Here we look at the achievements of two bulk ports on opposite sides of the Atlantic. The Port of Antwerp, like its competitors, reported a significant loss of dry bulk volumes in 2009, mainly in major bulk (iron ore & coal) due to a massive and never before seen idling of European steel mills. In minor bulk, it was the fertiliser business which suffered the most. However, the Belgian port resolutely stayed in the offensive by taking a number of strategic decisions, enabling it not only to secure restoration of volumes, but even allow for future growth. First, an agreement for deepening of the River Scheldt was reached between Belgian and Dutch authorities, making it possible to remain accessible for the largest type vessels. Antwerp is happy to be able to announce that these works will be finalised before the end of this year, but already allows the bulk of positive impact to be realised as from mid-2010. Furthermore, on the pretext ‘Never waste a good crisis,’ a joint project called ‘Total plan for a competitive port’ was set up between the private sector and port. It resulted in the re-engineering of the raw materials supply chain of major bulk and guarantees that Antwerp will remain a viable alternative in the Antwerp-Rotterdam-Amsterdam range for full cape-size vessels in years to come. Secondly, within the port, ongoing investments in both infra- and superstructure will secure Antwerp’s competitiveness; a principal green light for a second lock to the Left-bank area had already been given by the Flemish Authorities before summer recess, but only a couple of weeks ago, the Board approved a long-term financial plan of no less than Euro 1.6 billion to be invested in the coming 15 years, while at the same time it decided to freeze port dues for 2011 to the level of 2010. On top of that, several private operators continue to invest in renewal and/or expansion of their terminals. An excellent example of the latter is malt-producer Boortmalt who finalised earlier this year an important investment programme in additional production and storage capacity in the Port of Antwerp, and now secures close to 50% of export of the total European malt-production through the port. Moreover, special attention has been paid to reduce fine dust emissions during bulk-handling, by moving sensitive volumes from open to covered areas, or increasing use of dust control sprinkling systems. But these initiatives are not limited to the ‘hardware’ alone, specific training programmes will ensure that Antwerp’s highly reputed labour-force will keep their leading edge in specialised and safe dry bulk-material handling. Last but not least, no effort has been spared to expand Antwerp’s hinterland by improving accessibility by rail, road, barge and short-sea at highly competitive prices and even participating/co-investing in hinterland hubs. Antwerp is confident that its excellent central inland location will increasingly prove its worth during the next decades. It goes without saying that, with a justified demand for sustainability from both community and business, the eco-friendly nature of a river port compared to an ocean port becomes an important trump card. The port of Antwerp strongly believes that the recent global crisis, which basically forced all industries to rethink their supply chains and focus on cost-control, strict cash-flow-management and flexibility to match supply with demand, will create opportunities on a longer term basis. No longer is a port considered a mere transfer-point of cargo, it has become a vital link within complex supply chains: those ports that can best meet the crying needs of shippers by offering complete supply chain solutions, will undoubtedly be the ports of the future. Especially in the dry bulk domain, the Port of Antwerp together with its stakeholders is committed to offer such solutions: their continuous investments in state-of-the-art infrastructure and people, together with a firm and permanent embedment in both fore- and hinterland, are the best guarantees for a sustainable, bright future.

Port of Sept-Iles
Although not as large as the Port of Antwerp, the bulk orientated Port of Sept-Iles has similar ambitions as its counterpart. Boasting a variety of state-of-the-art facilities, the Port of Sept-Iles is one of North America’s leading iron ore ports and in 2011 will become Canada’s second largest in terms of expected annual volume handled, with over 35 million tonnes. At the beginning of this year, the port announced the signing of rate agreements with Labrador Iron Mines Limited (LIM) and New Millenium Capital Corporation (NML), clearing the way for direct shipping iron ore (DSO) to the Pointe-Noire port facilities.”These two new agreements will have a major impact on the port’s growth and development since they will eventually represent a combined total of an additional 7 million tonnes when operations are in full swing a few years from now,” stated Port of Sept-Iles CEO Pierre Gagnon. The two companies are currently starting to exploit iron deposits in Schefferville and Labrador. “These two agreements, along with the one signed in October 2009 with Consolidated Thompson Iron Mines Ltd (CLM), demonstrate how fast the iron industry is growing on the North Shore and in northern Quebec and Labrador. The Port of Sept-Iles is proud to be a part of that development and to work closely with these new mining companies to help them carry out their projects,” stated Port of Sept-Iles Chair of the Board Carol Soucy. In July, the first shipment of 165,225 metric tonnes of iron ore belonging to CLM left port bound for China aboard the Navios Aurora. This marks a new maritime destination, joining the other international destinations that account for over 85% of port traffic. This first shipment is destined exclusively for CLM’s Chinese partner Wisco, located in Wuhan in the province of Hubei. In the last few days, CLM has begun operating its new land-based storage facilities and an innovative ship-loading system that uses CSL’s Atlantic Superior self-unloading shuttle to load ships anchored in the Bay of Sept-Iles. “With an initial shipping capacity of 8 million tonnes by late 2010, which will grow to 16 million tonnes following the expansion of their activities at Bloom Lake in late 2012, CLM is set to play a key role at the Port of Sept-Iles. The company is one of our major partners, and we want to provide them with the support and services they need for future growth,” said Soucy.  But the port has not stopped since July and in September Prime Minister of Canada, Stephen Harper visited to launch the second phase of the project to increase the Relance Terminal’s capacity. The terminal’s main client is Aluminerie Alouette and a grant of USD7 million or 50% of the project costs was awarded through the Infrastructure Stimulus Fund for the rehabilitation or construction of infrastructure. This announcement took place during a ceremony to mark the inauguration of the large concrete silo number 8, part of the initial USD30 million-project. The Honourable Denis Lebel, Minister of State for the Economic Development Agency of Canada for the Regions of Quebec, was also present, as were Aluminerie Alouette representatives and other dignitaries from the Sept-Îles region.  Phase 2 of the project to increase La Relance Terminal’s capacity represents a total investment of USD14 million and the money will go into optimising the largest aluminum industry port terminal in the Americas. The project principally involves the construction of a logistical centre for aluminum management, improvements to docking systems, an increase in electrical capacity, and the establishment of a new service building for terminal security. These investments will accommodate the growing needs of terminal users, particularly Aluminerie Alouette.

For the port of Sept-Iles, the completion of this second optimisation phase and current investments ensures it can remain competitive and protect its international position as it tackles future challenges – similar to the actions of the Port of Antwerp.

“It was a very difficult year, but now it is behind us.” Once Seram operated four factories throughout Europe, now it has consolidated its manufacturing into a single 7,500 square meter plant in Perpignan, France. The inventor of the equilibrium crane concept back in 1973, Seram has more than 650 cranes in service worldwide and is still ranked as the world’s No. 1. Although smaller by world sales so far, the upstart E-Crane International (part of the Belgian Indusign NV engineering company) has continued at a record pace right through the global recession. It followed a record sales year in 2008 with another in 2009 and 2010 looks even better, according to Bas Tolhuizen, International Sales Manager for E-Crane Worldwide. “Every year we have seen 10 to 15% increases in sales, notwithstanding the economic situation,” says Tolhuizen. “We are steadily growing year in, year out and can’t complain.” E-Crane has full order books in Belgium at its Adegem production facilities and now has 150 balanced cranes in operation around the world.

Excellent year

In North America, 2010 is proving to be an excellent year, according to Mark Osborne, President of E-Crane International USA in Ohio. “We have done a lot of proposals from clients that we feel will go ahead. We have a lot prospects going forward and I am proud of our performance,” says Osborne. A year ago, Osborne predicted a “spike” in business late in 2010 and while it hadn’t happened by early December, he says there definitely has been a “spike in inquiries.” And another of the world’s leading balanced crane manufacturers, Metso Minerals with its equilibrated crane, is struggling to get sales back to the more traditional levels it enjoyed before the economic storm hit. “Our 2010 will be a fair year for us as many of the projects our customers placed on hold have been released and we are also seeing new projects,” says Tom Lippencott, Vice President Mining Capital Sales for Metso USA-Canada. Metso has seen market activity steadily increasing – not yet at the level of several years ago – but moving in the right direction. “We have seen activity in the world terminal market and this is the market that we feel is growing,” adds Lippencott. Metso Bulk Materials Handling Group in Pittsburgh, PA owns the exclusive rights to the Sobemai equilibrated crane technology from Belgium and has over 100 cranes installed around the world.

Trouble in France
Strikes and other labour troubles in France recently over reforms could present new opportunities, according to Julia of the Seram Group. Previously, port equipment such as balanced cranes, conveyors and the like, were owned by the French Government. Now, ownership of much of the bulk handling and other port equipment has been turned over to private operators in charge of port handling. As well, says Julia, the workforce has also gone private and is no longer entirely state employees, a move that led to many strikes in 2010. The good news for Seram and other balanced crane operators interested in the French market is that the operators can order whatever port equipment they can afford. Julia says that was difficult in the transition in 2010, but in 2011 placing orders for new equipment such as balanced cranes will be much easier throughout France. “We are getting orders; customers are starting to invest again.”

Order successes
As for contract successes, Seram reports the 2010 sale of about six balanced cranes to Australian recycling companies, plus new orders from Spain, which could not be spelled out at this stage of the contracts. In Europe, E-Crane Worldwide commissioned a rail-mounted 2000 series E-crane at the Port of Kokkola in Finland in October 2010. The new model 17359 GAE crane runs along the Deep Port Dock and handles iron ore, zinc, and coal up to 1,000 tonnes per hour using its outreach of 35 meters. Tolhuizen says Asia is becoming more and more important in E-Crane Worldwide’s future with “an explosion of eight orders from Bangladesh in 2010, one of our biggest growth markets.” Most of the balanced crane orders have been for smaller models. In Holland, the expansion of the Port of Rotterdam saw an E-Crane assist in building a concrete breakwater in a joint venture with Puma Dredging. With 40-tonne blocks to lift at a reach of 61 meters in the port project, E-Crane produced its biggest balanced crane ever by weight at 1,200 tonnes and with a lifting capacity of 50 tonnes. The giant crane is mounted on six crawlers. And in Argentina, a 2000 series E-Crane was commissioned in September for Siderar and used in handling iron ore. Tolhuizen says E-Crane has a growing reputation throughout the world and the company is signing more and more clients to maintenance contracts offering full crane service or solely to perform scheduled maintenance. E-Crane International USA commissioned a stationary 11-tonne capacity crane for the PPG Natrium industrial chemical company in West Virginia in April-May, says Osborne. The crane is now in use unloading coal used in on-site power production and steam processes. It took the E-Crane commissioning crew only eight days to replace an old cable crane at the dock with a new, Series 1000 model balanced crane. At Corpus Christi, Texas, E-Crane successfully commissioned two rail-mounted balanced cranes in September for Sherwin Alumina. The two cranes are being used to unload bauxite used in the aluminum process.  Many of the new projects at proposal stage involve biofuels, wood pellets and industrial processes which the company hopes to get more involved in during 2011. Osborne says clients appreciate E-Crane’s quick response to parts inquiries and technical support and this work played an important part in keeping the company vibrant during the economic recovery in the US. For the worldwide company Tolhuizen sums it up by saying: “There’s no doubting us being among the market leaders. It’s our core business; it’s the only thing we do. So we are offering service as we supply, and we are the ones offering solutions such as we did for the Puma dredging joint venture in Holland.” E-Crane is expecting “a decent year in 2011 with a solid year of work ahead.”

Why balanced?
But, why are balanced cranes from the big three manufacturers growing in acceptance? Balanced or equilibrium cranes are based on an ingenious design incorporating a parallelogram boom that provides a direct mechanical connection between the counterweight and the load. According to E-Crane, this unique system ensures near perfect balance throughout the crane’s full working range. Conventional cranes can use as much as 80% of their available energy just to move the boom, stick and grab. Not so for balanced cranes which offer significantly lower maintenance and operating costs.  Seram’s Julia explains that balanced cranes manufactured by the group don’t use much power to operate, just the energy needed to carry the load, not the boom and frame. “This gives us much lower operating costs than conventional cranes and makes us more popular than mobile cranes.” She instances, for example, a comparison between an electrically-powered balanced crane with a 5 tonne lifting capacity and a boom reach of 25 meters. Running costs for such a crane with its 160 kilowatt motor and an average consumption of 110 kW per hour, would give it an electricity cost of Euro 6-7 an hour. A typical diesel powered mobile crane would consume about 32 litres of diesel an hour at about Euro 1 per litre for a cost of Euro 28-29 an hour. “That’s a Euro 22 an hour cost difference and over a year of about 20,000 hours of operation that’s over Euro 44,000 in savings.” Diesel cranes also need 15 minutes to preheat the motor, 20 minutes to refuel and over 250 hours of maintenance a year. Balanced cranes don’t need that and Julia says the savings for these elements alone total 200 hours a year or 25 to 30 work days. And balanced cranes are highly versatile with most manufacturers offering them on rails, pedestal, free standing, trolley, and gantry or on legs. The Seram Group offers balanced cranes ranging from mod
els that can lift two to four tonnes at 17 meters reach up to 28.5 tonnes at 35 meters.

Innovations
Metso and other balanced crane makers use a system of continuous improvements for their cranes, particularly the control systems. Joystick controls mounted on consoles that are part of the operator’s chair have simplified operation and a touch screen is mounted above the operator to help easy monitoring of all crane movements. Recent models have an articulating operator’s cab that is positioned to give the crane operator the best vantage point Seram’s Julia says real time improvements have been achieved to the French company’s balanced crane series. And to make cranes even more economical and environmentally friendly, energy from braking is reused in running the crane.