Automated Container Terminals Will they ever catch up…? Presentation Joppe Burgers 29 May 2008 Busan, Korea

2 / 27 Automated Container Terminals Will they ever catch up…? n Introduction n Conventional Terminals n Automated Terminals n Examples Automated Terminals n Case study n Conclusion Contents of presentation Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion

3 / 27 Introduction Three types of container terminals: n Conventional n Semi automated n Automated Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

4 / 27 Quay  Terminal yardLand sideWaterside Introduction Vessel (un-)loading Truck / train (un-)loading Storage Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

5 / 27 Conventional Terminal Waterside handling equipment n Ship To Shore gantry crane n Mobile harbour crane n Wide-span gantry Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

6 / 27 Conventional Terminal Yard handling equipment n Straddle carrier n Rubber tired gantry n Rail mounted gantry Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

7 / 27 Conventional Terminal Internal transport n Port Tractor Trailer n Shuttle Carrier Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

8 / 27 Automated Terminals Conventional vs. Automated container terminal? n Higher capital investment? n Lower operational costs? n Labour Costs? n Technical skills? n Predictable productivity? n Experience? n Increase reliability? n Environmental issues? n Energy prices? n Regulations? n Health & Safety? Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

9 / 27 Automated Terminals Waterside handling equipment n Ship To Shore gantry n Dual Hoist STS gantry n Wide-span gantry Yard handling equipment n Straddle carrier n Rubber tired gantry n Rail mounted gantry n (Overhead grid cranes) n (Conveyor belt) Internal transport n Automatic Guided Vehicle n Shuttle carrier Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

10 / 27 Examples ECT Rotterdam n Single hoist Cranes, AGV’s and ASC’s Thamesport n ASC’s Hamburg CT Altenwerder n Double hoist Cranes, AGV’s and ASC’s Nagoya Port Terminal - Nagoya n Semi automated RTG Wan Hai lines - Tokyo n Semi automated RMG during day n Automated house keeping during night Euromax Rotterdam n Double hoist Cranes and ASC n Remote control desk EMC-Kaohsiung n Partly automated Taipei Container Port Terminal n Semi automated Busan New Port 2-1 n Double hoist Cranes and ASC PNC 1-2 n Double hoist Cranes and ASC Antwerp Gateway n Started with Straddles, transition to auto RMG Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

11 / 27 Brisbane: Fishermans Islands Apron areaAutoStrads StacksAutoStrads Transfer areaAutostrads Examples Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

12 / 27 Hamburg: CT Altenwerder BerthSemi automated double hoist Apron areaAGV StacksPassing ASC Examples Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

13 / 27 Examples Posport CTS – Busan New Port Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

14 / 27 n MSc project Wieger Rademaker (TU Delft & Royal Haskoning) n Is automation of container handling on small terminals feasible as a commercial investment? n Hurdles n High investments n Uncertain future development n No development budget n High technical level of personnel required n Proven technology preferred n Advantage n Lower operating and labour costs n High level of services Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

15 / 27 Approach n Preliminary design of an automated container terminal n Estimate of required investments n Cash flow analysis n Comparison with conventional alternative Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

16 / 27 Risavika CT n Stavanger, Norway n Modern container terminal n Site: 350 x 500 m n 4 other ports in Region Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

17 / 27 Case Study Design conclusions (KPI’s and Posport CTS) n 2 Quay cranes n 6 AGVs per quay crane n 6 RMGs Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

18 / 27 Terminal layout Automated Container Terminals Will they ever catch up…?

19 / 27 Cost estimate n Civil works: € 38,000,000 n Equipment: € 39,000,000 + n Total investment: € 77,000,000 Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

20 / 27 Operational costs n Benchmark operating costs (conventional terminals) n Per TEU: € 70 n Operating costs automated n Per TEU: € 55 n Labour costs savings (automation) n On basis equipment operating hours n Per TEU: € 13 n Annually: € 2,500,000 Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

21 / 27 Cash flow analysis n Discounted Cash Flow model n Net Present Value n Terminal income n Throughput: 200,000 TEU by year 3 n Handling charges: 100 € / TEU Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

22 / 27 Net present value - Leased quay wall Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

23 / 27 Is automation of container handling on small terminals feasible as a commercial investment? n Terminal not feasible as a commercial investment due to n Size of initial capital outlay n Investment risk from long investment period n Public sector involvement is required! However results show that Automation is catching up!!! Conclusions Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

24 / 27 Questions? Automated Container Terminals Will they ever catch up…? Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion

Container terminal automation Cost estimate civil works

Container terminal automation Cost estimate equipment

27 / 27 Container terminal automation Automated concept

28 / 27 Container terminal automation Conventional concept

29 / 27 Functional requirements n Waterside handling capacity n Quay length: 250 m n Handling capacity: 50 moves / hour n Storage capacity n Average: 3,900 TEU n Peak: 5,000 TEU n Landside handling capacity n Gate / Yard handling: 77 moves / hour Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

30 / 27 Container terminal automation n Investigate possibilities of public sector involvement n Follow development of Autostrad concept n Many operational advantages n Maintenance requirements have to improve n Determine lower boundary of feasibility n Studied terminal is at lower boundary of studied segment. n Find lower limit of scale advantages n Verify assumed throughput development Recommendations

31 / 27 Service requirements n Throughput 200,000 TEU / yr n Maximum vessel 2,000 TEU n Average vessel 720 TEU n High service level n 2 cranes per berth n 15% waiting time n 24 / 7 waterside operations n 12 / 6 land side operation Case Study Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

32 / 27 Container terminal automation BOT-structure Net present value

33 / 27 Container terminal automation Financed with outside capital Net present value

34 / 27 Container terminal automation n Outside investments reduce payback period n Investment in terminal infrastructure n Outside financing n BOT-structure will not achieve 8% return in 20 years Conclusions DCF analysis

35 / 27 Container terminal automation Vessel dimensions

36 / 27 Container terminal automation Container handling process STS MHC / Wide-span gantry Quay  Storage yardLand sideWaterside Chassis / AGV / Shuttle Straddle Carrier / AutoStrad Yard gantry cranes: RTG / RMG / OBC Waterside handling equipment n Ship to shore gantry crane n Mobile harbour crane Yard handling equipment n Straddle carrier n Rubber tired gantry n Rail mounted gantry Internal transport n Port tractor trailer n AGV n Shuttle carrier AB A B

37 / 27 Container terminal automation Vessel arrivalVessel (un-)loading Vessel departure Truck / train arrival Truck / train (un-)loading Truck / train departure Yard containers Terminal Terminal functions

38 / 27 n Queuing theory Container terminal automation Vessel loading / unloading Quay handover Yard handover Quay craneAGV Road vehicle transfers RMG LSWS System design Selection criteria Concept selection Simulation study System calculations System design n Posport CT simulation study

39 / 27 Container terminal automation n Quay handling n Ship-to-shore gantry crane n Yard handling n AGV / RMG terminal Automated handling concept Selection criteria Concept selection Simulation study System calculations System design n Selection criteria n Flexibility n Proven technology n Reliability n Area requirements

40 / 27 Container terminal automation n How can automated container handling be implemented on small terminals with “off-the-shelf” technology? Research question

41 / 27 Conventional Terminal Waterside handling equipment n Ship To Shore gantry crane n Mobile harbour crane n Wide-span gantry Yard handling equipment n Straddle carrier n Rubber tired gantry n Rail mounted gantry Internal transport n Port Tractor-Trailer n Shuttle carrier AB A B AB Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

42 / 27 Automated Terminals Aids to increase human (in)efficiency n Anti Collision System, n Anti Sway n Stack positioning aids, n Efficiency improvement, n Automatic number recognition, n Etcetera Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?

43 / 27 Automated Terminals Eliminate dependency on human intervention n (Semi-) Automated STS Cranes n Automatic Guided Vehicles n Auto Strads/ Shuttle Carriers n Auto RMG/ RTG n Conveyor belt system n Etcetera Introduction Conventional Terminals Automated Terminals Examples Case Study Conclusion Automated Container Terminals Will they ever catch up…?