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Wiggins Island Coal Export Terminal
BMH presentation – 4 June 2013
Wharf

Stockyard
Rail receival
Wiggins Island Coal Export Terminal – BMH 2013
Wiggins Island Coal Export terminal

Presentation 4 June 2013
Design Case S...
Wiggins Island overview - 3D fly through
Site Coal Export Terminal – BMH 2013

BMH 2013
Wiggins IslandWICET facility facts 2013
Basic Coal Export Terminal – BMH

• Terminal throughput 27 Mtpa
• Rail receival
– ...
• Stockyard
Wiggins Island Coal Export Terminal – BMH 2013
– Dedicated storage facility with approximately 1.6Mt of
on gro...
• Wiggins Island Coal Export Terminal – BMH 2013
Offshore
– 2km long jetty conveyor to offshore wharf
– Loading rate 8250t...
Wiggins Island Coal Export Terminal – BMH 2013
• Design brief

– Stage 1 capacity of 27 Mtpa expanding in stages to 70+ Mt...
CAPACITY Island Coal Export Terminal – BMH 2013
Wiggins
– Initial handling rates and equipment selected with
static modell...
BLENDINGIsland Coal Export Terminal – BMH 2013
Wiggins CAPABILITY
• Dedicated storage with high blending capability
– 70% ...
HIGHLY AUTOMATED SOLUTION
Wiggins Island Coal Export Terminal – BMH 2013
• Rail receival
– Automated readers and tags on w...
HIGHLY AUTOMATED SOLUTION
Wiggins Island Coal Export Terminal – BMH 2013

• Stockyard and stacking operations
– Automated ...
HIGHLY AUTOMATED SOLUTION
Wiggins Island Coal Export Terminal – BMH 2013
• Reclaiming operations and shiploading
– Automat...
EQUIPMENT SELECTION ANDTerminal – BMH 2013
Wiggins Island Coal Export INNOVATION
• Belt conveyors/feeders are based on pro...
EQUIPMENT SELECTION AND INNOVATION
Wiggins Island Coal Export Terminal – BMH 2013
• Stacker design undertaken by Aurecon’s...
Wiggins Island Coal Export Terminal – BMH 2013

•Stacker over
Suncorp Stadium
•Each leg within
+/-200mm at travel
speed of...
EQUIPMENT SELECTION AND INNOVATION
Wiggins Island Coal Export Terminal – BMH 2013
• Shiploader design undertaken by Aureco...
EQUIPMENT SELECTION AND INNOVATION
Wiggins Island Coal Export Terminal – BMH 2013
• 3D modelling used in the design proces...
LEADING ENVIRONMENTAL CONTROLS BMH 2013
Wiggins Island Coal Export Terminal –
• Noise
– Conveyors incorporate low noise id...
LEADING ENVIRONMENTAL CONTROLS BMH 2013
Wiggins Island Coal Export Terminal –
• Dust
– Dust collection system for the rail...
LEADING ENVIRONMENTAL CONTROLS BMH 2013
Wiggins Island Coal Export Terminal –
• Dust (Cont’d)
– Real time dust monitoring ...
LEADING ENVIRONMENTAL CONTROLS
Wiggins Island Coal Export Terminal – BMH 2013
• Spillage
– Multiple scraper belt cleaning ...
• Wiggins Island Coal progress
Stockyard equipment Export Terminal – BMH 2013

BMH 2013

Gantry structure progress

Bridge...
FUTURE Island Coal Export Terminal – BMH 2013
Wiggins PROOFING THE DESIGN
• Capacity
– Future expansion planning is underw...
THANK YOU
Wiggins Island Coal Export Terminal – BMH 2013

BMH 2013
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Lee Williams, Aurecon - Wiggins Island Coal Terminal – Design Case Study

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Lee Williams, Principal Bulk Materials Handling Engineer, Aurecon delivered this presentation at the 10th Annual Bulk Materials Handling conference 2013. This conference is an expert led forum on the engineering behind the latest expansions and upgrades of bulk materials facilities. It also evaluates the latest engineering feats that are creating record levels of throughput whilst minimising downtime.

For more information on this conference, please vist http://www.informa.com.au/bmh2014

Published in: News & Politics
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Transcript of "Lee Williams, Aurecon - Wiggins Island Coal Terminal – Design Case Study"

  1. 1. Wiggins Island Coal Export Terminal BMH presentation – 4 June 2013 Wharf Stockyard Rail receival
  2. 2. Wiggins Island Coal Export Terminal – BMH 2013 Wiggins Island Coal Export terminal Presentation 4 June 2013 Design Case Study • • – – – – Basic overview of terminal Design brief and response Terminal capacity BMH 2013 Automation Equipment selection and innovation Environmental considerations
  3. 3. Wiggins Island overview - 3D fly through Site Coal Export Terminal – BMH 2013 BMH 2013
  4. 4. Wiggins IslandWICET facility facts 2013 Basic Coal Export Terminal – BMH • Terminal throughput 27 Mtpa • Rail receival – Automated rail receival station with wagon vibrator – Bottom dump wagons – Unloading rate up to 8250tph via belt feeder BMH 2013
  5. 5. • Stockyard Wiggins Island Coal Export Terminal – BMH 2013 – 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 multipleBMH 2013 coal stockpiles on shiploading – 1200T surge bin
  6. 6. • Wiggins Island Coal Export Terminal – BMH 2013 Offshore – 2km long jetty conveyor to offshore wharf – Loading rate 8250tph – Long travelling, luffing shiploader – Vessel size 40,000dwt to 220,000dwt BMH 2013
  7. 7. Wiggins Island Coal Export Terminal – BMH 2013 • 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 BMH 2013 – Design for a range of coal types – some poor handleability expected – Leading environmental controls and solutions
  8. 8. CAPACITY Island Coal Export Terminal – BMH 2013 Wiggins – 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 BMH 2013 27Mtpa Shipping queue vs Throughput Base Case 27Mtpa Shipping queue vs Throughput Sensitivity analysis
  9. 9. BLENDINGIsland Coal Export Terminal – BMH 2013 Wiggins CAPABILITY • 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 BMHTunnel cross section 2013
  10. 10. HIGHLY AUTOMATED SOLUTION Wiggins Island Coal Export Terminal – BMH 2013 • 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 BMH 2013
  11. 11. HIGHLY AUTOMATED SOLUTION Wiggins Island Coal Export Terminal – BMH 2013 • 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 BMH based be placed between batches 2013 on stacker repositioning time (Important for remote rail receival site)
  12. 12. HIGHLY AUTOMATED SOLUTION Wiggins Island Coal Export Terminal – BMH 2013 • Reclaiming operations and shiploading – Automated reclaim feeder control to maintain load rate accuracy – Shiploader designed to be capable of remote teleoperation as a first step towards future automation – Wharf is designed to be retro-fitted with Moormaster BMH 2013 automated mooring system which eliminates rope handling on the wharf
  13. 13. EQUIPMENT SELECTION ANDTerminal – BMH 2013 Wiggins Island Coal Export INNOVATION • 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 BMH 2013 – Shiploader 2200mm, 6m/s OC1 start tensions Rail receival section
  14. 14. EQUIPMENT SELECTION AND INNOVATION Wiggins Island Coal Export Terminal – BMH 2013 • 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 BMH 2013
  15. 15. Wiggins Island Coal Export Terminal – BMH 2013 •Stacker over Suncorp Stadium •Each leg within +/-200mm at travel speed of 30m/min BMH 2013 260m OVERALL Photo courtesy of Google
  16. 16. EQUIPMENT SELECTION AND INNOVATION Wiggins Island Coal Export Terminal – BMH 2013 • 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 BMH 2013
  17. 17. EQUIPMENT SELECTION AND INNOVATION Wiggins Island Coal Export Terminal – BMH 2013 • 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 BMH 2013
  18. 18. LEADING ENVIRONMENTAL CONTROLS BMH 2013 Wiggins Island Coal Export Terminal – • 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 BMH 2013 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
  19. 19. LEADING ENVIRONMENTAL CONTROLS BMH 2013 Wiggins Island Coal Export Terminal – • 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 BMH 2013 – Full coverage stockyard water sprays with a control link to the Bureau of Meteorology (BOM) to allow preemptive actions to be taken – Telescopic chutes on stacker discharge
  20. 20. LEADING ENVIRONMENTAL CONTROLS BMH 2013 Wiggins Island Coal Export Terminal – • 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 around2013 site to reduce wind BMH the effects as well as provide a visual barrier
  21. 21. LEADING ENVIRONMENTAL CONTROLS Wiggins Island Coal Export Terminal – BMH 2013 • 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 BMH 2013 and return system capture
  22. 22. • Wiggins Island Coal progress Stockyard equipment Export Terminal – BMH 2013 BMH 2013 Gantry structure progress Bridge stacker progress
  23. 23. FUTURE Island Coal Export Terminal – BMH 2013 Wiggins 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 BMH 2013 – 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
  24. 24. THANK YOU Wiggins Island Coal Export Terminal – BMH 2013 BMH 2013
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