Digital Re-print - January | February 2012

Increasing storage capacity

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FEATURE

FEATURE

INCREASING
by Kevin Groom Technical Director at Bentall Rowlands, Scunthorpe, UK

STORAGE CAPACITy
range to meet the requirements of an everchanging market. Within its portfolio it manufactures a variety of silos such as flat bottomed silos, to complement this Bentalls also produces an extensive range of silo accessory equipment and on floor storage equipment. All design and manufacture is done in-house making sure that bespoke solutions can be offered and that they design to Eurocode, DIN and various Seismic requirements.

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entall Rowlands Storage Systems are renowned worldwide for their designing, manufacturer and installation of grain storage silos and ancillary equipment. For example, PMR Contracts Limited silos, supplied by Bentall Rowlands survived the Christchurch earthquake, which flattened most other silos in the city. Bentalls specialise in the production of turnkey storage, storage handling, storing seeds, cereals, malts, oilseeds, grains, pellets, rice and in general for the agriculture/agro-industry, biofuels and biomass. It has worked with many of the UK’s cooperative central stores as well as worldwide, such as Woldgrain Storage Ltd, PMR Contracts Ltd and GBH Mombasa. The company markets its product range through an extensive dealer network for the agricultural market and through specialist companies for industrial projects. Close relationships with key raw material suppliers allow a program of continual product improvement. Improving product quality and supply by utilising the latest raw material technology ensures it stays ahead of the rest by supplying quality steel at competitive product prices. Bentall Rowlands has an extensive product

Utilising the latest steels available
The need for larger and larger stores worldwide to house grain, plastics and biofuels etc, has led Bentalls to invest in a new plant and equipment to be able to cope and lead the way in utilising the latest steels available. Bentalls keeps in close contact with the major steel producers who are constantly developing high strength low alloy steels together with the standard G600 coated galvanised steel, which has started to pay dividends as end users are becoming aware of the need for trouble free storage, which can last decades as well as natural disasters. The life expectancy is based on category C3 which is urban inland/mild coastal which has a corrosion rate of 1.35 microns per year; this is before any maintenance is required. Because of this advance in the strength of steels, Bentalls has been able to supply large diameter silos

and hoppers keeping to safety standards and margins, one of which is Tanzania, this 32.0m diameter silo is planned for 100,000 tonnes of storage. Also 13.0m diameter hoppers have been built in Uganda, which is the largest so far. Demand for bulk storage and handling equipment is being increased worldwide. Growing volumes and competitive pricing in grain handling charges require efficient solutions. After the unloading of ships, road or rail vehicles, the bulk materials are typically held in intermediate storage in bulk storage bins before onward conveying or processing. Bins balance the flow of materials between the stages of raw material intake, production of intermediates and end products and holding the finished products prior to shipping. One of the biggest challenges of the century is to supply food worldwide. Every year, millions of tonnes of grain are collected stored and handled. More storage systems are being built worldwide to help prevent raw material losses, as this is the most important commodity, as harvests have thrown challenges up year upon year. This has made storage systems increase their quality to help preserve the products.

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Woldgrain Storage Ltd is one of Bentall’s UK-based customers after supplying them with 14 silos and 11 hoppers for the conGrain

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FEATURE

“Demand for bulk storage and handling equipment is being increased worldwide. Growing volumes and competitive pricing in grain handling charges require efficient solutions”

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struction of Project Valiant, with a 20.0m diameter silo going up in May 2011. They are one of the largest grain trading companies within the UK. Woldgrain Storage Ltd was established in 1980 and is currently a 57,000-ton grain storage facility, situated at the foot of the Lincolnshire Wolds. The facility has been added to and been brought up to date over the past few years, as intake and discharge rates are increasing rapidly and combines, lorries and the speed of movement have all got bigger and faster.

With the expansion of the facility it means that it will only take 20 minutes to turnaround each truck from weighbridge to weighbridge whereas it used to take 50-55 minutes to do the same thing, creating a more cost effective turnaround and avoiding the situation of trucks waiting to go out and come in, as time is money. The primary function of the business is to operate as a ‘Farmers Co-operative’, with the storage space being owned by the share holding membership. The Co-operative nature of the business means Woldgrain operates on a non-profit making basis. Woldgrain has just completed phase II of a major expansion programme, named Project Valiant that has seen the capacity rise to 57,000 tonnes, for which Bentall Rowlands supplied 14 silos and 11 hoppers of varying diameters. A grant from EMDA for 1.5 million of the capital cost, allowed for the building of an advanced processing facility with 2 new intake pits, 2 high capacity driers and a new colour sorter. This gives new and existing members a competitive advantage in the market place when it comes to marketing their grain. The facility will be further enhanced in Phase III of the Valiant Project. This is currently at the planning stage and will feature high capacity cleaners and additional storage space. The facility is already helping growers gain added value through cooperation, ensuring economies of scale and delivering vendor-assured grain to food producers and processors. A lot of central stores restrict the intake
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FEATURE to one or two product lines but Woldgrain don’t. They will take anything a member is growing, provided it is in a sufficient quantity. This is popular within members as there can be up to 15-16 different commodities to segregate, but this entices the local farmers to buy into the central store and commit tonnage to be looked after. Farmers can also be advised in marketing and sales through Openfield (Woldgrain are part of Openfield), Openfield provides peace of mind for the farmers as Woldgrain collects the grain after harvest and all the member has to do is speak to Openfield about when the market might be right for selling, this helps the farmer concentrate on other things. Zealand; Bentalls have supplied three contracts already consisting of nine silos and seven hoppers, with eight new silos being supplied in February, which will be for a leading flour milling company in Christchurch. The PMR contract was originally built for the New Zealand Government to store oilseed rape; the stored grain would then go for crushing to be turned into biofuel. The hopper silos were designed to hold the wet oil seed rape prior to going through a continuous flow drier. The larger silos are fitted with aeration and are used for the long-term storage of the oil seed rape. The pressroom runs for 46 weeks of the year pressing the oil seed rape to produce Bio Diesel. The waste cake that is produced from the

Revolutionised the handling of bulk cereal imports
One of Bentalls largest contracts has been Grain Bulk Handlers. Since opening for business in 2000, Grain Bulk Handlers Ltd has revolutionised the handling of bulk cereal imports in Mombasa and in doing so has brought operations up to international standards in accordance with the port’s Master Plan. Grain Bulk Handlers Ltd (GBHL) receives deliveries of bulk cereal imports from around the world at the port of Mombasa in order to meet the ever-increasing demand from millers, traders, NGOs and relief agencies in East and Central Africa, including Great Lakes, Southern Sudan and Somalia.

“One important aspect of design of structures using Seismic codes was recently demonstrated with the very unfortunate and devastating earthquake in Christchurch New Zealand”

Due to this up-to-date facility and fast turnaround there is an increase in farmers taking up these options of central stores. As the onsite drying and temperate control keeps their grains at the best possible price. As more and more farmers take up these options Woldgrain keeps expanding and Bentalls are keen to supply them.

Seismic codes
One important aspect of design of structures using Seismic codes was recently demonstrated with the very unfortunate and devastating earthquake in Christchurch New Zealand, where many silo’s and hoppers suffered structural damage. However, the facilities Bentalls provided in these areas stood the test. Contracts recently supplied by Bentalls together with PMR Contracts LTD in New Zealand for Biofuels were unaffected. PMR Contracts LTD does contracts on the North and South islands of New
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pressing is in turn fed to dairy cows making sure there is no waste. The site consists of silos which are 16M diameter by 12.8m high with a capacity approximately 1000 tonnes for each silo in oilseed rape and also two eight metre diameter hopper silos by 12.0m overall height capacity 240 tonnes of oilseed rape. The oilseed rape site was only situated 14 miles away from the first quake, which measured in at 7.2. PMR were very concerned that the silos would split, as there were news reports of collapsing silos, but after doing an engineering inspection on the plant there was no damage. But only 500m away a feedmill had all of its silos collapse. The reason why the site did not fail is all silos are designed using Seismic codes and to withstand earthquakes of a certain magnitude as laid out in the New Zealand and Australian codes of practice which Bentalls stringently adhered to.

GBHL immediately improved quayside productivity by being able to discharge at a rate of 600 tonnes per hour. The average daily discharge rate at the terminal from specialised bulk carriers is 11,000 tonnes. On some occasions daily performance rates are as high as 13,800 tonnes. There were a number of other benefits for ship operators and importers in terms of faster discharge times, lower freight and insurance costs, greater economies of scale, improved cargo quality, better accounting and reduced inventories and crucially, better accounting of discharged and delivered quantities. The KPA has also seen better berth utilisation as stipulated in their master plan and increased revenues from harbour dues. Equally, the Kenyan economy has gained from additional hard currency earnings. As an interim measure GBHL leased warehouses at the port, near the terminal and within the Island to offer warehousing service on
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FEATURE

“The aim of introducing long term bulk storage silos was to reduce the cost of warehouse storage and subsequent distribution”

long-term basis for grain handled through its terminal (especially those for transit and transshipment) totaling to approximately 75,000 tonnes capacity. Use of the warehouses helped in easing cargo dwell times at the transit silos. There was, however, a need for a longterm solution to the problem. GBHL management was convinced that the answer to this problem was the provision of a long-term warehousing service for bulk grain. Thus, plans to develop long-term bulk storage silos at an area in the vicinity of the transit terminal was conceived which could be connected to the current transit silo complex by conveyors. The aim of introducing long-term bulk storage silos was to reduce the cost of warehouse storage and subsequent distribution for GBHL clients. Moreover it became crucial in providing a distribution hub for commodity traders and relief agencies to expand their use of Mombasa to service regional demand.

complex; road delivery complex comprising two bagging points and one bulk hopper; two road weighbridges with date link to the transit terminal complex and computer network; internal paved roads, retaining walls, storm water drainage, ring-man fire prevention system and five silos of 5000 tonnes each giving total capacity of 25,000 tonnes, with related elevators, conveyors and dust extraction systems. Phase I was designed by Bentalls with planning for further expansion. With global land prices increasing utilisation of land space is becoming a key issue when designing bulk storage Ssystems. Phase II extension provides good evidence of our silos and equipment nesting capabilities, utilising costly land to its maximum benefit. GBH Phase II investment isn’t set to be the last therefore once again consideration is taken for further future expansion.

Phase 3
This phase shall add to the previous phases by providing a further 22 silos of 5000 tonnes each plus eight silos of 1250 tonnes providing a total bulk storage capacity of 120,000 tonnes for long term basis. The GBHL extension, being for long-term storage facility has design features, which ensure the condition of bulk grain stored, does not deteriorate in the silos. For the purpose of preserving as well as enhancing the condition of bulk grain in store, the long-term storage silos are fitted with temperature monitors and devices for aeration of cargo. The silos also have facilities to enable fumigation of bulk grain in store whenever necessary. This way, bulk grain stored on long-term basis remains in excellent condition. Bentalls pride itself on the fact that many existing customers come back to Bentalls year-after-year for the quality and service we provide; the best recommendation is our worldwide customer base.

Phase 2
This phase adds to the existing storage capacity developed in Phase 1. Additional features were also added to enhance service delivery. Bentalls supplied the main assets which were: five silos of 5000 tonnes each plus four silos of 1250 tonnes providing a total capacity of 30,000 tonnes; control room with data link to the main control room situated in the transit terminal; expansion of the delivery complex to include two extra road delivery points plus one bulk and one bagged rail delivery points; railway siding, including a rail weighbridge and delivery pit for receipt of export cargo.

Phase 1
This phase involved the acquisition and development of many of the key elements of the overall project. Bentalls supplied five silos each silo with a volume of 6505 square metres, which store 5106 tonnes each. The site comprises: freehold land previously rented by GBHL as lorry parking area, perimeter wall surrounding the entire site; 300 metre single belt conveyor with a transfer speed of 200 tonnes per hour to link the long-term storage silos to the transit terminal
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About the company:
Bentall Rowlands of Scunthorpe in the UK was founded in the early 1980s. The company specialises in the production of turnkey storage, bulk storage handling and processing equipment for agriculture and industry on a worldwide scale.

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Increasing storage capacity Digital microwave moisture measurement Global grain & feed markets

Bulk storage & handling

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