INNOVATION July-August 2014

Neptune Bulk Terminals In response to increased demand for steelmaking coal worldwide, CWA Engineers undertook the project to increase throughput at Neptune Bulk Terminals, while reducing impact to the environment and community. CWA designed and refurbished structures to maximize efficiency and minimize wastage, including a new yard conveyor, transfer point and tower, berm, surge bin roof structure, rail concrete blocks and spill trays. The improved terminal features noise control, automated wash-down systems, clean-up surfaces, modernized conveyor transfers, as well as improved safety features, all while increasing capacity of the terminal from 5.5 million tonnes per annum (mtpa) to 12 mtpa. State-of-the-art dustless transfer technology incorporating discrete element modelling techniques were utilized to produce soft-handling of the material. This technology, coupled with improved dust-control systems, minimized dust formation. Simpson Bay Causeway In 2013, FormaShape was contracted to design and fabricate 1.5 km of fibreglass reinforced panels for decorative cladding on the newly constructed Simpson Bay Causeway, which connects the French and Dutch sides of St. Maarten. Critical design elements included a shape and surface finish to maximize reflectivity and illumination of the integrated LED lighting system. BASF UNO paints with high-gloss UV clear coat, combined with Philips LED components create a stunning night-time effect with alternating colours and patterns. The 780 panels, situated 10 m above sea water, required a mechanical anchoring system to withstand corrosion and hurricane-force winds. FEA analysis in conjunction with load testing of the fibreglass laminate was conducted to ensure performance of the panel and attachment designs. Project owner: Simpson Bay Lagoon Authority. General contractor: Volker Stevin Caribbean. Panel design and manufacturing: FormaShape (a division of Whitewater Composites). General manager: Tim Boothman, P.Eng. Structural analysis and attachment design: Henry Czenczek, P.Eng.

Electrolyser Test Stations In early 2013, Greenlight Innovation successfully delivered and installed three electrolyser test stations to the Forschungszentrum Jülich, a research facility in Jülich, Germany. Greenlight is a world leader in the area of electro-chemical cell test equipment and the test stations are critical tools for the development and testing of advanced electrolyser technology. FZ Jülich is developing PEM electrolysis technology for hydrogen gas production, which can address the intermittent nature of renewables such as wind and solar. During off-peak times, excess electricity can be put through an electrolyser to make hydrogen, which can either be directly injected into the natural gas grid, or stored for later use in a hydrogen fuel cell. The automated electrolyser test rigs are designed to continuously operate under dynamic conditions, simulating the conditions that would be experienced if the electrolyser were attached to a wind or solar farm. Project team: Christian Bosio, P.Eng.; Daren Toppin, P.Eng.; Rob Manson, EIT.

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