Teck Resources Limited (Teck), Canada’s largest diversified mining company, is expanding their existing steelmaking coal handling system at Neptune Bulk Terminals (NBT) in North Vancouver, British Columbia. CWA performed Phase 1 of the expansion, which increased the terminal throughput from 8.5 million tonnes per year to 12.5 million tonnes per year. Phase 2, which is in progress, will further increase the terminal’s capacity. CWA is currently performing the detailed design of the project including upgrades to the inbound and outbound systems.
CWA investigated potential arrangements for the inbound system that might optimize the cost and schedule and provide the most operational and throughput benefits by conducting trade-off studies and preliminary design work for several options:
- A shallow dumper pit design including a low-profile feeder system to minimize construction cost, risk, and potentially schedule.
- A tandem railcar dumper to maximize the railcar unloading rate and overall terminal throughput.
- A second indexer to allow the unloading of trains in both directions.
- A shiploader concept that would maximize constructability and long-term performance and enable the loading of larger vessels.
- An overpass to improve access for vehicles and construction traffic into the rail loop at the site.
All associated equipment, infrastructure, and utilities were included in the investigation and preliminary design work.
CWA prepared a project schedule, a construction execution plan, a procurement plan, and a capital cost estimate for the railcar receiving layout option. Solutions were developed for site access, delivery logistics, and laydown area requirements for the duration of construction with the objective of minimizing the impacts to ongoing terminal operations.
A risk assessment for the project was also carried out that included facilitating a risk workshop with Teck and NBT to identify major risks and uncertainties, as well as the mitigation efforts to be undertaken.
Based on the trade-off studies and preliminary design work, CWA implemented a multifaceted, task-specific approach that included detailed design and specifications for procurement. The key elements of this work included the following.
For the implementation of a new tandem rotary railcar dumper system, CWA:
- Performed the detailed design of the following elements:
- A receiving collection hopper.
- A 60ft-deep dumper pit.
- A wet scrubber dust collection system.
- Dumper pit access structures and ancillary maintenance equipment.
- Produced procurement specifications for:
- The tandem rotary railcar dumper equipment.
- An indexer.
- A low-profile feeder.
- An enclosure building.
- An ice crusher system.
CWA also performed the detailed design of a new inbound conveyor system rated for 8,000 tonnes per hour to deliver product from the dumper to the yard. Aspects designed for this system included conveyors, transfers, and a distribution tower capable of feeding the product onto one or both yard belts.
CWA performed the detailed design of:
- Marine foundations for the new shiploader.
- A new 8,000-tonne-per-hour shiploader feed conveyor.
- A one-of-a-kind new material distribution system that allows loading from two separate yard conveyors to both the old and new shiploaders at proportional feed rates.
CWA produced procurement specifications for:
- A new, higher-capacity shiploader to allow larger ships to dock at the terminal.
- A new sampling system.
CWA performed the detailed design for the following elements across the entire site:
- Civil and underground utilities.
- Electrical infrastructure for new power requirements.
- Control systems.
- Fire protection systems.
- Water collection and management systems.