DESIGN/BUILD BULK MATERIAL TRANSFER TERMINALS
Dry bulk material commodities such as cement, lime, fly ash, slag and sand need to be distributed to end users as inexpensively as possible. The manufacturer’s distribution network consists of:
- Load-out system from the manufacturing point to marine or rail transport
- Terminals to receive and store bulk shipments
- Loading the product to the customer trucks, railcars, or barge
Safe, rapid, no-spill, no-dusting unloading of bulk rail car shipments into product storage and again from storage to customer’s transport is important for efficient logistics.
The two primary concerns of the owner are the cost and schedule to build the transfer terminals to increase market penetration.
PENTA designs, constructs, and commissions low-cost distribution terminals. Standardized designs and prefabricated systems compress schedules by significantly reducing engineering and procurement time allowing for more efficient construction times. One such system is the prefabricated “PENTA PIT”, a high-speed rail unloading system that successfully reduces costs and expedites construction schedules for many terminal projects. To learn more about PENTA’s modular designs, please visit https://www.penta.net/modular-distribution-terminals/.
PENTA works closely with our customers to provide design/build terminal solutions that grow their business. Our services include import terminals and inland terminals that handle commodities between barge, ship, rail, and truck. For more information about our projects, please visit https://penta.net/projects/.
FEASIBILITY STUDIES AND CAPEX
Every project should begin with a feasibility study to evaluate potential terminal sites, storage arrangements, and logistics. The Owner’s input for equipment preferences is used as a basis for pricing and design focuses on safe ease of equipment access and serviceability for maintenance and operation. The selection of conveying and transfer equipment and product storage design has significant impact on engineering and procurement cost and schedule. It is also important to select the optimum foundation design with the collaboration of a geotechnical consultant. Once the terminal site is selected and the product storage and material handling equipment defined, a formal design-build project delivery offer is developed. In the design-build approach, a total engineering, equipment supply, construction and facility commissioning package is offered with single point responsibility.
DESIGN-BUILD PROJECT DELIVERY
PENTA takes single point responsibility providing a management team consisting of a Project Manager, Construction Manager and Safety Manager that manages project budget, schedule and safety requirements ensuring successful completion of all project phases. PENTA completes all required engineering (civil/structural, mechanical, and electrical), procurement of all equipment, and completion of construction including site/civil work, mechanical equipment installation, and electrical equipment installation. Modularized systems such as containerized electrical rooms and compressor rooms are utilized to compress construction schedule. Following construction, PENTA manages dry and wet commissioning of the terminal ensuring successful operation before turning over the newly constructed facility to the customer.
Transfer Terminal 1
PENTA recently completed a Greenfield cement distribution terminal in Fort Worth, Texas, on a design/build basis. The client’s planned throughput and the market conditions required a system designed to have two truck load-out spouts under two drive-through steel bins to load two trucks simultaneously. To accommodate maintenance shutdown of one of the silos, the material can be conveyed from either of the silos to both load-out spouts. The terminal consists of PENTA’s proprietary rail unloading system to transfer cement from the
railcars to the bins. A rail shed was installed for weather protection. In addition, six-inch blow-off lines are provided to allow cement trucks to unload to either of the silos. Due to stringent regulatory emissions requirements, dust collection was carefully sized and integrated within the system to control emissions. Truck loading was carried out through an aerated bin bottom and dustless loading spouts. The system is fully-automated and the control room is in an office where the operator has a clear view of the loading process through strategically-placed cameras. The office is designed to accommodate the needs of the truck drivers and the terminal operating staff.
Transfer Terminal 2
PENTA was tasked to build a fast-track solution for bulk rail transport and road tanker deliveries in Montana, near the North Dakota border to service the oil fields. PENTA designed, procured and constructed a secondary rail-to-truck loading system while the main terminal was under construction. The secondary system, including rail car unloading, truck loading, truck scale, operator’s station and new rail siding was completed and fully operational within 3.5 months. Power and compressed air supply needs were met with portable systems configured by PENTA. The main terminal consisting of rail car unloading, bulk storage, office/control building and truck loading system was completed within 10 months using extensive prefabrication and modular designs. The secondary system now handles alternate materials and can be used as a backup.
Transfer Terminal 3
PENTA needed to supply a fast-track approach for an owner to receive bulk cement shipments via rail and load customer tanker trucks in Alexandria, Louisiana. PENTA designed, procured and constructed a secondary rail-to-truck loading system while a main terminal was under construction. The secondary system, including new rail siding, main substation, compressor station, rail car unloading, truck loading, truck scale and operators station was completed and fully operational within 4 months. The main cement terminal comprised rail siding modifications, rail car unloading, bulk storage, office/control building and truck loading system and was completed within 6 additional months using extensive prefabrication and modular designs.