Many terminal operators are looking for new technology to help them deal with these challenges. BEC Industries, LLC (BEC) is an engineering firm which specialises in product design and development. BEC is focused on innovative material handling technologies for military and commercial applications and has developed a transformational material handling system that is ready for implementation into the container handling industry. The BEC Goods Retrieval and Inventory Distribution (GRID) System is a multi-directional overhead material handling system which uses a pioneering overhead transfer unit (TU) to manage densely stored containers. The military application of this system sorts and pre-stages containers on a ship while at sea, speeding container retrieval and deployment. BEC presented the concept design for this system to the United States Military and was awarded several military contracts which were completed successfully. Those contracts funded the development of the prototype and testing of the system at sea onboard a Navy ship. BEC is now applying the GRID system to the commercial markets where it offers significant benefits to the container handling industry, as well as others.
CURRENT PORT OPERATION CHALLENGES
Capacity Issues and Congestion
As container traffic increases, land shortages prevent ports from expanding to meet that demand. A survey of port and logistics studies and publications show that worldwide, port volume grew 12 –15% annually from 2006 – 2008. In addition to pollution, truck traffic in and out of port terminals causes heavy congestion on highways and freeways. State and government agencies like the Gateway Cities Council of Governments are working on action plans, including one for the I-710 corridor in southern California. Given capacity limitations, congestion, and pollution issues, utilisation of land outside the immediate port area is being considered as a solution. Unfortunately, most ports are land locked for one reason or another and this is not an option.
Pollution
The cities and residential areas around ports are suffering from airborne materials pollution caused by diesel exhaust from the yard equipment (hustlers, cranes, reach stackers, straddle carriers, etc.) and other equipment that picks up or drops off loads (semi-tractors, trains, ships, shuttles, etc). As a result, local and state governments are applying pressure to clean up emissions and to “go green.” Southern California’s largest fixed pollution sources are the ports of Los Angeles and Long Beach, and according to the Coalition for Clean Air, the two million people who live within 15 miles of the ports face a cancer risk at least 50 times higher than what is considered to be safe, and an estimated 1200 people die prematurely every year as a result of the pollutants generated from the ports. In children, exposure to high levels of pollutants has been linked to asthma and bronchitis; and numerous studies have shown that children living near areas with high concentrations of diesel exhaust are more likely to suffer from decreased lung function. These studies have port community residents concerned and vocal about the effects of diesel fumes and other air contaminants on their health.
Container Scanning
The United States Government intends to require 100% scanning of inbound containers in the near future, even though there is no system currently in place that can accomplish this. Port operators around the world are struggling to develop methods for meeting this requirement.
THE GRID SYSTEM PORT SOLUTION
When applied to port terminal operations the GRID System can be integrated with the existing Quay crane to address all of the challenges listed above. Once the container has been fed into the GRID System utilising a transfer table, the overhead transfer unit (TU) handles every aspect of container movement within the facility. As shown in Figure 1, the portside of the GRID System operation can include movement of incoming or outgoing containers by scanning or detection equipment for security screening without halting the transportation process. The overhead GRID system is configured to store incoming containers in a dense cube for subsequent delivery directly to rail or truck. A warehouse area can be included to facilitate less-than-container-load outbound shipments, and segregated inspection areas can be included for added safety. Outbound containers are handled in a similar manner. The GRID system allows pre-staging of the containers to expedite simultaneous offload and onload from and to the ship, significantly decreasing its berthing time.
Figure 1: BEC GRID System port application showing interface with a Quay crane using a transfer table. The system TU then transfers containers to trucks, storage, rail, or a cross-dock area.
Transfer Unit (TU) The TU itself, shown schematically in Figure 2, is essentially an under-slung bridge crane that is capable of moving in the X and Y direction while being suspended from the overhead grid. It raises and lowers containers with a standard spreader beam. This configuration provides for very dense storage and easy sorting of containers, similar to a Rubik’s cube. The TU can be configured to work automatically, semi-automatically, or manually, depending on the needs of the terminal operator. Multiple TUs operating in the GRID system provide significant throughput capability as well as total system redundancy. If one of the TUs needs servicing, it can be moved to the side while the other TUs continue. Only one type of equipment other than the quay crane (the TU) requires servicing within the terminal and overall maintenance costs at the terminal are reduced because of the minimal maintenance required by the TU.
Figure 2: Schematic of TU
Transfer to and from ship The container is transferred to and from the Quay crane by utilizing a transfer table, as shown in
Figure 3. Inbound containers are placed on the top table, where they are gravity fed under the GRID System so the TU can lift and transfer them to the storage cube. Similarly, outbound containers are placed on the lower table where they move out from under the GRID system to facilitate the Quay crane transfer to the ship.
Figure 3: Transfer table configuration
Transfer to and from land transportation
Containers are directly transferred to and from rail and truck by extending the GRID system over the transfer area, as shown in Figure 4. This procedure significantly reduces the time and number of container transfers required for the processes that are used today in most ports.
Figure 4: Load/unload configuration
Capacity and Throughput
The GRID System configuration allows storage of containers up to seven or eight high and eliminates the need for aisles within the storage footprint. It significantly increases the existing container storage capacity of typical terminals. Throughput simulation studies have been conducted in conjunction with the Center for the Commercial Deployment of Transportation Technologies (CCDoTT). These studies show that the throughput provided with this system is significantly greater than that provided with conventional methods of operation.
Container Management
Whether the system is configured for automatic or manual use, the operational controls can be integrated into existing inventory management and tracking systems. This provides considerable system improvement without requiring the operator to retrain employees with new management software.
Combating Pollution
The GRID System is completely electric and therefore it is totally green within the port terminal. The GRID system can also be used at intermodal facilities for storage and container handling and loading, which would reduce emissions to only those produced by the trucks and trains being loaded at the facility. The system also provides an ideal configuration for utilising solar energy. Solar panels can be mounted on the existing GRID structure to produce
electricity for the operation of the system. This can provide a significant system advantage in areas with abundant sunlight.
Container Scanning
The BEC GRID system provides a means for accomplishing 100% scanning without impeding the flow of containers through the port. This is done by placing scanning devices along the paths that the containers travel during normal operation. If a container is flagged for inspection based on the results of the scan, it can easily be brought to a separate inspection area. This scanning can be done on both inbound and outbound containers, addressing security concerns for customers receiving goods on both ends of the supply chain.
INTERMODAL APPLICATIONS
BEC has also been working with CCDoTT on intermodal operations. CCDoTT and BEC are developing the concept of CCDoTT’s ECCO Mag-lev System, which takes containers from the port terminal to an intermodal facility where the BEC GRID System will unload containers and transfer them to storage or directly to rail or truck. This design provides a valuable solution for capacity and throughput issues at both port and intermodal facilities. It addresses the critical pollution and environmental problems ports are under pressure to solve. Reducing diesel emissions from port-side rail and truck operations in these congested areas is a major focus for CCDoTT, as well as for government and port officials throughout the world. Figure 5 show an overview of an intermodal facility. The Mag-lev system brings the containers from the port to the intermodal facility and returns outbound containers to the port. The BEC GRID System is used to unload/load the Mag-lev, and unload/load trucks and rail. In the graphic, the transfer area closest to the GRID storage area is for the Mag-lev and the ones furthest from the area are for rail and trucks. The overhead grid extends the length of the rail loading zone to avoid the train starting and stopping while loading. This design is to reduce the pollution in the area. The utilisation of the GRID system in current intermodal facilities provides the same advantages when transferring to and from rail, truck, and temporary storage. Scanning devices can be incorporated in the intermodal facility for outbound containers therefore expediting container movement through the port terminal.
Figure 5: Overview showing an intermodal facility supporting port storage with the GRID System loading/unloading a Mag-lev system, train, and truck
SUMMARY
The GRID System technology for movement and management of containers has been proven for shipboard operations and the incorporation of this design in port operations is straightforward. In summary, the BEC GRID solves the following problems faced by port operators today:
• Two to three times the storage density of typical port layout.
• Faster ship-to-shore crane cycle times.
• Faster simultaneous ship load/offload.
• Fewer container transfers than conventional port operations.
• Greater efficiency by parallel loading of trucks and rail.
• Greater efficiency and security with en-route scanning.
• Powered exclusively by electricity.
• Reduces maintenance and operating costs to only one type of equipment
• Eliminates O&M cost for support equipment.
• Drastic reduction in air pollution from diesel exhaust.
• Modular design for retrofitting and expansion.
• Provision for solar panel installation.
• Operating redundancy.
• Increased efficiency and capacity without corresponding operating and maintenance costs.