lee williams, aurecon - wiggins island coal terminal – design case study

Wiggins Island Coal Export Terminal

BMH presentation – 4 June 2013

Wharf

Rail receival

Stockyard

Wiggins Island Coal Export Terminal – BMH 2013

BMH 2013 BMH 2013

Wiggins Island Coal Export terminal

Presentation 4 June 2013

Design Case Study

• Basic overview of terminal

• Design brief and response

– Terminal capacity

– Automation

– Equipment selection and innovation

– Environmental considerations


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Site overview - 3D fly through


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Basic WICET facility facts

• Terminal throughput 27 Mtpa

• Rail receival

– Automated rail receival station with wagon vibrator

– Bottom dump wagons

– Unloading rate up to 8250tph via belt feeder


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• Stockyard

– Dedicated storage facility with approximately 1.6Mt of

on ground storage

– Stacking via automated bridge stacker with dozer

push reclaim onto tunnel conveyors

– Stacking rate up to

8250tph, reclaim 6900tph

– Blending from multiple

coal stockpiles on

shiploading

– 1200T surge bin


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• Offshore

– 2km long jetty conveyor to offshore wharf

– Loading rate 8250tph

– Long travelling, luffing shiploader

– Vessel size 40,000dwt to 220,000dwt


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• Design brief

– Stage 1 capacity of 27 Mtpa expanding in stages to 70+ Mtpa

– Dedicated storage facility with high blending capability

– Highly automated design

– High level of reliability

– Design for a range of coal types – some poor handleability

expected

– Leading environmental controls and solutions


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– Initial handling rates and equipment selected with

static modelling and previous experience benchmark

– Once basic design complete, equipment selection

and sizing was confirmed by application of a dynamic

simulation model

Shipping queue vs Throughput

Base Case

Shipping queue vs Throughput

Sensitivity analysis

CAPACITY

27Mtpa 27Mtpa


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• Dedicated storage with high blending capability

– 70% of blended product with up to 5 way blending required

– Terminal with multiple drawdown points and dozer discharge

allowed maximum flexibility for blending operations

– Dedicated storage requirement of approximately 6% of

yearly throughput

BLENDING CAPABILITY

Tunnel cross section


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• Rail receival

– Automated readers and tags on wagons

– Automated triggers to discharge coal

– Train speed feedback to loco drivers

– Wagon vibrator to assist discharge of sticky coals

– Volumetric control of feed rate to maximise conveyor fill

independent of density

HIGHLY AUTOMATED SOLUTION


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• Stockyard and stacking operations

– Automated stacker able to stack to a pre-defined area with a

selected stacking pattern with minimal operator intervention

– Dust suppression sprays which operate automatically with

input from the Bureau of Meteorology

– Coal tracking system on unloading operations so a “gap” can

be placed between batches based on stacker repositioning

time (Important for remote rail receival site)



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• Reclaiming operations and shiploading

– Automated reclaim feeder control to maintain load

rate accuracy

– Shiploader designed to be capable of remote tele-

operation as a first step towards future automation

– Wharf is designed to be retro-fitted with Moormaster

automated mooring system which eliminates rope

handling on the wharf



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• Belt conveyors/feeders are based on proven designs. Idler

selection and spacing optimised. Low rolling resistance covers

used widely. Extensive dynamic modelling undertaken

– Feeders (Rail receival and surge bin) 3200mm

– Overland conveyor 1800mm, 6.9m/s, horizontal curve

– Yard conveyors 2000mm, 6m/s

– Shiploader 2200mm, 6m/s

EQUIPMENT SELECTION AND INNOVATION

Rail receival section OC1 start tensions


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• Stacker design undertaken by Aurecon’s experienced

machine designers

• Subject to extensive internal and external reviews and risk

assessments

• Fully automated, articulated machine

• Multi layer skew control and protection system



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260m OVERALL

•Stacker over

Suncorp Stadium

•Each leg within

+/-200mm at travel

speed of 30m/min

Photo courtesy of Google


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• Shiploader design undertaken by Aurecon’s machine

design team. Designed in tandem with the wharf

• Lightweight shiploader design to reduce loading on wharf

and allow a relatively lightweight wharf structure



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• 3D modelling used in the design process to maximise the

feedback from operators. Good interaction during HAZOPs

and safety reviews

• Multi discipline formal and informal walk throughs were

undertaken regularly to ensure client requirements were

met


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• Noise

– Conveyors incorporate low noise idlers with tight

tolerances on roundness and balance

– Tight tolerances on allowable noise generated from

individual drives and motors. Factory testing

– Drives generally located at ground level to minimise

the effective noise travel length

– Directional alert sirens incorporated on travelling

equipment to direct sound to the hazardous areas

only and limit any unnecessary leakage to surrounds

LEADING ENVIRONMENTAL CONTROLS


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• Dust

– Dust collection system for the rail receival hopper

– Moisture analysers and water addition system on the

unloading stream to complement DEM moisture levels

– Partial enclosure of most elevated conveyors

– Dust suppression sprays at conveyor transfer points

– Full coverage stockyard water sprays with a control link

to the Bureau of Meteorology (BOM) to allow pre-

emptive actions to be taken

– Telescopic chutes on

stacker discharge



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• Dust (Cont’d)

– Real time dust monitoring around the stockyard and

rail receival with captured data used on a daily basis

to improve dust management practices

– Moisture analyser and water addition system on the

shiploading stream

– Vegetation buffer around the site to reduce wind

effects as well as provide a visual barrier


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• Spillage

– Multiple scraper belt cleaning with belt washing

– Solid floors in elevated gallery sections

– Solid floors along length of jetty conveyor

– Capture trays under the wharf conveyor

– Shiploader capture controls

– Overall offshore slurry capture and return system



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• Stockyard equipment progress

Gantry structure progress

Bridge stacker

progress


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FUTURE PROOFING THE DESIGN

• Capacity – Future expansion planning is underway

– Terminal is designed for future upgrades with minimal

operational interruptions

• Automation – Rail receival automation is already good

– Opportunities in the stockyard for dozer remote operation

– Opportunities on shiploading for remote operation and some

degree of automation

• Environmental controls – Performance will be monitored with the continuous monitors

– Further opportunities may arise but will largely depend on coal

properties


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THANK YOU

lee williams, aurecon - wiggins island coal terminal – design case study

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