Background and Development
The development of the InterHop originated from the need for a low-dust or dust-free receiving hopper for clinker and raw materials at a port operator in Abidjan, Ivory Coast.
During ship unloading operations, significant dust emissions occurred, which, combined with moisture, accumulated on the roofs of storage facilities. This not only caused environmental pollution but also posed a risk to the structural integrity of the buildings.
In close cooperation with the customer, Intercem developed a solution that ensures both high handling capacity and a significant reduction in dust emissions.
Following the successful commissioning of the first InterHop, operational performance fully met expectations. Due to the positive experience, a second system was installed and has been operating reliably since October 2023.
Performance and Technical Concept
The InterHop is designed for maximum efficiency and flexibility:
- Unloading of up to 40 tonnes of material within just 10 seconds
- Truck loading as well as direct transfer to belt conveyors
- Robust heavy-duty design for continuous operation
- Adjustable design depending on site conditions and requirements
The system ensures minimal dust emissions during:
- Ship unloading with grab cranes
- Truck loading
- Material transfer to conveyor systems
With a capacity of approximately 65 m³ and an optimised geometry, the hopper guarantees a continuous material flow while preventing blockages.
Modern Technologies for Sustainable Operation
A key development goal was achieving near dust-free operation throughout all process stages. This is realised using advanced technologies:
- High-performance filter systems
- Automation and control systems
- Compressed air systems
- Independent power supply via generator
These technologies result in substantial advantages:
- Significantly reduced dust emissions
- Lower energy consumption
- High operational reliability
- Minimal maintenance requirements
Flexible Applications
The InterHop is not limited to port operations but can also be used for:
- Rail unloading stations
- Truck unloading stations
- Integrated solutions in cement plants
Thanks to its modular and mobile design, the system can be flexibly adapted to different logistics infrastructures.
Growing Demand and New Projects
The positive operational experience with existing installations has led to a growing demand for InterHop systems worldwide.
In addition, Intercem has recently been commissioned by another major port operator to supply two new InterHop units. These systems have been developed as a project-specific solution in close cooperation with the customer.
These are mobile ship unloading units featuring:
- High-performance dedusting systems with capacities exceeding 100,000 m³/h
- Mobile bogie systems for flexible positioning within the port
- Hydraulic discharge systems for truck loading with capacities of up to 650 t/h
- Fully integrated operation and automation systems
- Independent power supply via generators
- Fully enclosed truck loading stations with dust protection
Each hopper has a capacity of approximately 45 m³ and a dead weight of around 150 tonnes per unit.
The systems will be fully pre-assembled, tested, and commissioned prior to shipment to ensure fast installation and smooth operation on site.
Conclusion
The InterHop is a proven solution for efficient and environmentally friendly bulk material handling.
Key benefits include:
- Significant reduction of dust emissions
- Faster handling operations
- Lower energy consumption
- Reduced operational costs (e.g. through shorter vessel berthing times)
- High reliability and long service life
From engineering and manufacturing to commissioning, Intercem provides all services from a single source.
The increasing number of repeat orders and new projects clearly demonstrates customer satisfaction and highlights the growing importance of sustainable solutions in modern port operations.
