Construction and installation of PJSC Ukrelevatorprom (ADM)

Main objective: Large-scale reconstruction of raw material receiving and loading facilities, increasing the capacity of conveying lines to 500–600 t/h, implementation of modern dedusting (aspiration) systems, and automation of technological processes with minimum production downtime.

Completed works and implementation stages

Engineering design (Detailed Design Stage / PU Sections):

• Project “Reconstruction of the receiving and cleaning unit and loading gallery with a capacity of 500 t/h”.
• Technical upgrade project for the above-silo galleries of Section No. 2 (increasing capacity from 350 to 600 t/h).
• Design documentation for the installation of a sampler at the railcar unloading station.
• Development of technical upgrade projects for the truck unloading station (canopy over RAG truck unloaders, part of the process and conveying system).

Development of specialized aspiration and dedusting sections:

• Dedusting of under-silo galleries;
• Dedusting systems for hopper scales and discharge boxes of belt conveyors;
• Detailed designs for the dedusting system of the SPM-1200 ship loader.

Construction, installation and reconstruction:

Truck receiving:

• Reconstruction of the truck unloading station: dismantling and installation works;
• Installation of modern truck unloaders (lifting capacity: 80 t, platform length: 22 m) and receiving hoppers with a capacity of 60 m³;
• Installation of weighing and gravity-flow equipment.

Rail receiving:

• Installation and commissioning of the grain receiving unit for rail transport.

Loading and conveying galleries:

• General contracting (2014): Construction of a loading gallery with a capacity of 500 t/h in accordance with the project “Reconstruction of the receiving and cleaning unit and loading gallery with a capacity of 500 t/h”;
• Installation and technical upgrade of the above-silo galleries (Site No. 2);
• Installation of the dedusting system for the SPM-1200 ship loader.

Fabrication and installation of steel structures:

• Fabrication and installation of bucket elevator towers, transfer towers, conveying galleries, canopies and shelters.

Automation (Process Control System):

• Reconstruction of the remote automated control system for the port terminal with a storage capacity of 210,000 t.
• Design, manufacture, installation and commissioning of an additional automated operator workstation for the remote automated control system.
• Installation, configuration and commissioning of an automated process control system based on Siemens equipment.

Supplied equipment

Conveying equipment:

• ZEO-BC belt conveyors (capacity $Q = 500$ t/h)
• Chain conveyors (scraper conveyors, capacity up to $Q = 600$ t/h)

Gravity-flow equipment and transfer points

Aspiration equipment:

• ZEO-FC filter cyclones (capacity 6,000–15,000 m³/h)
• ZEO-FG local filter units (for transfer points)
• ZEO-FK cartridge-bag filters ($Q = 20,000$ m³/h)
• Specialized aspiration systems for under-silo galleries, truck receiving facilities, weighing systems and the SPM-1200 ship loader

Weighing and process equipment:

• Truck unloaders (80 t, 22 m platform) with 60 m³ receiving hoppers
• Weighing systems and samplers

Steel structures:

• Bucket elevator towers and transfer towers
• Steel structures for above-silo and loading galleries
• Protective canopies and shelters for truck receiving facilities

Key results of the completed works

1. Increased throughput capacity: The capacity of the above-silo gallery conveying lines was increased almost twofold — from 350 to 600 t/h. In addition, in 2014, a new loading gallery with a capacity of 500 t/h was constructed under the general contracting scope.

2. Modernization of truck receiving facilities: The installation of 80-ton truck unloaders with 22 m platforms and 60 m³ receiving hoppers enabled the terminal to handle modern large-capacity trucks and increase unloading speed.

3. Centralized control: A unified remote automated control system based on Siemens equipment was implemented, including additional operator workstations, providing full control over the terminal’s technological processes.

4. Industrial safety and environmental performance: The implementation of comprehensive ZEO aspiration systems at all key facilities (under-silo galleries, weighing systems, truck and rail receiving facilities, and the SPM-1200 ship loader) significantly reduced dust levels and minimized the risk of dust explosions at the facility.

Customer comment

Cooperation period:

2006-2017