CWA provided EPCM services to Neptune Bulk Terminals to increase the capacity of its metallurgical (steel-making) coal export facility from 8.5 million tonnes per year to 12.5 million tonnes per year. The project included the installation of a new stacker/reclaimer and a related conveyor system rated at 8,000 tonnes per hour.
As the project took place at a brownfield facility, it was crucial to minimize any disruptions to the terminal’s ongoing operations and impacts to the surrounding community.
CWA developed the project budget, the project schedule, and the contract schedule and managed the engineering contracts as the prime consultant for the project.
The increase in capacity was achieved by integrating an additional stacker/reclaimer into the existing system and upgrading the power supply to the site. CWA was responsible for the detailed design of all new conveyors and modifications to the existing conveyor and surge bin, utilizing 3D modelling and discrete element method (DEM) modelling.
Using a state-of-the-art soft-handling technique designed in house to manage dust generation from the transfer chute, CWA was able to minimize fugitive dust emissions to reduce potential impacts on the environment and the health and safety of operations personnel.
Implementing the project within the operating terminal required detailed planning, communication, and safety management. The new system was tied in through a series of short shutdowns and work-arounds to minimize disruptions to product shipments.