Modular Distribution Terminal

This modular distribution terminal was recently completed by PENTA as a two-phase EPC project for a plant in the Midwestern region of the U.S. The new modular cement transfer terminal replaced two portable transloaders that had been used to transfer cement from rail cars to cement trucks.

BENEFITS OF MODULAR / CONTAINERIZED DESIGN:

  • Less plant downtime
  • Expedited project schedule and completion

During Phase 1 of this project, PENTA installed a permanent backup rail to truck transfer system to unload cement from the rail cars directly into bulk cement tanker trucks. An incline screw conveyor feeding a dustless load spout was also part of Phase 1. PENTA delivered a pre-engineered rail shed provided weather protection for the rail unloading pit, we installed a containerized compressor room to supply utility air to both the backup system and the main terminal system, and we built a masonry building to providing space for the main electric room and the operator’s control station. This facility was built to act as a backup to the main terminal system, and will be used to unload cement and other materials as necessary after Phase 2.

Phase 2 entailed the installation of a 3,000-ton steel bolted cement storage bin, an office/control room building, and a rail unloading system. Cement is supplied to the silo by an inclined screw and transferred to a bucket elevator. From the bucket elevator an air gravity conveyor places the cement into the top of the silo. The silo withdrawal system features a dustless load spout to help comply with air quality laws. A pre-engineered building serves as weather protection for the rail pit. A 2-story masonry building was constructed to provide a storage room,  administrative office, restroom, control room, and kitchen facilities.

CHALLENGES & SOLUTIONS:

Every job presents interesting challenges for the PENTA team to overcome with innovative and cost-effective solutions.

  • This job was extremely close to an airport so the team had to obtain additional permits for the silo since they had to ensure it would not be in the way of airport traffic.
  • Geometry of the space was small and tight. They had to bore under the rail track to run the water/sewer/power to the new terminal.
  • A recent tornado destroyed the area so we built a tornado shelter under the terminal to ensure the safety of employees.

PENTA aligned our teams of electrical, mechanical, process, environmental, and civil/structural engineers with sister company PENTA Industrial Corporation to complete all phases of EPC projects. PENTA Engineering spearheads all conceptual/basic, front-end engineering design, final engineering, and site engineering for projects. PENTA Industrial focuses on the procurement of all equipment for the project, provided a full-time on-site Construction Manager. To learn more about our EPC and EPCM project solutions please visit http://www.penta.net/epc-and-epcm-services/.

Startup services and commissioning were successfully completed for this particular project in 2015.