Presentation
Joppe Burgers
29 May 2008
Busan, Korea
Automated Container Terminals
Will they ever catch up…?
Automated Container Terminals
Will they ever catch up…?
Contents of presentation
Introduction
Conventional
Terminals
Automated
Terminals
Examples
Case Study

Introduction

Conventional Terminals

Automated Terminals

Examples Automated Terminals

Case study

Conclusion
Conclusion
2 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Introduction
Conventional
Terminals
Automated
Terminals
Examples
Case Study
Three types of container terminals:

Conventional

Semi automated

Automated
Conclusion
3 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Introduction
Conventional
Terminals
Waterside
Quay

Terminal yard
Land side
Automated
Terminals
Examples
Case Study
Conclusion
Vessel
(un-)loading
Storage
Truck / train
(un-)loading
4 / 27
Automated Container Terminals
Will they ever catch up…?
Conventional Terminal
Introduction
Conventional Waterside handling equipment
Terminals
Ship
Automated
Terminals
To Shore gantry crane
Mobile harbour crane
Wide-span gantry
Examples
Case Study
Conclusion
5 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Conventional Terminal
Conventional Yard handling equipment
Terminals
Straddle
Automated
Terminals
carrier
Rubber tired gantry
Rail mounted gantry
Examples
Case Study
Conclusion
6 / 27
Automated Container Terminals
Will they ever catch up…?
Conventional Terminal
Introduction
Conventional Internal transport
Terminals
Port
Tractor Trailer
Shuttle Carrier
Automated
Terminals
Examples
Case Study
Conclusion
7 / 27
Automated Container Terminals
Will they ever catch up…?
Automated Terminals
Introduction
Conventional
Terminals
Automated
Terminals
Conventional vs. Automated container terminal?



Examples


Case Study


Conclusion




Higher capital investment?
Lower operational costs?
Labour Costs?
Technical skills?
Predictable productivity?
Experience?
Increase reliability?
Environmental issues?
Energy prices?
Regulations?
Health & Safety?
8 / 27
Automated Container Terminals
Will they ever catch up…?
Automated Terminals
Introduction
Conventional Waterside handling equipment
Terminals


Automated
Terminals

Ship To Shore gantry
Dual Hoist STS gantry
Wide-span gantry
Yard handling equipment
Examples


Case Study



Conclusion
Straddle carrier
Rubber tired gantry
Rail mounted gantry
(Overhead grid cranes)
(Conveyor belt)
Internal transport


Automatic Guided Vehicle
Shuttle carrier
9 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Conventional
Terminals
Automated
Terminals
Examples
Case Study
Conclusion
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
10 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Examples
Conventional
Terminals
Automated
Terminals
Examples
Case Study
Conclusion
Brisbane: Fishermans Islands
Apron area
AutoStrads
Stacks
AutoStrads
Transfer area
Autostrads
11 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Examples
Conventional
Terminals
Automated
Terminals
Examples
Case Study
Conclusion
Hamburg: CT Altenwerder
Berth
Semi automated double hoist
Apron area
AGV
Stacks
Passing ASC
12 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Conventional
Terminals
Examples
Posport CTS – Busan New Port
Automated
Terminals
Examples
Case Study
Conclusion
13 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals

MSc project Wieger Rademaker
(TU Delft & Royal Haskoning)
Automated
Terminals

Is automation of container handling on small terminals
feasible as a commercial investment?

Hurdles
Examples



Case Study


Conclusion

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
14 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Automated
Terminals
Examples
Approach

Preliminary design of an automated container terminal

Estimate of required investments

Cash flow analysis

Comparison with conventional alternative
Case Study
Conclusion
15 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Automated
Terminals
Risavika CT




Stavanger, Norway
Modern container terminal
Site: 350 x 500 m
4 other ports in Region
Examples
Case Study
Conclusion
16 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Design conclusions (KPI’s and Posport CTS)

Automated
Terminals


2 Quay cranes
6 AGVs per quay crane
6 RMGs
Examples
Case Study
Conclusion
17 / 27
Automated Container Terminals
Will they ever catch up…?
Terminal layout
18 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Cost estimate

Civil works
: € 38,000,000

Equipment
: € 39,000,000 +

Total investment
: € 77,000,000
Automated
Terminals
Examples
Case Study
Conclusion
19 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Operational costs

Automated
Terminals
Examples
Benchmark operating costs (conventional terminals)



Per TEU
: € 55
Labour costs savings (automation)

Conclusion
: € 70
Operating costs automated

Case Study
Per TEU


On basis equipment operating hours
Per TEU
: € 13
Annually
: € 2,500,000
20 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Automated
Terminals
Examples
Cash flow analysis

Discounted Cash Flow model

Net Present Value

Terminal income


Case Study
Throughput
: 200,000 TEU by year 3
Handling charges : 100 €/TEU
Conclusion
21 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Net present value - Leased quay wall
20.00
10.00
Automated
Terminals
0.00
29
20
28
20
27
20
26
20
25
20
24
20
23
20
22
20
21
20
20
20
19
20
18
20
17
20
16
20
15
20
14
20
13
20
12
20
11
20
10
20
09
20
08
20
-10.00
Examples
Case Study
€ 1,000,000
-20.00
-30.00
-40.00
Conclusion
-50.00
Cash flow (automated)
-60.00
Cash flow (conventional)
NPV (automated)
-70.00
NPV (conventional)
-80.00
Year
22 / 27
Automated Container Terminals
Will they ever catch up…?
Conclusions
Introduction
Conventional
Terminals
Is automation of container handling on small terminals
feasible as a commercial investment?

Automated
Terminals
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!
Examples
However results show that Automation is catching up!!!
Case Study
Conclusion
23 / 27
Automated Container Terminals
Will they ever catch up…?
Introduction
Questions?
Conventional
Terminals
Automated
Terminals
Examples
Case Study
Conclusion
24 / 27
Container terminal automation
Cost estimate civil works
Sub-total quay
Sub-total terminal area
Sub-total buildings
Sub-total facilities
€
€
€
€
11,381,250.00
6,517,000.00
2,833,000.00
7,800,000.00
Sub-total
Peliminaries (15%)
€
€
28,531,250.00
4,279,687.50
Sub-total
Contingency (15%)
€
€
32,810,937.50
4,921,640.63
Total
€
37,732,578.13
Container terminal automation
Cost estimate equipment
Lifetime
price (€)
units
cost (€)
Quay cranes
STS gantry cranes
Spreaders
20
4
5.000.000,00
140.000,00
2
3
10.000.000,00
420.000,00
Yard cranes
Automated RMG cranes
Spreaders
20
4
2.500.000,00
140.000,00
6
8
15.000.000,00
1.120.000,00
Terminal transport
AGV
10
400.000,00
12
4.800.000,00
Miscellaneous equipment
Empty handler
Tractor unit
Chassis
Service vehicles
Service van
8
10
4
4
4
400.000,00
130.000,00
25.000,00
15.000,00
30.000,00
2
2
3
2
1
800.000,00
260.000,00
75.000,00
30.000,00
30.000,00
Sub-total equipment
Contingency
Total
32.535.000,00
20%
6.507.000,00 +
39.042.000,00
Container terminal automation
Automated concept
Note
Present value (€)
Investment costs
Civil works
Equipment
Investment made in first year
Investment made in second year
37,732,578.13
39,042,000.00
Replacement costs
every 5 years
every 10 years
every 20 years
2% price inflation and 20% contingency
Spreaders, chassis and service vehicles
AGVs, empty handlers and tractors
Quay and yards cranes
1,645,000.00
5,890,000.00
25,000,000.00
Operating costs
Handling charges
Calculated per TEU (3.0% annual increase)
Calculated per TEU (1.5% annual increase)
55.00
100.00
27 / 27
Container terminal automation
Conventional concept
Note
Present value (€)
Investment costs
Civil works
Equipment
First year, est. @ 80% of automated design
Second year, 8 RTGs and 14 PTTs
30,186,062.50
27,450,000.00
Replacement costs
every 5 years
every 10 years
every 20 years
2% price inflation and 20% contingency
Spreaders, chassis and service vehicles
RTGs, empty handlers and tractors
Quay and yards cranes
2,225,000.00
10,650,000.00
10,000,000.00
Operating costs
Handling charges
Calculated per TEU (3.0% annual increase)
Calculated per TEU (1.5% annual increase)
70.00
100.00
28 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Functional requirements

Waterside handling capacity

Automated
Terminals



Case Study

: 250 m
: 50 moves/hour
Storage capacity

Examples
Quay length
Handling capacity
Average
Peak
: 3,900 TEU
: 5,000 TEU
Landside handling capacity

Gate / Yard handling
: 77 moves/hour
Conclusion
29 / 27
Container terminal automation
Recommendations

Investigate possibilities of public sector involvement

Follow development of Autostrad concept



Determine lower boundary of feasibility



Many operational advantages
Maintenance requirements have to improve
Studied terminal is at lower boundary of studied
segment.
Find lower limit of scale advantages
Verify assumed throughput development
30 / 27
Automated Container Terminals
Will they ever catch up…?
Case Study
Introduction
Conventional
Terminals
Automated
Terminals
Service requirements




Examples
Throughput 200,000 TEU/yr
Maximum vessel 2,000 TEU
Average vessel 720 TEU
High service level


Case Study


2 cranes per berth
15% waiting time
24 / 7 waterside operations
12 / 6 land side operation
Conclusion
31 / 27
Container terminal automation
Net present value
BOT-structure
20.00
10.00
0.00
29
20
28
20
27
20
26
20
25
20
24
20
23
20
22
20
21
20
20
20
19
20
18
20
17
20
16
20
15
20
14
20
13
20
12
20
11
20
10
20
09
20
08
20
-10.00
€ 1,000,000
-20.00
-30.00
-40.00
-50.00
Cash flow (automated)
-60.00
Cash flow (conventional)
NPV (automated)
-70.00
NPV (conventional)
-80.00
Year
32 / 27
Container terminal automation
Net present value
Financed with outside capital
20.00
10.00
0.00
29
20
28
20
27
20
26
20
25
20
24
20
23
20
22
20
21
20
20
20
19
20
18
20
17
20
16
20
15
20
14
20
13
20
12
20
11
20
10
20
09
20
08
20
-10.00
€ 1,000,000
-20.00
-30.00
-40.00
-50.00
Cash flow (automated)
-60.00
Cash flow (conventional)
NPV (automated)
-70.00
NPV (conventional)
-80.00
Year
33 / 27
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
34 / 27
Container terminal automation
Vessel dimensions
30
25
(m)
20
LOA
Beam
Draft
15
10
5
0
100
1000
TEU
35 / 27
Container terminal automation
Container handling process
Waterside
Quay

Storage yard
Land side
STS
Chassis / AGV / Shuttle
Yard gantry cranes: RTG / RMG / OBC
MHC / Wide-span gantry
Straddle Carrier / AutoStrad
Waterside handling equipment


Ship to shore gantry crane
Mobile harbour crane
Yard handling equipment



Straddle carrier
Rubber tired gantry
Rail mounted gantry
A
Internal transport



Port tractor trailer
AGV
Shuttle carrier
B
A
B
36 / 27
Container terminal automation
Terminal functions
Terminal
Vessel arrival
Vessel
(un-)loading
Vessel
departure
containers
Yard
containers
Truck / train
arrival
Truck / train
(un-)loading
Truck / train
departure
37 / 27
Container terminal automation
System design

Queuing theory
RMG

Posport CT simulation study
Quay crane
Vessel
loading / unloading
Selection
criteria
Quay
handover
Concept
selection
WS
AGV
Yard
handover
System
calculations
LS
Road vehicle
transfers
Simulation
study
System
design
38 / 27
Container terminal automation
Automated handling concept

Quay handling
Selection
criteria
Flexibility
Ship-to-shore
gantry crane
 Proven technology
 Reliability
 Yard handling
 Area requirements
 AGV / RMG terminal

Selection
criteria
Concept
selection
System
calculations
Simulation
study
System
design
39 / 27
Container terminal automation
Research question

How can automated container handling be
implemented on small terminals with “off-the-shelf”
technology?
40 / 27
Automated Container Terminals
Will they ever catch up…?
Conventional Terminal
Introduction
Conventional
Terminals
Waterside handling equipment



Ship To Shore gantry crane
Mobile harbour crane
Wide-span gantry
Automated
Terminals Yard handling equipment


Examples

Straddle carrier
Rubber tired gantry
Rail mounted gantry
Internal transport
Case Study


Port Tractor-Trailer
Shuttle carrier
A
Conclusion
B
A
A
B
B
41 / 27
Automated Container Terminals
Will they ever catch up…?
Automated Terminals
Introduction
Conventional
Terminals
Automated
Terminals
Aids to increase human (in)efficiency



Examples


Case Study

Anti Collision System,
Anti Sway
Stack positioning aids,
Efficiency improvement,
Automatic number recognition,
Etcetera
Conclusion
42 / 27
Automated Container Terminals
Will they ever catch up…?
Automated Terminals
Introduction
Conventional
Terminals
Automated
Terminals
Eliminate dependency on human intervention



Examples


Case Study

(Semi-) Automated STS Cranes
Automatic Guided Vehicles
Auto Strads/ Shuttle Carriers
Auto RMG/ RTG
Conveyor belt system
Etcetera
Conclusion
43 / 27