ZOOMRY
Panamax ships (with a deadweight of 60,000 to 90,000 tons) are one of the main ship types for international bulk cargo transportation. They can pass through the Panama Canal and are suitable for medium-range transportation of grains, coal, etc. Their design meets the navigation restrictions of the Panama Canal (overall length ≤ 274.32 meters, breadth molded ≤ 32.30 meters). The loading operations for these ships have extremely high requirements for equipment efficiency, flexibility, environmental protection, and adaptability.
Core Ship Loader Types
Rail-Mounted Ship Loader
Rail-mounted ship loaders move along fixed rails on the wharf and, together with telescopic boom conveyors, can cover all hatches of Panamax ships, making them a common configuration in large bulk cargo terminals. Their technical features focus on "continuous operation" and "high throughput": they are usually equipped with Conveyor Belts 1000-1800mm wide, with a belt speed of 2.0-3.15m/s. A single unit can achieve a loading capacity of 2000-4500 tons per hour, efficiently handling bulk commodities such as coal, iron ore, and grains.
In terms of environmental protection design, rail-mounted ship loaders generally integrate enclosed conveyor covers, Z-type guide chutes, and buffer plates, which can effectively reduce dust emission when materials fall. Some high-end equipment is also equipped with dry fog dust suppression systems, enabling dust emission to be controlled below 5mg/m³, meeting international environmental standards such as EU CE and US EPA.
Disadvantages: Poor flexibility, as they rely on fixed rails for operation. The laying of rails increases the initial site construction cost; moreover, the fixed rail positions cannot adapt to temporary changes in wharf terrain or ship berthing positions, requiring high forward-looking planning for the wharf.
Mobile Radial Ship Loader
Mobile radial swing telescopic ship loaders have "flexibility" as their core advantage. Driven by hydraulics, they can achieve ±110° radial swing and 35-55m boom telescoping, covering multiple hatches of Panamax ships from a single feeding point, thus significantly reducing equipment movement time. Their loading capacity ranges from 500 to 6000 tons per hour, which can meet the medium throughput needs of small and medium-sized terminals and handle high-load scenarios in large ports through multi-unit collaborative operations.
In terms of structural design, such equipment usually adopts a modular design, which can be disassembled and transported via 40-foot containers, suitable for cross-border deployment by overseas customers. The integration of wireless remote control and PLC control systems enables single-person operation, reducing labor costs. Leading Mobile Ship Loaders like those from Zoomry have added intelligent load sensing functions on this basis, which can monitor material flow in real-time and automatically adjust the boom angle to avoid overloading or uneven loading, with the loading accuracy error controlled within 3%.
Disadvantages: Mobile radial ship loaders have poor stability during movement. When under heavy load (such as loading iron ore), they are prone to shaking due to uneven ground, requiring supporting flat sites or auxiliary support devices; second, operation must be restricted in windy weather (wind speed ≥ 10m/s), otherwise, it may cause boom vibration; third, the energy consumption of a single unit is 15%-20% higher than that of rail-mounted ship loaders, which will increase operating costs during long-term high-load operation.
Screw Ship Loader
Featuring an fully enclosed screw conveying design, it is suitable for dust-free loading of powdery materials (such as cement, sulfur). It adopts a scissor arm arrangement, which can go deep into narrow areas inside the cabin to avoid dust emission caused by free fall of materials; the loading capacity can reach 12,000 tons per hour.
Disadvantages: The application range of screw ship loaders is narrow: first, they cannot handle bulk materials with a particle size exceeding 50mm (which is easy to jam the screw blades); second, materials are prone to being crushed during conveying, making them unsuitable for goods requiring high particle integrity (such as grains); third, friction between screw blades and the machine shell generates heat, which may cause material caking (such as cement) in high-temperature environments, requiring supporting cooling systems.
Auxiliary Loading and Unloading Equipment
Portal Crane + Grab Bucket
Portal cranes equipped with 40-50 ton grab buckets are a common configuration in small and medium-sized terminals or multi-cargo ports. They can not only complete bulk cargo loading but also switch to hooks to handle general cargo, with strong adaptability. A single unit can load and unload 300-800 tons of bulk cargo per hour, suitable for small-batch replenishment or temporary operations of Panamax ships.
Disadvantages: Low loading efficiency, as it is an intermittent operation (the cycle of grab bucket lifting, opening, and closing takes about 30 seconds each time), making it difficult to meet the needs of continuous high throughput; dust emission is serious when the grab bucket unloads, and even with a dust cover installed, the dust emission is still higher than that of enclosed conveying equipment; the equipment weight reaches 200-500 tons, requiring high bearing capacity of the wharf foundation, and the operation noise is high (≥85 decibels), which does not meet the environmental protection requirements of ports near residential areas.
belt conveyor System
The belt conveyor system is a key link connecting the storage yard and the ship loader, and its performance directly affects the continuity of loading operations. For the loading needs of Panamax ships, such systems usually adopt conveyor belts 1000-1400mm wide, with a belt speed of 2.0-3.15m/s and a rated efficiency of 3500-4500 tons per hour, enabling long-distance (≤5km) continuous transportation of bulk commodities such as coal and ore.
Zoomry has integrated several core technologies into the belt conveyor system: first, the use of polymer material idlers reduces the friction coefficient by 50% and energy consumption by 15%; second, customized rollers (with tungsten carbide sprayed surfaces) improve wear resistance by 200%; third, the integration of an intelligent deviation monitoring system can provide real-time early warning and automatic correction, reducing downtime.
Disadvantages: The "fixed path" makes it difficult to adjust after installation, resulting in poor adaptability to later expansion of the wharf or changes in cargo types; multiple drive units are required for long-distance transportation, increasing equipment complexity and maintenance costs; special designs (such as turning roller sets) are needed at turning points, otherwise, it may lead to increased belt wear.
Mobile Hopper and Self-Unloading System
Mobile hoppers are equipped with enclosed hoppers and dust removal devices, mainly used for truck unloading or temporary cabin replenishment. They usually have a capacity of 5-20 cubic meters and can cooperate with belt conveyors to achieve seamless transfer from "truck-hopper-ship loader". Some Panamax self-unloading ships are also equipped with screw conveyors or hydraulic flaps, enabling them to complete loading independently when there is no shore-based equipment.
Disadvantages: Mobile hoppers have limited capacity and need to be frequently connected with upstream equipment, which is prone to operational interruptions; they have high requirements for ground flatness and are difficult to move in rugged terrain; the self-unloading system of self-unloading ships occupies part of the cabin capacity, resulting in a 15%-20% reduction in actual loading capacity compared with conventional ships.
Core Advantages of Zoomry
- Enclosed design: The discharge port of the ship loader adopts flexible connections and Z-type guide chutes, reducing the impact speed of materials through multi-stage buffering to reduce dust emission; Zoomry has added a deflector on this basis to stabilize the falling trajectory of materials, reducing dust emission by 40%.
- Dry fog dust suppression: Micron-level fog nozzles are installed at belt transfer points and hopper discharge ports to wrap dust particles with water mist for sedimentation, suitable for dry areas; however, it is prone to frosting in low-temperature environments (≤5℃), requiring supporting insulation devices.
- Vacuum dust collection: Dust is sucked into the dust collection box through a negative pressure system, with a purification efficiency of 99%, but the energy consumption is high (accounting for about 15% of the total energy consumption of the equipment), suitable for areas with extremely high environmental protection requirements (such as European ports).
- Intelligent monitoring: Real-time monitoring of material distribution in the cabin through laser scanning and weight sensors, automatically adjusting the discharge position of the ship loader to avoid ship overload; Zoomry's system can achieve a positioning accuracy of ±50mm, with a loading error of <3%.
- Remote control: Supporting remote operation via 5G or satellite communication, operators can complete equipment start-stop, parameter adjustment, and fault diagnosis in the central control room, reducing the exposure risk of on-site operators.
Selection Suggestions
- Cargo characteristics: For powdery materials, screw ship loaders are preferred; for bulk materials, belt or rail-mounted ship loaders are suitable; for multi-cargo types, portal cranes + grab buckets are a good choice.
- Port conditions: Deep-water terminals (water depth ≥14m) are suitable for rail-mounted ship loaders; small and medium-sized terminals (water depth ≤10m) prioritize mobile ship loaders; belt conveyor systems are considered for areas with complex terrain.
- Environmental protection standards: For regions such as Europe and North America, vacuum dust collection + enclosed design are preferred; for dry regions such as the Middle East and Africa, dry fog dust suppression can be used to balance cost and compliance.
- Operating costs: For high-throughput scenarios (>5 million tons/year), rail-mounted ship loaders are selected (with low unit energy consumption); for small and medium-throughput scenarios (<3 million tons/year), mobile ship loaders are preferred (with low initial investment).
As a professional manufacturer of bulk material conveying equipment, Zoomry can provide customized solutions according to customers' specific needs. Its core products such as belt conveyors and mobile ship loaders have passed international certifications such as ISO 9001, CE, and ATEX, adapting to technical standards and environmental protection requirements of most ports around the world.
