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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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
Site overview - 3D fly through
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• 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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• Offshore
– 2km long jetty conveyor to offshore wharf
– Loading rate 8250tph
– Long travelling, luffing shiploader
– Vessel size 40,000dwt to 220,000dwt
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 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
– Design for a range of coal types – some poor handleability
expected
– Leading environmental controls and solutions
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
– 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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• 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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 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
HIGHLY AUTOMATED SOLUTION
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 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
be placed between batches based on stacker repositioning
time (Important for remote rail receival site)
HIGHLY AUTOMATED SOLUTION
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• 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
HIGHLY AUTOMATED SOLUTION
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• 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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 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
EQUIPMENT SELECTION AND INNOVATION
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
260m OVERALL
•Stacker over
Suncorp Stadium
•Each leg within
+/-200mm at travel
speed of 30m/min
Photo courtesy of Google
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 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
EQUIPMENT SELECTION AND INNOVATION
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
EQUIPMENT SELECTION AND INNOVATION
• 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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• 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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• 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
LEADING ENVIRONMENTAL CONTROLS
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
LEADING ENVIRONMENTAL CONTROLS
• 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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 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 capture and return system
LEADING ENVIRONMENTAL CONTROLS
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
• Stockyard equipment progress
Gantry structure progress
Bridge stacker
progress
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
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
Wiggins Island Coal Export Terminal – BMH 2013
BMH 2013 BMH 2013
THANK YOU