Automated Container Terminals Will they ever catch up…?

1. PresentationJoppe Burgers 29 May 2008Busan,Korea Automated Container TerminalsWill they ever catch up…?

2. Automated Container TerminalsWill they ever catch up…? Contents of presentation • Introduction • Conventional Terminals • Automated Terminals • Examples Automated Terminals • Case study • Conclusion Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion

3. Automated Container TerminalsWill they ever catch up…? Introduction • Three types of container terminals: • Conventional • Semi automated • Automated Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion

4. Storage Automated Container TerminalsWill they ever catch up…? Introduction Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Waterside Quay  Terminal yard Land side Vessel (un-)loading Truck / train (un-)loading

5. Automated Container TerminalsWill they ever catch up…? • Conventional Terminal Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion • Waterside handling equipment • Ship To Shore gantry crane • Mobile harbour crane • Wide-span gantry

6. Automated Container TerminalsWill they ever catch up…? • Conventional Terminal Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion • Yard handling equipment • Straddle carrier • Rubber tired gantry • Rail mounted gantry

7. Automated Container TerminalsWill they ever catch up…? • Conventional Terminal Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion • Internal transport • Port Tractor Trailer • Shuttle Carrier

8. Automated Container TerminalsWill they ever catch up…? Automated Terminals • Conventional vs. Automated container terminal? • Higher capital investment? • Lower operational costs? • Labour Costs? • Technical skills? • Predictable productivity? • Experience? • Increase reliability? • Environmental issues? • Energy prices? • Regulations? • Health & Safety? Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

9. Automated Container TerminalsWill they ever catch up…? • Automated Terminals Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion • Waterside handling equipment • Ship To Shore gantry • Dual Hoist STS gantry • Wide-span gantry • Yard handling equipment • Straddle carrier • Rubber tired gantry • Rail mounted gantry • (Overhead grid cranes) • (Conveyor belt) • Internal transport • Automatic Guided Vehicle • Shuttle carrier

10. Automated Container TerminalsWill they ever catch up…? Examples • ECT Rotterdam • Single hoist Cranes, AGV’s and ASC’s • Thamesport • ASC’s • Hamburg CT Altenwerder • Double hoist Cranes, AGV’s and ASC’s • Nagoya Port Terminal - Nagoya • Semi automated RTG • Wan Hai lines - Tokyo • Semi automated RMG during day • Automated house keeping during night • Euromax Rotterdam • Double hoist Cranes and ASC • Remote control desk • EMC-Kaohsiung • Partly automated • Taipei Container Port Terminal • Semi automated • Busan New Port 2-1 • Double hoist Cranes and ASC • PNC 1-2 • Double hoist Cranes and ASC • Antwerp Gateway • Started with Straddles, transition to auto RMG Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

11. Automated Container TerminalsWill they ever catch up…? Examples • Brisbane: Fishermans Islands • Apron area AutoStrads • Stacks AutoStrads • Transfer area Autostrads Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

12. Hamburg: CT Altenwerder Berth Semi automated double hoist Apron area AGV Stacks Passing ASC Automated Container TerminalsWill they ever catch up…? Examples Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

13. Automated Container TerminalsWill they ever catch up…? Examples • Posport CTS – Busan New Port Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

14. Automated Container TerminalsWill they ever catch up…? Case Study • MSc project Wieger Rademaker • (TU Delft & Royal Haskoning) • Is automation of container handling on small terminals feasible as a commercial investment? • Hurdles • High investments • Uncertain future development • No development budget • High technical level of personnel required • Proven technology preferred • Advantage • Lower operating and labour costs • High level of services Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

15. Automated Container TerminalsWill they ever catch up…? Case Study • Approach • Preliminary design of an automated container terminal • Estimate of required investments • Cash flow analysis • Comparison with conventional alternative Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

16. Automated Container TerminalsWill they ever catch up…? Case Study • Risavika CT • Stavanger, Norway • Modern container terminal • Site: 350 x 500 m • 4 other ports in Region Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

17. Automated Container TerminalsWill they ever catch up…? Case Study Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion • Design conclusions (KPI’s and Posport CTS) • 2 Quay cranes • 6 AGVs per quay crane • 6 RMGs

18. Automated Container TerminalsWill they ever catch up…? Terminal layout

19. Automated Container TerminalsWill they ever catch up…? Case Study • Cost estimate • Civil works : € 38,000,000 • Equipment : € 39,000,000 + • Total investment : € 77,000,000 Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

20. Automated Container TerminalsWill they ever catch up…? Case Study • Operational costs • Benchmark operating costs (conventional terminals) • Per TEU : € 70 • Operating costs automated • Per TEU : € 55 • Labour costs savings (automation) • On basis equipment operating hours • Per TEU : € 13 • Annually : € 2,500,000 Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

21. Automated Container TerminalsWill they ever catch up…? Case Study • Cash flow analysis • Discounted Cash Flow model • Net Present Value • Terminal income • Throughput : 200,000 TEU by year 3 • Handling charges : 100 €/TEU Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

22. Automated Container TerminalsWill they ever catch up…? Case Study • Net present value - Leased quay wall Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

23. Automated Container TerminalsWill they ever catch up…? Conclusions • Is automation of container handling on small terminals feasible as a commercial investment? • Terminal not feasible as a commercial investment due to • Size of initial capital outlay • Investment risk from long investment period • Public sector involvement is required! • However results show that Automation is catching up!!! Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

24. Automated Container TerminalsWill they ever catch up…? Questions? Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

25. Container terminal automation Cost estimate civil works

26. Container terminal automation Cost estimate equipment

27. Container terminal automation Automated concept

28. Container terminal automation Conventional concept

29. Automated Container TerminalsWill they ever catch up…? Case Study • Functional requirements • Waterside handling capacity • Quay length : 250 m • Handling capacity : 50 moves/hour • Storage capacity • Average : 3,900 TEU • Peak : 5,000 TEU • Landside handling capacity • Gate / Yard handling : 77 moves/hour Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

30. Container terminal automation Recommendations • Investigate possibilities of public sector involvement • Follow development of Autostrad concept • Many operational advantages • Maintenance requirements have to improve • Determine lower boundary of feasibility • Studied terminal is at lower boundary of studied segment. • Find lower limit of scale advantages • Verify assumed throughput development

31. Automated Container TerminalsWill they ever catch up…? Case Study • Service requirements • Throughput 200,000 TEU/yr • Maximum vessel 2,000 TEU • Average vessel 720 TEU • High service level • 2 cranes per berth • 15% waiting time • 24 / 7 waterside operations • 12 / 6 land side operation Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

32. Container terminal automation Net present value • BOT-structure

33. Container terminal automation Net present value • Financed with outside capital

34. Container terminal automation Conclusions DCF analysis • Outside investments reduce payback period • Investment in terminal infrastructure • Outside financing • BOT-structure will not achieve 8% return in 20 years

35. Container terminal automation Vessel dimensions

36. Waterside Quay  Storage yard Land side STS Chassis / AGV / Shuttle Yard gantry cranes: RTG / RMG / OBC MHC / Wide-span gantry Straddle Carrier / AutoStrad A B A B Container terminal automation • Container handling process • Waterside handling equipment • Ship to shore gantry crane • Mobile harbour crane • Yard handling equipment • Straddle carrier • Rubber tired gantry • Rail mounted gantry • Internal transport • Port tractor trailer • AGV • Shuttle carrier

37. Terminal Vessel arrival Vessel (un-)loading Vessel departure containers Yard containers Truck / train arrival Truck / train (un-)loading Truck / train departure Container terminal automation Terminal functions

38. RMG WS LS Quay crane AGV Vessel loading / unloading Quay handover Yard handover Road vehicle transfers Container terminal automation System design • Queuing theory • Posport CT simulation study Selection criteria Concept selection System calculations Simulation study System design

39. Container terminal automation Automated handling concept • Quay handling • Ship-to-shore gantry crane • Yard handling • AGV / RMG terminal • Selection criteria • Flexibility • Proven technology • Reliability • Area requirements Selection criteria Concept selection System calculations Simulation study System design

40. Container terminal automation Research question • How can automated container handling be implemented on small terminals with “off-the-shelf” technology?

41. A B A B A B Automated Container TerminalsWill they ever catch up…? • Conventional Terminal Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion • Waterside handling equipment • Ship To Shore gantry crane • Mobile harbour crane • Wide-span gantry • Yard handling equipment • Straddle carrier • Rubber tired gantry • Rail mounted gantry • Internal transport • Port Tractor-Trailer • Shuttle carrier

42. Automated Container TerminalsWill they ever catch up…? Automated Terminals • Aids to increase human (in)efficiency • Anti Collision System, • Anti Sway • Stack positioning aids, • Efficiency improvement, • Automatic number recognition, • Etcetera Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion

43. Automated Container TerminalsWill they ever catch up…? Automated Terminals • Eliminate dependency on human intervention • (Semi-) Automated STS Cranes • Automatic Guided Vehicles • Auto Strads/ Shuttle Carriers • Auto RMG/ RTG • Conveyor belt system • Etcetera Introduction ConventionalTerminals Automated Terminals Examples Case Study Conclusion