REV 

NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

R E V I S I O N

PROJECT TITLE : NEW GENERAL CARGO TERMINAL at Owendo, Gabon.

OWNER :

GSEZ Ports S.A.

COWI INDIA (P) Ltd.

CLIENT :

AFCONS OVERSEAS PROJECT SARL

CLIENT'S CONSULTANT :
ROYAL HASKONINGDHV (RHDHV)

M/S. GI AGRO SYSTEMS                                                                 
(A division of BaligroupIndia ltd.)

NAME DATE SIGN TITLE :

DESIGNED Ajay Kapoor 12‐12‐2016 Design Basis Report

 

REVIEWED SCALE :
Dimensions in mm REV.
APPROVED Ajay Kapoor 12‐12‐2016 ‐‐

RELEASE STATUS DOC. NO. : SS‐GABON‐PR‐0004 0

INFORMATION  
FOR CONSTRUCITON REF. DOC. No.: SS‐GABON‐PR‐0001 ‐ Process Flow Chart 2

FOR APPROVAL AS BUILT DRAWING Sheet No.: No. of Pages :  10

 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 1 of 10 
 

1. DESIGN BASIS REPORT

An overview of the process for the grain storage is shown below

.
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 2 of 10 
 

1.1 INTAKE AND PRECLEANING

Grain Unloading (Intake Hopper)  Chain Conveyor PC1  Magnet  Elevator PE1  Feeding Hopper Precleaner
Utilities  a) Reverse Bag Filter with Airlock, b) Centrifugal Fan, c) Aspiration Ducting, d) Spouting, e) Compressor and Pipeline.

Processes Description and Equipment Used

 Grain Unloading  The grain (wheat) is unloaded into intake receiving hopper for feeding into the
Precleaner.

 Intake  Two (2) trucks can be unloaded into the intake hopper simultaneously.

 Intake Hopper is equipped with aspiration system for dust free environment

 Chain Conveyor will collect the grain from intake hopper and convey horizontally to
Elevator PE1 for vertical lifting. Chain Conveyor is provided with over flow sensor at
outlet
Elevator
 Permanent type Magnet is used for removal of ferrous particles from the grain

 Elevator PE1 will convey grain vertically to top and feed to feeding hoppers for
Precleaner. Elevator is equipped with speed sensor.

Conveyor Head
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 3 of 10 
 

Processes Description and Equipment Used

 Precleaning  Feeding Hopper is used above Precleaner for constant flow to the Precleaner.
Feeding hopper is provided with high level sensor.

 Precleaner is used for pre cleaning of grain and remove coarse, fine and light
impurities from grain

Precleaner is equipped with drum sieve, one scalping screen and four layers of
screens. It’s high efficient pre and after suction system is installed for extracting light
impurities both at machine inlet and outlet.

Rotary drum sieve offers high quality grading of grain and removes straws, stones etc.
Scalping screen removes coarse impurities. Next 2 rows of screens separate oversize
material and 2 rows of screens separates undersize material.

Screens are fitted in specially designed wooden frames and screens are kept clean by
rubber balls which bounce in between the screens and ball frames.

 The impurities that are separated from grain are bagged at ground level

 To control the dust at intake and aspirating impurities, aspiration system is provided
consisting of reverse bag filter, airlock and centrifugal fan

Precleaner
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 4 of 10 
 

1.2 SILO LOADING AND STORAGE

Precleaner  Elevator PE2  2 Way Valve  Chain Conveyor PC2  Silos (2 Nos)
Utilities  a) Aeration Blower, b) Sweep Auger, c) Temperature Cable, d) Chiller

Processes Description and Equipment Used

 Silo Storage  The grain (wheat) after Precleaner is fed to Elevator PE2 for vertical lifting and then
after for storage in to the silos. Elevator is provided with speed sensor

 2 Way valve (pneumatically controlled) is used for diverting grain to storage or directly
to hopper silos for loading into trucks.

 Grain is then fed to horizontal chain conveyor (PC2) for feeding into the silos. The
chain conveyor is provided with overflow flap sensor. It consists of 2 outlet hoppers at
distances above center of each silo.
Silo Storage
 Pneumatic Slide provided at first outlet of PC2 is opened (pneumatically controlled) for
filling first grain in the silo (S1). When high level sensor is activated, slide gate closes
and grain is fed to next silo (S2) at 2nd outlet hopper provided at end of chain
conveyor.

 Silos – Capacity 5000 MT each, 60 feet diameter x 27 Rings equipped with

 High and Low Level Sensors Slide Gates

 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 5 of 10 
 

Processes Description and Equipment Used

 Sweep Auger for clearing grain at bottom during emptying the silo

 Temperature Cable for measuring temperature at different levels of grain

 Aeration Blowers and full floor aeration for aerating the grain
Aeration Blower
 Chiller for providing chilled air to silo for lowering the temperature of grain for
long storage days.

 Spiral Stairs for accessing to the top of silo

 Roof exhauster provided at roof for escaping the air during aeration / chilling
process

 Fumigation (J pump) provided for discharging fumigant to the silo through Roof Exhauster
aeration blower connections. A loop can be provided from the roof exhauster to
the inlet of the J pump.

Spiral Stair
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 6 of 10 
 

1.3 SILO UNLOADING

Silo  Chain Conveyor PC3  Elevator PE3  Chain Conveyor PC4  Hopper Bottom Silo (2 Nos)

Processes Description and Equipment Used

 Silo Unloading  The grain (wheat) from Silo (S1 / S2) is unloaded detailed as below:

 Pneumatic Slide at outlet at the center of silo is opened (controlled

pneumatically)

 Manual Slide is also provided to adjust the flow of grain from the silo
Sweep Auger
 After emptying the grain from the center of silo (when flow stops of its own),
next manual slide provided along the flow axis of grain is opened to discharge
grain.

 Similarly all manual slide gates are opened one by one along the direction of
flow of grain.

 Then after, gate of silo may be opened and sweep auger is started to sweep the
grain step by step and grain is simultaneously unloaded from the outlets
opened one by one.

 Chain Conveyor PC3 is installed below the silos to convey horizontally and feeding in
to Elevator PE3. Conveyor PC3 has many inlets below each outlet of silo, and single
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 7 of 10 
 

Processes Description and Equipment Used

outlet at end before feeding to elevator.

 2 way Valve is provided at end of Conveyor PC3 to divert the grain to loading hopper
silos OR again to storage silos for re-circulation. Valve is controlled pneumatically.

 Chain Conveyor PC3 drops the grain at end into the Elevator PE3, which lifts it
vertically and feeding to Conveyor PC4.

 Conveyor PC4 will convey horizontally and feed the grain to hopper silos (S3 and S4).

 Pneumatic Slide provided at first outlet of PC4 is opened (pneumatically controlled) for
filling first grain in the silo (S3). When high level sensor is activated, slide gate closes
and grain is fed to next silo (S4) at 2nd outlet hopper provided at end of chain
conveyor.
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 8 of 10 
 

1.4 LOADING TO TRUCKS

Hopper Silo  Flow Controller  Loading to Trucks

Processes Description and Equipment Used

 Loading to trucks  The grain (wheat) from Silo (S3 / S4) is unloaded detailed as below:

 Flow Controller is provided below the hopper silo for controlling the flow of grain
discharged from silo

 Discharge capacity is input at the flow controller and grain is discharged at set
flow capacity from the silo

 As an alternative, predefined quantity can be set at flow controller to discharge

known quantity and flow controller closes when the predefined quantity is
achieved.

 Truck is standing below the silo and spout from the flow controller will discharge grain
directly into the truck
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 9 of 10 
 

1.5 UTILITIES AND ELECTRICAL

Processes Description and Equipment Used

 Utilities  Program Logic Control (PLC) with PC based SCADA system

PLC (Program Logic Control) based control system is provided for running the plant
with operator station having operator screen to monitor and operate the system. This
allows the operator an ability to select the process flow based on selections of silos /
system. The operator is able to track the process on panel view. Panel view and PC
based SCADA system will both help reduce plant down time by fast diagnostic
feature. The machines used in the cleaning should be in its best performance and be
capable of running on full load with maximum efficiency for improving the productivity.

 Controls and Valves

In Automation Control System, the pneumatically operated pneumatic slide gates are
provided. Their control is attached to the PLC for automatic control of the flow of the
grain in the system.

High and Low Level switches are installed in silos and tanks.

 Compressor

Air compressor is used to provide compressed air to machines like reverse bag filter
and slide gates. The compressor is complete with drive arrangements, electric motor,
and all standard accessories like water filter, dryer, pressure gauge, valves etc.
 G.I. Agro Systems
(A Division of Bali Group India)
Design Basis Report 
Document – SS/GABON/PR/0004  Rev. 0  Page 10 of 10 
 

Processes Description and Equipment Used

 Electrical

Motor Control Centre - Plant is divided in different zones as per in the flow sheet.
MCC is compartment type panel having main incomer with digital voltmeter &
ammeter. Main incomer is connected with insulated bus bar running along topside of
panel.

Control - Each starter consist of motor protection circuit breaker & contactor. Auto /
manual selector switch, main isolator, motor ON indication will be mounted on the
door. Start/stop push button station will be mounted in the field near the machine for
operator to on/off machine