Hay Point Coal Terminal Queensland, Australia

Transcription

1 Hay Point Coal Terminal Queensland, Australia Overview of Operations 1

2 BMA Coal Logistics Chain Export Terminals BMA owned and operated Shipping Tonnes FY02 Hay Point Services 30.6mt Common User Facilities Dalrymple Bay Coal 1.4mt R.G. Tanna 13.2mt Barney Point 1.0mt Total shipping Queensland Rail provides: 46.2mt - Coal transportation via electrified rail locomotives and track infrastructure - Rail Haulage Contracts with QR have recently been re-negotiated due to access to competition - Good performance and operational efficiency of rail network 2

3 History Construction nominal stockyard capacity of 0.4Mt single tippler, rail mounted stacker, tracked bucketwheel reclaimer, single berth. Oct 1971 First coal loaded (ex Goonyella Mine) Expansion to handle coal from Saraji and planned Norwich Park Mine duplicated rail unloading and shiploading facilities, constructed two rail mounted stacker reclaimers, nominal stockyard capacity increased to 2Mt Multi-stage expansion to increase throughput and flexibility tipplers replaced by bottom dump unloading system, high capacity stacker constructed, original bucketwheel reclaimer replaced with stacker reclaimer, new surge bin, other optimisation. 3

4 SAFETY: Safety, Community and Environment Have previously achieved - 2 YEARS LTI FREE. Won NOSA Safety Excellence Award for - BEST 4 STAR PORT LOADING FACILITY DRIVE FOR ZERO HARM. COMMUNITY: Celebrated 30 yrs of Operation on 5th November Participation in community projects. Regular donations to local groups/organisations. ENVIRONMENT: Extensive Dust and Noise Monitoring and Minimisation Programs. World Class Water management program on site. Six Monthly Community Environmental audit of the terminal. 4

5 Coal Handling Process Train Train from from Mine Mine Unloaded by by Bottom Dump Dump Facilities Stacked in in Designated Stockpile(s) Reclaimed (by (by one one or or more more machines) Conveyed Directly to to Ship Ship Loaded into into Ship Ship 5

6 Site Schematic 6

7 Coal Receival Coal delivered by trains (7,800-10,000t per train) on a balloon loop. Unloaded by bottom dump station (4500tph) Typically 10 trains received per day (90,000tpd). Nominal Rail inloading capacity is in excess of 40Mtpa. 7

8 Stacking and Reclaiming Stacking and reclaiming is carried out using:- Strachan Henshaw 7000tph automatic stacker, Strachan Henshaw 4800tph and two Dravo 3500tph manually operated stacker/reclaimers. Nominal Stockyard throughput capacity of Mtpa 8

9 Stockyard Coals are stacked on and reclaimed from designated stockpiles stockpile areas are prepared and profiled before new coal types are stacked to minimise crosscontamination by other coals Interlocks prevent machines from accessing stockpiles containing incorrect coal types Stockyard Capacity with Coal Types Wet Season 850,000 tonnes Dry Season 1.2 million tonnes 9

10 Shiploading Shiploader on each berth Berth 1: Luffing boom with telescopic chute tph Berth 2: Rail mounted shuttle boom with telescopic chute tph Nominal Ship loading capacity of 36 Mtpa 10

11 Shiploading Capability Best Annual Shipping: 28.5Mt in 00/01 Design Ship Size: Berth 1: 14, ,000 DWT, Berth 2: 25, ,000 DWT. Largest ship loaded: Iron Pacific (230,000 DWT) Largest cargo: 207,769t on Iron Pacific Average Cargo Size: 93,000t 11

12 Blending About 25-30% of shipments are blends of two or more coal types - integral part of Hay Point operations. Very flexible operation with good blending capabilities and extensive blending experience. Blending methods: Controlled simultaneous reclaiming of two or three component coals ( on-the-belt blend), continuous real time computer monitoring of actual blend ratio vs target blend ratio, Windrow bed blended stockpiles containing two component coals, Combination of above. 12

13 Quality Control Contract specifications available electronically for each consignment Communication between mine and port personnel on actual/potential quality issues for a cargo Train quality (supplied before the coal arrives at the port) determines whether the coal: can be sent directly to the vessel, can be stacked in normal manner, requires special corrective action. Coal Tracking system being developed to track quantities and qualities from train to vessel hatch. Port quality system certified to AS/NZS ISO 9001:

14 Cargo Destinations - 60 Customers 24 Countries 320 Ships in FY02 Cape 147 ships (100, ,000t) Panamax 102 ships(50, ,000t) Handy 71ships (< 50,000t) South America Europe Middle East South Africa Korea India Taiwan Japan 14

15 Hay Point Terminal Performance Indicators Actual FY98 Actual FY99 Actual FY00 # Actual FY01 Forecast FY02 Tonnes Shipped (Mt) Tonnes Blended* (%) No. of Coal Types Handled No. of Permanent Employees *up to 47 Blended Products # Annualised for 13 month year 15

16 Shipping tonnes ('000) per Employee Shipping tonnes ('000) per Employee Actual FY 98 Actual FY99 Actual FY00 Actual FY01 Forecast FY02 16

17 Productivity Year End December 2001 Productivity Tonnes / Employee/Year st Quartile 2 nd Quartile 3 rd Quartile 4 th Quartile Hay Point is in the top quartile of the World s Coal Export Terminals 17

18 Port Controllable Costs $/t % Change from Base year Port Controllable Costs $/t - % Change from Base year % Actual FY 98 Actual FY99 Actual FY00 Actual FY01 Forecast FY02 18

19 Hay Point Initiatives/Operating Excellence Hay Point Expansion Stage 1 & Stage 2 Labour and maintenance cost savings. Outsourcing / Shared Services/Cost Reduction program. Automation of stacking function on bulk handling machines - labour savings. Improve Gross Train Inloading Rates from 3,450tph to 3,800tph. Structural Integrity Program Stacker Reclaimer 1 & 2, Shiploader 1. Life extension of existing structures. Corrosion protection trestle/berth, concrete remediation of berth structures. Debottlenecking of process/material flow paths. Improve Gross Outloading rates on Shiploader 2. Reduce jackhhammering/automatic coal release in both dump stations. Automatic Reclaiming Stacker Reclaimer 0. 19

20 Gross Train Inloading Rates - TPH Dump Station 1(DS1) / Dump Station 2 (DS2) Average TPH TPH DS1 DS2 Linear (DS1) Linear (DS2) Jul-00 Sep-00 Nov-00 Jan-01 Mar-01 May-01 Jul-01 Date Sep-01 Nov-01 Jan-02 Mar-02

21 Expansion - Stacker Reclaimer

22 Expansion - Stacker Reclaimer 2.5 plus Stockyard 22

23 Hay Point - Summary Integral part of the BMA Coal Logistics Chain. Owned and operated by BMA rather than a common user terminal - allows: - Optimisation of logistics chain (Pit to ship/customer) - Minimisation of demurrage costs and maximisation of despatch income. - Smoothing of quality variation in coal to customers - Highly capital efficient operation due to single owner and operator allowing maximum flexibility versus a common user facility. Total Cost in lowest quartile of World Coal Export Terminals. Productivity in top quartile of World Coal Export Terminals. Full suite of Coals from a one stop shop ie HCC, WCC/SSCC, PCI,thermal Customer focus and blending to suit customers requirements. Capacity to expand. Range of products available/blending capabilities and port reliability, ensures BMA s reputation s a reliable supplier of seaborne coal. 23