintenance translate to day-to-day sav-
On-Board Modem ings.
Provides immediate communication with Metso
service technicians for remote troubleshooting of
system problems.
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Metso Minerals Bulk Materials Handling
Our Ranges: Equipment & Systems
Railcar Dumpers & Positioners
Bucketwheel Stacker/Reclaimers
Scraper Reclaimers
Ship and Barge Loaders
Stackers (Radial/Linear)
Grab Type Unloaders
Continuous Barge Unloaders
Cable Belt Overland Conveyors
Self-Unloading Ship Systems
Complete Systems
metso
minerals
linking innovations™
Subject to alteration without prior notice Brochure No. 1318-03-02-MP/Pittsburgh
Engineered Products
Apron Feeders
Wobbler Feeders
Rail Car & Barge Pullers
Rail Car Indexers
Ash Submerged Chain Conveyors
Ash Dry Chain Conveyors
Fly Ash Mixer Conditioners
En-Masse Conveyors/Elevators
Coal Preparation Equipment
Throwers & Ship Trimmers
Metso Minerals Industries, Inc.
4800 Grand Avenue
Pittsburgh, PA 15225-1599
USA
Phone: +1 412 269 5000
Fax: +1 412 269 5030
Aftermarket Services
Machine Upgrades/Retrofits
Service Life Extension Projects
Equipment Inspections
Operations & Maintenance Training
Start-Up Assistance/Commissioning
Annual Service Agreements
Troubleshooting Services
Breakdown Assistance
Replacement Parts Programs
Metso Minerals (Brazil) Ltda.
Av Independencia, 2500
18087-050 Sorocaba - SP
BRAZIL
Phone: +55 15 219 1625/1636
Fax: +55 15 219 1680
Metso Minerals (UK) Ltd.
52, Ashton Vale Road
Bristol BS3 2HQ
UNITED KINGDOM
Phone: +44 117 978 6200
Fax: +44 117 923 1603
Metso Minerals (Mumbai) Pvt. Ltd.
Jinja Apartments
Opp. Naupada P.O.
Thane (West), Maharashtra 400 602
INDIA
Phone: +91 22 545 2751/2755
Fax: +91 22 545 2760
Metso South Africa (Pty) Ltd.
64 Jet Park Road
Jet Park, Johannesburg, 1459
SOUTH AFRICA
Phone: +27 11 961 4100
Fax: +27 11 397 5086
Metso Minerals (Australia) Limited
18 Lidco Street
Arndell Park NSW 2148
AUSTRALIA
Phone: +61 2 8825 1670
Fax: +61 2 8825 1799
www.metsominerals.com
Email: bulk.info@metso.com
©2002 Metso Minerals Printed in USA