DSI Sandwich Belt high angle conveyors take on many forms and offer many advantages.  They offer a clean, environmentally sound operation because the material being carried remains hugged between the two conveyor belts.  A DSI Sandwich belt high angle conveyor is capable of higher conveying speeds and greater capacities than other high angle conveying methods. High angles of 90° are typical, and lifts of 300m are easily accomplished.

With all the positive features of the DSI Sandwich Belt conveyor, it has been successfully used in mining, quarries, plants and tunneling, but one sector less talked about is ports and terminals.  The DSI Sandwich Belt high angle conveyor has not only been implemented on ship loaders, but the ingenuity of Dos Santos International took the technology beyond perceived limits to offer efficient and sustainable solutions to solve challenges at ports and terminals.

The DSI Mobile Sandwich Belt shiploader is driven from the dock when not in use, stored and parked much like parking a car.

Australia’s first DSI Sandwich Belt high angle conveyor ship loader elevates 1,000 tons per hour of a variety of materials, from high value ores to grains and wood chips, from trucks to ship.  Conventional conveyors would not have fit the limited dock space, so a smaller footprint was required.  Recognized for the ability and advantage to elevate at much higher angles, the DSI Sandwich Belt conveyor was engineered to elevate materials at a 50° angle.

Each set of twin tires is mounted at a vertical kingpin and can rotate 360 degrees about that vertical axis.

Additionally, because of the limited dock space, it was ideal to have a system that was mobile and could be removed from the dock when not loading ships.  The ingenuity of DSI partner, Cortex Resources of Hawthorne, Victoria, Australia produced this revolutionary driveable and completely mobile shiploader.

One of the more incredible features of the DSI Mobile Sandwich Belt ship loader is how it is driven.  Like a dream come true for the kid in all of us, this system is driven by remote control.  The operator straps the remote control to their body and proceeds to drive the shiploader slowly and carefully to the dock, while standing or

 walking along the dock.  The shiploader is carried on a tripod of rubber tire assemblies.  Each is mounted on a vertical axis and can be rotated.  The rear tire assembly consists of four rubber tires that steer and drive the ship loader.  The two forward tire assemblies each consist of two non-driven tires.

Materials are loaded at the mouth of the Sandwich Belt high angle conveyor by a mobile feeder.

Thus, without repositioning the DSI Mobile Sandwich Belt shiploader, with the forward tires set parallel to the longitudinal axis, it can travel forward and back and be steered to either direction.  With the tail tires fixed, the front tires can be oriented and traveled for a slewing motion.  With the forward tires set perpendicular to the longitudinal axis, it can be travelled side to side while oriented in its loading position over the ship.

Materials for export are trucked to the dock and dumped onto a special mobile feeder.  The bulk is fed continuously and uniformly into the mobile Sandwich Belt’s receiving chute.

The DSI Mobile Sandwich Belt shiploader elevates the bulk over the ship’s deck to the hatch where it is discharged into the ship’s hold.  At the Sandwich Belt conveyor’s discharge, a special telescoping chute, with a rotating pivot spoon, facilitates even and complete filling of the holds.

The Port of Adelaide is the main port in South Australia.  It works with a range of outbound mining cargoes including:  limestone, metals and scrap metal, iron-ore, iron and steel, mineral sands, mineral concentrates, cement and cement clinker.  It also transfers materials such as grains and wood chips.

The telescoping chute can extend into the ship's hold to softly load and distribute the material.

The mobile shiploader set the stage for DSI to supply their Sandwich Belt high angle conveyor at the Yara Sluiskil shiploader upgrade in the Netherlands.

The initial design concept for the upgrade used a conventional conveyor “stinger” boom out from the perpendicular dock conveyor, to the tail of a standard DSI high angle conveyor.  This had the disadvantage of an additional transfer and extra equipment, so the client readily embraced the idea of replacing the stinger conveyor with an extended high angle conveyor tail to receive the material directly from the dock conveyor tripper.  Layout of the new arrangement immediately revealed that sufficient tripper height did not exist to accommodate the tail pulley of the sandwich belt high angle conveyor.

The solution was to employ the DSI Adder Sandwich Belt high angle design, using a lighter construction belt that can be wrapped around a smaller tail pulley.  To accomplish the high angle lift, the DSI Adder Snake swallows the narrow conventional belt, along with its material, into the two wider sandwich belts, allowing the material to enter the sandwich belts with minimal disturbance. It does this without the energy loss and additional equipment required for a standard transfer.

Adder Snake generalized layout.
Adder Snake generalized Sandwich entrance.

The concept of the DSI Adder Snake, invented by DSI’s vice president, Marc dos Santos, was inspired by a very different application, elevating material from under large storage domes.  The use of this technology extends to a wide variety of applications, including marine terminals, stacker/reclaimers, and long overland systems.

The Yara shiploader application provided the first opportunity to implement the Adder Snake concept.  The DSI Sandwich Belt high angle conveyor transfers urea and amidas prills at a rate of 600 t/h at a 45° angle.  The material will be transferred from the tripped dock conveyor onto the 1200mm wide Adder Belt, which is then swallowed with the bulk into the 1600mm wide Belt Sandwich.  The bulk is then elevated to the shiploader boom conveyor.  The sandwich conveyor discharge is centered on the rotation axis of the boom, allowing the boom to rotate freely.

The DSI Sandwich Belt high angle conveyor transfers urea and amidas prills at a rate of 600 t/h at a 45 degree angle.

In a most recent installation, Dos Santos International is supplying their Sandwich Belt high angle conveyor to be installed on a floating grain terminal on the Mississippi River.  The profile for the system is 18.5 meters of lift at a 50 degree incline.  It boasts an impressive belt width of 84 inches and a volumetric rate of 2268 t/h (2950cu-m/h).  This will elevate mostly hard grains like corn and soybeans, but could include some meals.

While typically thought of as an elevating solution in mines, quarries and plants, the DSI Sandwich Belt high angle conveyor has proven a high level of flexibility to bring cost saving solutions on both land and sea.

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