The Terminal

Storage

KGT’s Storage facility consists of 30 bins; 18 large bins with capacity of 3,800 metric tons each and 12 smaller bins 1,600 tons each. Therefore total capacity is 88,000 metric tons. Each bin is equipped with a computerised product temperature monitoring system.

Equipments

KGT is equipped with a range of Buhler installations including a mobile mechanical bulk ship unloader with a maximum unloading capacity of 1,100 mtph; a mechanical railmounted ship loader with a peak loading capacity of 1,250 mtph; and direct ship-to-ship transfer facilities without the need to intake into silo. Other facilities at the terminal include automatic weighing facilities; the recycling of goods stored inside the bins; and a computerised temperature monitoring system installed inside each of the terminal’s thirty storage bins.

Berthing Quay

KGT is also serviced by a berthing quay (Laboratory /Magazine Wharf) with an overall length of 440 metres.  Magazine Wharf, which is 252 metres long, is allocated for the unloading of vessels while Laboratory Wharf, which is 190 metres long, is used for vessel loading.  These two berths have adequate depths for the berthing of oncoming and outgoing vessels.  In fact, the terminal can accept fully laden Panamax grain bulk carriers of up to 80,000 DWT and can load coasters and feeder vessels of up to 20,000 DWT.

Facilities in General

KGT’s general design parameters include:

• unloading of bulk carriers (up to 80,000 t. vessels) at a max rate of 1,100 t/h
• loading of bulk carriers (up to 20,000 t. vessels) at a max rate of 1,250 t/h
• storage and handling of grain products at the storage silo (88,000 t)
• bulk loading of trucks (two truck loading stations)

The system is designed for the handling of all types of grain such as wheat, maize, soya beans and barley with a bulk density of 0.75 t/m³.

Other services offered include:

· Direct ship-to-ship transfer
· Recycling
· Fumigation
· Colouring
· Truck loading facility (for local clients)

Discharging Facility

Berth – Magazine Wharf, Port of Valletta
Length – 160m
Draught – 12m

Shorebased discharging equipment: 1 mobile mechanical ship unloader HL-SKT type with a maximum bulk unloading capacity of 1,100 metric tons / hour.  For this equipment a maximum distance from water level to vessel’s top hatch coaming – 19m Maximum vessel size: 80,000 Mt DWT (provided that vessel characteristics fall within details above).

Loading Facility

Berth – Laboratory Wharf, Port of Valletta
Length – 120m Draught – 10.6m (35 feet)
Shorebased loading equipment: 1 mechanical railmounted (Buhler-Miag) with a peak capacity of 1,250 metric tons / hour.
Highest working position: 10.5 m above sea level
Maximum reach of loading pipe: 14m
Maximum vessels (up to 20,000 Mt DWT if vessel’s characteristics fall within details size specified above)

Direct ship-to-ship transfer Facilities

Direct ship-to-ship transfer facilities are also available and cargo may be discharged from bulk carriers and loaded direct to outgoing coasters and feeder vessels without intake into the silos

Recycling facilities

Facilities are available for the recycling of grains stored inside the silo bins.

Fumigation facilities

Fumigation pellet dispensers are installed at the distribute conveyors for insect prevention.

Temperature monitoring

A computerised temperature monitoring system is installed inside each of the terminal’s 30 storage bins.

Bulk Unloading and Loading Facilities

A mechanical ship unloader Type HL-SKT with an unloading capacity of 1,100 t/h equipped with an intake scale is installed.  The peak transfer loading capacity is 1,250 t/h to handle peak overload capacity.  The unloader delivers the product to the quay conveyor B1.  Belt conveyor B1 delivers the product to the transfer point with the possibility of selecting the silo route (via B3) or the second conveyor serving the ship loader (B2) for direct ship to ship transfer.  One belt conveyor (B3) delivers the product to the bucket elevators(elevators E2 and E3) at a capacity of 1,250 t/h.  One belt conveyor (B12) delivers the product at a capacity of 1,250 t/h from the ship loading scales to belt conveyor B2.  From B2 product is delivered to the loader.

Two distribute belt conveyors (B5 and B6), each with a capacity of 625 t/h, deliver the grain to the storage bins.  Both conveyors are equipped with a self propelled travelling tripper and a built-in flap box.

Each tripper is equipped with an aspiration filter delivering the dust directly back into the product stream.

Three reclaim belt conveyors (B7, B8, B9) each with a capacity of 625 t/h and equipped with a travelling feeder with dosing slide to deliver the material back to the three bucket elevators (E1, E2, E3).

Loading Rates

Loading rate per WWD depends on various factors, mainly the type and construction of the vessel but also, operating hours, type of product, discharging/loading sequence requested by the vessel etc.

KGT’s equipment is rated at a maximum of approximately 1,200 Mt/hr for loading  Through experience, if the right conditions are provided, considering time lost for shifting between holds and the reduced loading rate at the top of the hold, KGT generally estimates an average rate of 800 Mt/hr.  For small vessels the rate is usually reduced.

It is important that the vessels will be regular singledeck and selftrimming, suitable for the transport of grains in bulk without stowage bags.  No cargo is to be stowed in wingtanks.  Trimming is not performed at KGT.

Weighing and Truck Loading Stations

KGT has a truck loading facility for local clients.  This facility includes four separate bins (e, f, g and h) which means that the Company can load four different products simultaneously.  This means that the Company can offer vessel discharging and local loading of different products at the same time.  Weighing is performed by means of a weighbridge.

A truck loading station, able to load one product at a time, is located on the quay.  A 250kg hopper scale fed from bin C weighs the grain prior to loading each truck.

Two 4 tonne bulk loading hopper scales for ship loading are installed.  Each scale operates with a capacity of 625 t/h.

Aspiration Systems

Tree main aspiration systems (systems 1, 2 and 3) are installed at the silo head house for connection to the upper conveying system, lower conveying system and the scales.  Another aspiration system (system 4) is installed at the transfer point.   Bag filters are installed for safety reasons.  All four filters are installed outside the silo building.

The unloader, loader, travelling trippers on top of the silo bins and the new truck loading station are equipped with their own filter systems.  The aspiration ducting is made of galvanized sheet metal.

Spouting System

KGT’s spouting system consists of all connections between the conveyors and machinery such as spouts, hoppers, flap boxes slides.  All flap boxes and slide valves are either motorized or hand-operated with limit switches to indicate the flap and slide position at the control panel in the control room.

General Machinery

High level indicators are installed at the main storage bins (1 to 30) and the loading out bins (A to H).  The high level indicator at the main bins will give the signal to select a new position for the distribute tripper.

To protect the grain against insects, 2 x 2 =4 Aluminium Phosphine pellet dispensers are installed at the distribute conveyors.

Grain Temperature Monitoring System

A computerised temperature monitoring system was installed and commissioned in November 2010. The system scans temperature sensors continuously resulting in temperature readings of each bin approximately every hour. Actual temperatures can be read and printed from the Control Room.

Other features include

• Delta temperature
The temperature changes in all sensors within the last 24 hours

• Alarms
According to actual- and delta temperatures and grain Level

• Alarm set points
On each individual cable based on actual and delta temperatures

• Level Control (manual)
Selective display of grain level for each bin

• On-line help
Instant help to operator – no manual is required

• Standard Data base
Saves information for up to 4 weeks

Silo Machinery

KGT has the following facilities:

Three elevators (E1, E2 and E3) are installed for the following main simultaneous operations:

two line intake (625 t/h each) to full range of silo bins

with elevator E2 + chain conveyor C1 + belt conveyor B5 to any of bins 2 to 4, 6 to 8, and 13 to 21
with elevator E3 + chain conveyor C2 + belt conveyor B6 to any of bins 6 to 8, 10 to 12 and 22 to 30.

Bins 1, 5 and 9 are filled directly from the elevators.

two line load out bin filling (625 t/h each): from two reclaim belt conveyors (B7, B8, B9), their corresponding bucket elevators (E1, E2, E3), directly, or via C1 and/or C2, to the load out bins A and B.  One line to ship loading: 2 x 625 = 1,250 t/h bulk hopper scales (fed from bins A and B) to B12 etc.

one line New Truck Loading Station load out bin filling from one reclaim belt conveyor (B7, B8 or B9), its corresponding bucket elevator, to chain conveyor C20, elevator E20 and chain conveyor C21 to bin E, F, G or H.

one line bin C (truck loading station) load out bin filling from one reclaim belt conveyor (B7, B8 or B9), its corresponding elevator, directly, or via C1 and/or C2 to bin C.

one line or simultaneous two line recycling from reclaim belt conveyor/s (B7, B8 or B9), its/their corresponding elevator/s, via chain conveyor/s (C1 or C2) to distribute belt conveyor (B5, B6).

Two Buhler-Miag cross distribution chain conveyors (C1 and C2) positioned underneath the elevator outlets will deliver the product to the distribute belt conveyor (B5m B6) or the loading out bins (A, B, C, D).

Each conveyor handles a capacity of 625 t/h.  Safety trip lines are installed at all belt conveyors.

One motorized and one manually operated personnel silo descent hoist is used for bin inspection/cleaning.