17 November 2010 - Aurecon (in association with Sunstate Cement) and Aurecon’s Joint Venture, Aurecon Hatch (in association with Newcastle Coal Infrastructure Group - NCIG), have won gold for two bulk handling facilities – Sunstate Cement Expansion and NCIG Coal Export Terminal at prestigious awards sponsored by Bulk Handling Review.
Sunstate Cement operates a major cement milling and distribution facility located at Fishermans Island within the Port of Brisbane supplying cement to Queensland’s construction industry.
Lee Williams, Aurecon’s project leader for the expansion explains: “In 2008, Sunstate Cement embarked upon an million expansion program to meet the growing building and infrastructure needs of the State’s booming economy. As part of their expansion program, a new wharf receival facility was constructed.”
Aurecon was asked to address the challenges for the new facility by implementing a new inloading system in a very compressed time frame. The new receival system comprises 3 off mobile receival hoppers, and several conveyors linking back to the Sunstate plant.
Lee said: “The new wharf receival system has shown significant improvements in environmental outcomes with reduced dust emissions, along with improvements in productivity already evident.
Faster and cleaner unloading of vessels will reduce potential delays and provide more berth capacity for other users and customers of the Port. Other benefits include:
Aurecon Hatch is a long standing Joint Venture between Aurecon and Hatch and the JV is one of the largest suppliers of engineering and project management services to Australia’s export coal industry. Aurecon Hatch in association with Newcastle Coal Infrastructure Group (NCIG) won joint first place with Aurecon/Sunstate Cement for their work on the billion NCIG - Coal Export Terminal
In accepting the award, Andrew Woolaston (Aurecon Hatch’s Project Director) said: “This award recognises an exceptional bulk handling facility which services the resources sector, ports and terminals. NCIG’s stage 1 development is the world’s largest initial build for a coal export terminal with a start up capacity of 30 Mtpa. The planning, design and construction of the terminal has been executed in a demanding economic period which has included an infrastructure boom and a global financial crisis.”
Aurecon Hatch was originally engaged by the NCIG to address coal export capacity limitations that had resulted at the Port of Newcastle and assist with the development of a greenfield Coal Export terminal at the port. The JV was subsequently appointed as Principal Contractor as part of the EPCM role and had full accountability for safety. With over four million man-hours being expended on the project, there was only one lost time injury resulting in three days lost time and the JV has recently won the WorkCover NSW SafeWork Leadership Award 2010.
Andrew said: “Aurecon Hatch in conjunction with the NCIG Owners Team delivered an innovative solution for the new Coal Terminal. We incorporated wide bed stockpiles into the design of the plant along with the use of combined stacker reclaimers in place of separate stackers and reclaimers. These wide bed stockpiles meant that the storage capacity of the stockyards could be almost doubled from approximately 3.0 million tonnes to around 6.0 million tonnes while still achieving the desired throughput of 66 Mtpa for the fully developed facility.
“In addition, the use of combined stacker reclaimers significantly simplified the final plant layout reducing the major yard machines from seven machines (four stackers and two reclaimers) to a total of four combined stacker reclaimer machines. This resulted in reduced requirements for machine berms, conveyors, transfer houses, services, engineering and management - a savings of around million capital costs for our client.
This innovative use of equipment and yard configuration is a world first for a coal export terminal.