DCL Bulk Loading Systems

LOADOUT SYSTEMS

DCL means Dust Control Loading Systems. We specialize in Loadout Systems. Whether you are loading trucks, railcars, ships or barges we have the experience to assure a fast, clean, dust free operation.

DCL’s complete line of products allows for system responsibility from the silo to whatever vessel, tanker or storage unit you are loading. If your goal is to load trucks in 5 minutes or ships in less than 12 hours we have references. If you are dealing with sensitive environmental issues DCL can provide guaranteed emission statements that comply with the strictest EPA and DEQ requirements. Abrasive, corrosive or volatile products require knowledge of the correct materials for manufacturing of components in your system. DCL’s 37 years of knowledge and experience with multiple products from grains and aggregates to minerals and chemicals lets you have the confidence that you’re dealing with the right supplier.

The ability to provide complete turnkey systems combines controls with equipment and DCL offers PLC, HMI and Motor Control panels along with remote enclosures. Our staff of Electrical Engineers allows us to develop programs to adapt with your existing systems and meet the demands of your loadout system. From full automation to partial our expertise will allow for utilization of the latest technology.

TRUCK LOADING

Each terminal is unique in its layout, functionality, and product being loaded.

Low height, multiple vehicle sizes, and hatch location of vehicles require a supplier that understands what it takes to meet you goals.

There are two major variables to truck loading, open and enclosed. The choice between the two is determined by what product you’re loading and what type of truck. For example loading a tanker truck with cement varies from loading aggregates into a gravel train truck. The enclosed tanker already has a contained area and it’s a matter of removing air inside the tanker that is displaced by the product being loaded. With an open style truck the Loading Spout must create its own containment. This is done by using a barrier skirt at the discharge of the Loading Spout. You must still remove the displaced air but the discharge skirt is a much smaller area than the inside of a tanker.

Providing a loading system to meet your needs encompasses moving product from your storage area (silo, dome, flat bottom storage) to the truck. A series of flow aids for your storage can be provided by DCL with our Fluidized Bin bottom or Fluidized Air Pads. The next critical component is the control valves. Whether it is maintenance, complete on/off, or portioning flow control we offer the complete line. Should you need to divert flow we also offer diverters and triverters. Actual conveying of material can be done with Air gravity conveyors (airslide) for powders or drag, screw or belt conveyors for other materials. DCL manufactures the Air Gravity conveyors but for other choices we have close partnerships with manufactures in the industry. Loading systems require dust control. Achieved by In-line collectors (CFM – compact filter modules) or bag house style collectors. Both offered and produced by DCL.

Loading Spout Positioners provide flexibility and efficiency to your load out system. The Positioner moves the Loading Spout into the operators’ desired location. This works well to improve the speed of the operation by eliminating the need to re-spot the truck under the spout. The final component is the Loading Spout. This component bridges the distance between the conveyor discharge and the vehicle being loaded. The Loading Spout is where DCL expertise really shines. As the largest supplier of Loading Spouts in North America we have created a reputation of knowing application and designing systems to accommodate the toughest challenges. Each terminal is unique in its layout, functionality, and product being loaded. Low height, multiple sizes of vehicles, and hatch location of vehicles require a supplier that understands what it takes to meet you goals.

Remember DCL offers full controls of load out systems and can offer any degree of automation you desire. Ask about our SmartLoader™ and learn ways you can outperform your competitors.

RAILCAR LOADING

Railcar loading system requires specific components to achieve a loading rate and eliminate any dust emissions.

DCL provides dust collection, material flow control valves, conveyors, and loading spouts.

Railcar loading has two variable railcars either enclosed tanker or open wagon loading. Each has its own distinct requirements to achieve fast, clean loading. DCL has designed systems to load tankers with offset, slotted, or inline hatches. We have designed open wagon loading systems that involve loading three cars at once or rapid loading systems in which the trains never stops moving. We have the knowledge and experience to provide your complete system.

Each railcar loading system requires specific components to achieve a loading rate and eliminate any dust emissions. We want to design your system from the silo to the railcar. We will provide dust collection, material flow control valves, conveyors, and loading spouts.

We have worked with plastic pellets manufacturers and developed a trimmer that maximizes capacity for each car. We have also worked with others in the industry to provide material spreaders that maximize the amount of grain being loaded in each car. DCL has developed a Loading Spout Positioners that will travel the complete length of the railcar. No need to re-spot the railcar let the filling come to the loading point and maximize your terminal efficiency.

A railcar system isn’t complete without electrical controls. DCL offers fully automated tanker loading or partial controls that will interact with your existing PLC panels.

SHIP LOADING

Specific components designed for closed or open loading eliminate any dust emissions.

DCL provides dust collection, material flow control valves, conveyors, and loading spouts.

Demerge cost can be one of the greatest challenges a maritime terminal operator can face. The ability to load fast and dust free can make these costs manageable and save thousands of dollars. Loading rates of 1,600 to 2,000 MTPH is not an uncommon request when loading aggregates, grains or cement. Designing a Loading Spout that can accommodate Panamax ships in a retracted position while being able to reach the bottom of a cargo hold at low tide calls for DCL expertise.

Variable boom designs can put restrictions on how you load. DCL’s capable staff of Design Engineers welcomes the test. The use of double pivot joints can maximize the use of a luffing or slewing boom to reach all cargo areas. Loading Spouts design with swivel trajectory discharges allows the operator to put product in all corners and to top the load off for maximum capacity.

Materials of construction for ship loading spouts are critical. DCL designs for all variables whether corrosive, abrasive, food grade or explosion proof. The use of hardened steel, chromium carbide or stainless is not new to us. In certain areas we have designed using Aluminum to lighten the overall weight while maintaining the structural integrity.

From utilizing a marine grade finish or NEMA 4x standard electrical components to the use of wireless level sensors and 32oz. outer sleeve material you can be assured that DCL products are built to last.

BARGE LOADING

Whether you’re on a river in the ocean or on the Great Lakes we have the experience and knowledge to provide a flexible solution to your terminal operation.

Loading Spout travels with a vertical reach of up to 100’ have been supplied and are in operation.

Speed, efficient, and dust free loading are common request from barge loadout terminal operators. Hatch cover removal and reset are typical time consumers when loading barges. Depending on the product being loaded we can design your load out for minimal hatch removal while maximizing the capacity.

DCL understands product characteristics and knows how to handle difficult products. Anyone who has dealt with loading Cement, Flyash, or Alumina into a barges knows the product will have a splash effect that can cause dusting. DCL developed a velocity suppressor that will slow the product down before discharge. When dropping product more than 40ft. this is a critical design application. A “Bellhousing” discharge was developed by DCL for additional dust control. This feature provides a secondary barrier that captures the initial impact of product and the secondary generation of dust as the product flows away from the discharge.

Specific design criteria pertaining to variable water heights is no problem for DCL. Whether you’re on a river in the ocean or on the Great Lakes we have the experience and knowledge to provide a flexible solution to your terminal operation. Loading Spout travels with a vertical reach of up to 100’ have been supplied and are in operation.

Combine field proven design with quality components and add controls packages for a dependable and durable terminal operation.

STOCKPILE

Loading and open stock pile in the yard or using a shuttle conveyor in flat bottom storage. DCL has you covered with knowledge based design practices. Inclined conveyors are common in open stockpiling. To prevent dusting a loading Spout is used to control the material discharged from the conveyor and build the open pile. Critical to design in this application is the weight of the loading spout on the end of the conveyor. Correct sizing to handle the conveyor rate and material of construction is crucial in the design.

DCL’s model “TS” (Telescoping Stacker) has been used in many applications. Whether you want stainless, hardened steel or mild steel we can help with advise. DCL was the first producer of a Loading Spout using Tivar tubes for gypsum applications. The Tivar eliminated material build up and help prevent tubes from sticking together. Finding solutions to particular material applications is our best attribute. Contact us with your application challenge.