k u . o c . h c e m w b .

w w w

professional bulk materials handling solutions for any environment

Product Profile

& B W

Reliability from Strength

Company History
B&W was formed in 1966 as a partnership between Tom Brown and Raymond Woodbine and operated from rented premises. In the early years the partnership developed a respected local business working in the Agriculture industry in a buoyant local farming environment. The Lancaster Way site offered much improved production capacity with roughly four times the production space plus the added benefit of a dedicated blasting and painting facility to satisfy clients demands for high performance finishes in the most demanding industries. The improved production facilities developed at Lancaster Way, as illustrated above, have substantially eliminated dependence on outside subcontractors for fabrication and finishing with significant gains in efficiency. In house manufacture has enabled close quality control in accordance with ISO 9000 standards and the company has now developed an enviable reputation for quality of construction and finish...

Loadmaster A/D produced in the early 1970s

These activities expanded and in 1978 a limited company was formed as B&W Mechanical Handling Ltd. and the company moved to a larger dedicated freehold factory at Lisle Lane in the City of Ely. Operations continued at Lisle Lane till 1991 when as a result of the illness of the founder partners the company ownership was transferred to the present shareholders. As part of the restructuring package the Lisle Lane property was sold and the company relocated to its present base at Lancaster Way.

Rail Mounted Shiploader handling coal at 3500 t.p.h.

Product History
In the early 1980s the development of the EC Grain Intervention scheme for agricultural produce generated a vast cereals surplus within the UK and as a result existing storage and handling systems were unable to cope with the greatly increased tonnages. B&W were well placed to capitalise on this new market opportunity and rapidly developed a range of high performance handling equipment dedicated to this industry. In the agricultural industry B&W had already established the Samson concept to satisfy the demands of intensive farming operations handling root crops for processing. The Stormajor design as illustrated opposite grew from the original Samson principle with the addition of a radial outloading boom ideal for handling cereals direct from tipping trucks. To export these large quantities of cereals new export facilities were required and B&W reacted to this changing market by developing an entirely new range of specialised mobile Ship Loading systems, typically as illustrated above. The new B&W designs were extremely robust and rapidly found markets outside agriculture... Recognising the expanding grain handling market would be short lived in 1985 B&W embarked on a sustained market diversification programme with the objective of extending the range of application of these new products to many different market sectors. This programme of diversification is ongoing and has resulted in a major shift in emphasis to the heavy materials handling industries such as Cement and Steel where continuous operation handling aggressive materials demands the highest engineering standards.

Stormajor loading Cereals to a typical grain storage operation

Lancaster Series loading cereals to small ships for export

Over the following years the Stormajor became the industry standard for this market establishing B&W as a main stream supplier...

Product Development
The market diversification from grain handling to heavy industry demanded a new approach to machine design recognising the demands of continuous process applications in the Ports, Steel and Cement industries particularly. Whilst changes in machine design and specification were made across all products the Samson Surface Feeder in particular has undergone a rigorous development programme culminating in the design of a series of five distinct models from the Samson 380 to the Samson 3200 covering applications from cereals through to heavy mining projects.. The detailed development of the Samson concept has extended to all aspects of the construction matching the machinery to the market demands to achieve the level of performance and reliability demanded by professional users operating in the most difficult working conditions. In parallel with the Samson development associated products such as the Stormajor and Shiploader designs have undergone a similar process of market driven design changes. The Stormajor illustrated below being a typical example incorporating full powered travel systems with Electronic Ackerman Steering and integral on-board diesel gen-set allowing the complete machine to be driven under its own power within the stockyard. Integrated facilities with electronic control systems have been extended to the Shiploader designs expanding the range of application through to dedicated export terminals handling heavy materials including comprehensive dust control facilities. With the latest development of the new Sterling Series of Tower Design Shiploaders B&W have extended the application of mobile equipment from barges through to Cape Size bulk carriers.

Samson handling Tyre Chip Fuel for Blue Circle Cement

Stormajor stockpiling heavy ores for a Saudi steelworks

Market Development
The fundamental principle of Surface Installation and Mobility is central to the marketing philosophy of all B&W products focusing on flexibility and economy combined with high engineering standards for long term reliability. By avoiding the expensive fixed civil works associated with traditional underground pits and hoppers new projects may be realised economically with the flexibility of future relocation should plant development demand. Similarly with Mobile Shiploaders and Stackers high performance may be maintained without the need for fixed infrastructure allowing fast track economical solutions maximising return on capital investment. Combining these principles with effective pollution control and reduced operating and maintenance costs offers the client a unique opportunity to increase productivity and profitability without sacrificing reliability or performance. The mobile Shiploader as illustrated above is typical of this philosophy incorporating the Samson equipment with an Outloading Boom to a fully mobile chassis with powered travel providing autonomous operation. Similarly the Stormajor opposite demonstrates how a barge loading facility may be made on a river berth with no foundations or civil works. This concept of mobility is extended to Mobile Link Conveyors operating in a stone quarry with a Mobile Crusher eliminating the need for a fixed primary plant. In addition to the benefits of lower capital costs and fast track availability surface equipment retains a high residual value and may be sold-on when not required...!! By applying high engineering standards to surface equipment B&W offer a radical alternative to fixed installations in any working environment

Stormajor barge loading on a river berth handling sand

Mobile Samson Surface Feeder operating with a Mobile Shiploader

Mobile Equipment Programme

Loadmaster Series
Including the Loadmaster A/D and E Series mobile conveyors the Loadmaster is a long established design with boom lengths from 9 to 18 metres covering handling rates to 400 t.p.h..

Lancaster Series
A medium duty design for Ship Loading and Stacking the Lancaster Series are available from 18 to 25 metres covering handling rates to 600 tonnes per hour.

Stormajor & Hydrastor

A comprehensive range of mobile radial boom stacker/loader designs incorporating the Samson surface feeder to receive virtually any bulk material direct from trucks or shovels. The Hydrastor is similar in principle but the Samson section is replaced by a belt feeder.

Mobile Shiploaders
Dedicated designs for ship loading with many specialised features including mounted Samson surface feeders and a complete range of trimming and powered manoeuvring systems.

Link Conveyors
Self propelled mobile conveyors for operation in mines and quarries for material transfer between face crusher and fixed conveying equipment.

Industrial Equipment Programme

Samson
Combining the strength of an apron feeder with the cleanliness of a belt system the Samson offers unique opportunities for innovative plant design where material is delivered by truck, shovel or rail wagon.

Kleen-Line Conveyors
A specialised form of Troughed Belt where the wing idlers are replaced by continuous slider plates the Kleen-Line offers major benefits in reduced spillage and dust generation, shown here handling Screenings in a Sewage Works.

Steep Angle Conveyors

Using the Side-Wall-Belt principle these conveyors may be installed at angles up to 90 degrees offering compact installation when space is limited.

Troughed Belt Conveyors

An economical standardised range of belt conveyors for general materials handling based on Press Formed Steel panels or modular lattice structures covering the full range of process plant requirements.

Radial Stackers
Using standard conveyor structures based on the Loadmaster or Lancaster range or bespoke machines for specific applications in mining and stockyards.

Quality Management - ISO 9002

B&W are accredited to the International Quality standard ISO 9002 ensuring fully documented, reliable and consistent quality standards are maintained throughout the production process. Quality throughout design, manufacture and installation require infinite attention to the smallest detail resulting in effective products with excellent long term reliability.. Quality at every stage is a state of mind nurtured by B&W starting with apprentice training schemes and instilled at every level of management. Quality standards are rigorously maintained throughout every stage by proper inspection ensuring close adherence to project and performance specifications.

Quality of design and manufacture is the dominant philosophy of B&W and it is applied and documented rigorously throughout the manufacturing process from the smallest mobile conveyors through the largest Shiploaders

Engineering Standards

Long term reliability under difficult working conditions can only be guaranteed by strict adherence to the highest engineering standards from the initial design through to the final equipment installation. B&Ws philosophy of Reliability from Strength is adopted throughout the product range and typified in the machine illustrated here designed for ship loading cement clinker incorporating sophisticated powered travel and manoeuvring systems. Robust construction combined with the highest quality components properly installed and protected ensures long and trouble-free equipment life. When reliability really counts B&W products are engineered to delivering low long term cost of ownership for real economy in operation.

Design Philosophy
Always looking for the most economical solution B&W combine specialist equipment such as the Samson with conventional conveyor technology to minimise the total project cost. Surface installation is a key factor in this philosophy to reduce the cost of civil works and eliminate underground pits and hoppers whilst retaining performance and enhancing overall reliability. Using innovative designs combined with extensive experience in all aspects of bulk materials handling B&W are able to offer a complete package tailored to the clients individual demands with the added benefit of total flexibility in plant location.

Combining innovative plant layout with specialist equipment designs installation and operating costs are minimised without sacrificing performance or reliability

Using the highest quality components combined with excellent maintenance access high availability is guaranteed with the minimum of operating costs.

Project Management
In addition to supplying the specialist products described herein B&W also offer a complete project management service geared to the demands of professional users in all industry sectors. This service is extended to the procurement of specialist equipment such as screens and crushers etc. to be combined into a total semi-turnkey project service. Effective project management including full site installation and commissioning services with all associated documentation ensures timely completion and effective integration with all other civil, electrical and mechanical services required for the most complex projects.

Effective project management ensures timely deliveries and installation along with related site works including all necessary project documentation

This service incorporates full safety management plus all necessary operational and maintenance manuals with on-site training.

Target Markets
Typical applications in major industry sectors where B&W products offer unique benefits compared to more traditional bulk handling solutions

Ports and Terminals Cement Industry

Dry Bulk Ship Loading Barge Loading Stacking Clinker Exports Ship Loading Imported Clinker Raw Material Intake and Storage Coal and Pet Coke Intake and Storage Recycled Material Handling Alternative Fuels Intake and Storage Silo Discharge and Conveying Dust Controlled Conveying

Steel Industry

Coal and Coke Intake and Handling Ore Intake and Handling Stockyard Feeders and Stackers Waste Material Handling Alloys Intake and Handling

Mining

Primary Feed Applications Link Conveyors for Face Crushers Radial Stackers Truck Haulage Feeders Railcar Loaders

Glass Works Salt Plant

Sand Intake and Handling Cullet Intake and Handling Raw Salt Intake and Handling Salt Exports Ship Loading Salt Stacking

Target Markets
These examples are based on existing references at established clients where B&W products have proven effective and economical solutions

Grain Handling

Bulk Intake Facilities Flat Storage Ship Loading Barge Loading Rail Truck Loading

Maltings Clay Industry

Malting Barley Intake Malt Distribution Conveyors Raw Clay Intake and Handling Kaolin Intake and Handling Ship Loading Process Conveyors

Waste Treatment

Imported Sludge Intake and Handling Sludge Storage Pasteurisation - N-viro Process Screenings Handling

Concrete Plant Power Generation

Aggregate Intake and Handling Roadbourne Coal Intake and Handling Rail Car Discharge and Handling De-Sulphurised Gypsum Handling Stockyard Feeders and Stackers

Sugar Factories

Fuel Intake and Handling Raw Beet Intake and Handling Limestone Intake and Handling Shredded Pulp and Pulp Nuts Handling

Frequently Asked Questions Samson

Why is the Samson Economical..??
Surface installation avoids expensive underground pits. In rocky areas pits are very expensive to excavate. In wet areas pits need expensive lining to stop flooding. Reduced length and cost of ongoing conveyors. The Samson is complete - no extra hoppers to buy. Absolute minimum civil works requirement. Minimising civil works reduces plant design costs. By reducing civil works project costs are much reduced. Easy site assembly and installation.

Why is the Samson Flexible..??

With no excavation required site location is simplified. The Samson is a complete unit and easily relocated. As a complete unit the Samson retains resale value.

Pollution Control is Vital..!!!

The wide belt design minimise material fall. Material is drawn from the vehicle in a controlled stream. By reducing material fall dust is not generated. By minimising displaced air dust is not dispersed.

Wet and Sticky Materials..??

The wide belt design guarantees reliable storage. The load depth is less than the belt width. Vertical hopper sides eliminate bridging. Sludges down to 18 % dry solids may be stored reliably.

Is the Samson Reliable...???

Experience of over 20 years of development. With 500 units installed world-wide.

The Samson Installed Above Ground reduces the total project cost and the cost of ongoing conveyors

There are five designs in the Samson range. Correct machine selection is vital. Many repeat orders demonstrates customer satisfaction. Many machines installed in continuous process plants. Unique design features developed through experience.

Frequently Asked Questions Samson

Which Samson Design...??
Samson 380 - Light duty up to 30 tons capacity Samson 450 - Medium Duty to 45 tons capacity. Samson 800 - Heavy Duty to 60 tons capacity. Samson 1600 - Very Heavy Duty to 100 tons capacity. Samson 3200 - Extreme Duty applications. Length, Angle and Capacity determine the basic design. Impact Loading may require a heavier series design. Samson 800 upwards preferred for continuous duty.

How Fast are Trucks Unloaded..??

The Samson receives material faster than it is discharged. Increasing the entry bed depth increases the receiving rate. Increasing the ramp height increases the entry capacity. Increased entry capacity gives faster truck tipping. Typical Truck Tipping Time - 3 to 5 minutes. Fast Truck Tipping Time - 10 to 30 seconds.

Output Rate Control..!!!

Using the Levelling-Blade close output regulation is possible. Typical minimum output rate - 50 tonnes per hour. Typical maximum output Rate - 2,000 tonnes per hour. For very low output rate an auxiliary feeder may be needed.

Samson Holding Capacity..??

Typical Holding Capacity = One Truck Load + Safety Margin. Machines have been produced with over 200 tons capacity. Using Shovels will increase the available holding capacity.

Is the Samson easy to maintain..??

Combining the Samson with screw feeders allows fast truck discharge with a metered output rate down to less than 5 cu. m. per hour
Surface installation makes access easy. Easy access generally result in regular inspections. Regular inspection encourages preventative maintenance. Quality components selected for long life.

Frequently Asked Questions Stormajor

What is the Stormajor..??
Stormajor comprises a Samson + a Radial Boom Conveyor. A complete and integrated machine on a single chassis. Available with Diesel or Electric Drives. Many optional facilities to suit specific applications.

Why is the Stormajor Economical..??

The Stormajor may replace expensive fixed installations. No special civil works or infrastructure required. Mobility allows operation across a wide area. Cantilevered outloading boom allows steep angle operation. Steep angle outloading boom allows compact design.

Typical Applications..??
Stockpiling from tipping trucks or loading shovels. Ship and Barge Loading. Transfer from truck to existing process conveyors. Heap Leaching and Solar Drying.

Pollution Control is Vital..!!!

Includes all the dust control features of the Samson. Available with a wide range of enclosures. Available with full dust extraction facilities.

Stockpiling Capacities..??
Outloading Boom angles variable from 0 to 30 degrees. Typical boom length - 21 m creates 10 m high stockpile. Maximum boom length - 30 m creates 15 m high stockpile, Typical Sewing Range - 60 degrees.

Materials and Handling Rates...???

The Stormajor offers an economical alternative to expensive fixed installations with high performance and total flexibility
Most dry bulk materials may be reliably handled. Suitable for materials from light cereals to heavy minerals. Typical Handling Rate Range - 300 to 1,000 t.p.h.. Maximum Handling Rate - 2,000 t.p.h. Special designs are required for wet and sticky materials.

Frequently Asked Questions Shiploader

Vessel Size..??
Lancaster Series typically load up to 5,000 DWT ships Shiploader Series load up to Handymax (45,000 DWT) Sterling Series load up to Cape Size (150,000 DWT)

Benefits of Mobile Shiploaders..??

No dedicated berth or infrastructure required. No special civil works or underground pits or foundations. The berth remains free for other port operations. May be easily moved between berths or to another port. Will generally handle a range of dry bulk materials. Retains high resale value minimising investment risk.

Specialised Facilities..??
Single or Twin integral Samson feeder units. In-Line, Radial and Parallel Powered Travel facilities. Comprehensive range of Ship Trimming equipment. Sophisticated electronic controls for simplified operation.

Pollution Control is Vital..!!!

Integral Samson feeders minimise dust from truck tipping. Available with full range of enclosures and dust extraction. Cascade loading chutes control dust down to the hold floor.

How much Quay Space is required..??

Standard Shiploaders require extended quay area. Quay width must be equal at least to the boom length. Special two part machines available for narrow jetties. Sterling Series tower design occupies minimum quay space.

Materials and Handling Rates...???

Comprehensive designs with integral powered travel systems and dedicated ship trimming equipment
Most dry bulk materials may be reliably handled. Suitable for materials from light cereals to heavy minerals. Typical Handling Rate Range - 300 to 2,000 t.p.h.. Typical average rate per truck tipping point - 500 cu m/hr Multiple Samson feeders for very high handling rates.

Conveyor Interfaces

Kleen-Line Transfer Conveyors

Kleen-Line conveyor sections linked to the Samson Surface Feeder offer real advantages when handling both wetsticky materials and drydusty materials to minimise spillage and dust generation for a more economical overall conveying package.

Kleen-Line Continuous Side Support

Pollution Control
Control of dust emissions is a critical element in all new plant designs to minimise environmental pollution.
The Samson concept is inherently superior to conventional underground pits and hoppers when handling dry and dusty materials. With the Samson the material is drawn from the truck body in a controlled stream with minimum material fall. Since the material fall is substantially reduced air is not displaced from the Samson enclosure and therefore any dust generated is not immediately dispersed aggravating dust pollution in the surrounding area. By minimising material fall and controlling the flow from the truck the material does not separate into free particles and therefore dust generation is almost eliminated. By minimising dust generation at source it is generally not necessary to provide dust extraction facilities in all but the most environmentally sensitive locations. Even where dust extraction is considered necessary the air flow rate is substantially reduced. Combined with the Kleen-Line conveyor design at the Samson discharge total dust emissions are closely controlled.

Material is Drawn from the Samson body in a Controlled Stream Minimising Dust Generation

By minimising dust generation and therefore extraction requirements the total project cost and the ongoing operating cost is greatly reduced making the combined Samson and KleenLine solution even more attractive...

Special Products
Tripper Carriages: Travelling Trippers discharge a troughed belt conveyor at any point along its length for stockpiling applications using fixed overhead conveyors. Tripper Carriages may be supplied for operation on structures produced by others or as a complete installation as illustrated opposite. For Ship Loading operations the travelling tripper may be combined with a quayside conveyor to discharge material to a travelling Shiploader. The Tripper may be self powered or may be linked to a travelling stacker boom or Shiploader for rail mounted installations.

Plough Dischargers: An economical alternative to the travelling tripper the Plough Discharger may operate on virtually any troughed belt conveyor. Ploughs may be positioned at fixed intervals along the conveyor as shown opposite or may be mounted to travelling carriages to cover an extended discharge area. The plough system is not suitable for all materials but in many applications this solution offers excellent reliability.

Drive Over Doors: For drive-over-tip applications where conventional grill bar opening may cause bridging and blockage handling cohesive materials the automatic Drive-Over-Door system has proven effective. The system illustrated opposite is combined with a Samson sub-floor feeder incorporated into the new Rugby Cement development handling clay, coal and pet-coke. Whilst the system is ideal for the Samson it may be used effectively with any type of underground hopper/feeder equipment.

New Products
A new generation of Mobile Shiploaders extending the range of loading capability to Panamax and Cape Size vessels.
The first of the new range of Sterling Series Shiploaders will be delivered to the Port of Immingham in England in September 2001 for cereals exports to vessels up to 45,000 DWT. Based on a fully mobile concept with rubber tyred undergear able to operate on any conventional flat quay surface the Sterling Series opens new opportunities for larger vessels but retaining the important flexibility of mobile solutions. Using vertical elevation with a radial outloading boom combined with inline and parallel manoeuvring systems the Sterling Series provides high freeboard clearance with excellent ship trimming for vessels up to 40 metres beam. The design illustrated includes four integral Samson Surface Feeders mounted to truck frame chassis for direct truck discharge. In this manner average loading rates in excess of 1,000 tonnes per hour may be readily achieved.

Sterling Series Shiploaders

Sterling Series for the Port of Immingham - New for 2002

Your Contacts at B&W

Barry Woodbine
Managing Director Sales & Commercial
barry@bwmech.co.uk

Andrew Mitchell
Managing Director Technical & Production
andrew@bwmech.co.uk

Thomas Fahrland
General Sales Manager Global Sales
thomas@bwmech.co.uk

David Chapman
Financial Controller
david@bwmech.co.uk

Gary Johnson
Area Sales Manager UK Sales
gary@bwmech.co.uk

Cyril Bateman
Area Sales Manager General Export Business
cbwmech@aol.com

Richard Starte
Area Sales Manager General Export Business
richard@bwmech.co.uk

Arthur Mann
Design Office Manager Technical Services
art@bwmech.co.uk

Graham Cant
After Sales Manager Site Services
graham@bwmech.co.uk

Viv Bateman
Contracts Manager Programme Co-ordination
viv@bwmech.co.uk

Andy Blackwell
Purchassing Manager Spares & Components
andy@bwmech.co.uk

Tony Howard
Emergency Services
graham@bwmech.co.uk

Support Services
B&W offer a comprehensive support service from the initial plant design concept through the installation and commissioning of the equipment and extending to long term maintenance contracts. Working in these critical industries B&W have developed an after sales service available 24 hours per day, 365 days per year geared to solving clients problems rapidly avoiding lost production. Effective customer orientated service is part of the B&W philosophy linked to quality and engineering expertise in all aspects of bulk materials handling. In parallel with conventional service support from our works team B&W also provide comprehensive on-site training for the maintenance and repair of equipment by the clients own engineers.

Chris Chapman
IT Services Manager
chris@bwmech.co.uk

Our customers demand and receive the highest standards of support ensuring continuous availability of equipment with minimum down time. This particularly critical in continuous process industries such as Steel and Cement works where downtime is hugely expensive. Similarly in the ports sector lost loading time incurs ship demurrage costs which can run into vast sums of money...

Lynne Barber
Office Manager Sales Support
lynne@bwmech.co.uk

Effective ongoing Service available on demand to ensure maximum plant availability

B&W Mechanical Handling Ltd

Lancaster Way, Ely, Cambridgeshire, CB6 3NP, England
Telephone - +44 1353 665001 - Fax - +44 1353 666734 Email - sales@bwmech.co.uk - Web Site - www.bwmech.co.uk
B.& W. Mechanical Handling Ltd. have a policy of continual product development and as such reserve the right to revise specifications provided herein without notice