Sweetener & Beverage Manufacturer Sugar Railcar Unload & Transfer System

The existing sugar unload system was a vacuum pneumatic system. In the first phase of the project, ADF performed a study to identify why the effective sugar unload rates (22,000 lb./hr.) and the original effective design rates (30,000 lb./hr.) did not match, as well as provide recommendations to increase capacity. Once the study was completed, the client chose the conceptual design option that would allow the facility to unload 5 railcars per day. This option involved gravity unloading of railcars into an unloading pit to allow for an effective unload rate of 60,000 lb./hr.   

ADF completed the following:

• Process Design:
  • Process study that determined the root cause for the slower unloading rates and provided recommendations to close the gap between the actual and intended unload rate.
  • Estimated probable cost of the new equipment, construction, materials and detailed design.
  • Created five conceptual designs involving different unloading techniques with varying unload rates.
  • Worked with vendors to develop a cost-effective, operator-friendly solution, including:
    • New unloading system allows hopper gates to be opened simultaneously to minimize dead time.
    • Designed the railcar boot lifts such that three could accommodate 10 different styles of railcars.
    • Designed the railcar scales to have an extended “sweet spot” to accommodate 10 different styles of railcars.
  • Finalized specifications and developed equipment list, which included an unload screw conveyor, railcar scales, airlocks, high pressure blower, diverters, dehumidifier and dust collection system.
  • Obtained quotes from multiple vendors for the screw conveyor and pneumatic transfer system.
  • Updated facility P&ID with equipment and instrumentation tags.
  • Created a functional description for the new unloading process.

• Mechanical Design:
  • 3D laser scanned the rail bay and created a 3D model of the existing sugar unload system.
  • Created five conceptual 3D models for consideration.
  • Created and finalized 3D model for new unloading area based on approved equipment drawings.
  • Created equipment layouts with elevations and sections showing tie-in locations.
• Structural Design:
  • Designed new rail car unloading pit foundation and steel.
    • Special design considerations were required to allow for trucks to pass over the unload pit.
    • Obtained budgetary quotes for sheet piling and/or lagging, which were required due to the new pit being located between two silo footers.
  • Created structural drawing package, including plans, elevations, sections and details for all structural steel and foundation.