Post on 27-Apr-2015
ORE LINE: Capacity Expansion
PRESENTATION to the Railway & Harbour Engineering Division of SAICE
on 11 September 2007
Willem Kuys
1TRANSNET freight rail
Content
HistoryInternational Iron Ore TradeDesign Parameters Broad plan
•Infrastructure•Distributed Power•Locomotives•Wagons•Power Sipply•Signalling
Volume and Capacity Build-up
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History
• The 861 kilometre line was built by Iscor and opened in 1976 with a capacity of 17,5 mtpa
• The line has 10 crossing loops for train crossings spaced 80-90 kilometres apart
• Spoornet took over the line 1977 as a 15 year run-out project
• Idea was that line would revert back to Iscor after 15 years.
• Assmang started exporting iron ore over the Ore line from Beeshoek (70 km south of Sishen) in 1978
• The capacity of the line was increased in 2002/03 by installing intermediate loops increasing these to 20
3TRANSNET freight rail
Prince AlfredHamlet
Sishen
Saldanha
Cape Town
East London
Port Elizabeth
Mosselbaai
Bredasdorp
Protem
StellenboschFranschhoek
Bitterfontein
Porterville
Atlantis
RiversdaleKnysna
George AvontuurPatensie
Klipplaat
Oudtshoorn
Rosmead
Kirkwood
Cookhouse
Noupoort
De Aar
Prieska
Upington
Kakamas
Naroegas
Worcester
Touwsrivier
Sakrivier
CalviniaHutchinson
Kootjieskolk
Beaufort West
Belmont
Douglas
Hotazel
Warrenton
Pudimoe Makwassie
Mafikeng
Ottosdal
Vermaas
KlerksdorpOrkney
Coligny
Vierfontein
BultfonteinWhites
Kroonstad
Bloemfontein
Aliwal North
Sannaspos
Dreunberg
Springfontein
Koffiefontein
HofmeyrSchoombee
Barkly EastMaclear
Queenstown
Blaney
Bethulie
Umtata
Amabele
Maseru
Marquard
Ladybrand
Bethlehem
Wolwehoek
Lichtenburg
Warden
Harrismith
Bergville
Kokstad
Matatiele
Harding
Port Shepstone
Kelso
Durban
Kranskop
RichmondUnderberg
Stanger
Nkwalini Richards Bay
VryheidHlobane
Ennersdale
Ladysmith
Roossenekal
Steelpoort
MachadodorpBelfast
Lothair
Komatipoort
Barberton
Phalaborwa
Messina
Louis Trichardt
Soekmekaar
ZebedielaVaalwater
Nylstroom
JohannesburgPretoria
Middelwit
Ellisras
Northam
Utrecht
VolksrustVrede
Potchefstroom
Empangeni
Simuma
Donnybrook
Greytown
Franklin
Kimberley
Marble Hall
Standerton
Bethal
GelukplaasHawerklip
Graskop
Winburg
Theunissen
Breyten
Derwent
Pienaarsrivier
Plaston
Naboomspruit
Golela
Sterkstroom
Stormberg
Pietermaritzburg
Newcastle
Ancona
Welverdiend
Ramatlhabama
Thabazimbi
Kaapmuiden
Hoedspruit
Beit Bridge
Nelspruit
Witbank
VredefortDover
Arlington
Ermelo
Addo
Grahamstown
Graaff-Reinet
Mhlume
Glenside
Bruyns Hill
Mt Alida
Alicedale
Ngqura
Ore Line
Kumba Erts
Assmang Beeshoek
Sedibeng Palingpan
Assmang Khumani
Kumba (Sishen South)
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SEABORNE TRADE OF IRON ORE Growing at 5.3% p.a.
300350400450500550600650700
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
f20
05f
2006
f20
07f
MIL
LIO
N M
T 570 Mt
(Source: CRU)
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MARKET ANALYSIS – DEMANDSEABORNE IRON ORE IMPORTSSEABORNE IRON ORE IMPORTS
0
100
200
300
400
500
600
700
800
900
1000
2003 2008 2013 2018 2023
China
Other
29%
71%
78%
22%
66%
34%
2003 20252015
China will become the dominant iron ore importerChina will become the dominant iron ore importer(Source: Market Analysis)
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MARKET SHARE OF THE SEABORNE MARKET
33%
36%
8%
5%
6%
3%
2%1%
6%
BrazilAustraliaIndiaSouth AfricaCanadaSwedenMauritaniaVenezuelaOther
(Source: Tex Report, AME)
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IRON ORE LINE LAYOUT
To Saldanha Steel
KUMBA/ASSMANGLoading Stations
SAPOTippler,
Stacking/Reclaiming
SAPOReclaiming & Ship Loading
Shipping patterns
SALKORCompiling/De-compiling
trains,Shunting, NTG, Wagon & Locomotive maintenance
RAIL OPERATIONSTrain operations, Crews,
Traffic Control, Perway, Communication, Signalling, Power supply & Infrastructure
maintenanceBeeshoek
Sishen South
ERTS
BKN
NPABerth capacity, Berths,
Marine services
Off Loading8 – 9
Hours
Rail Distance of 861 km; Single line TrainOperations : Loaded throughput 22 hours;
Empty thoughput 20 hours
Loading 8 – 9
Hours
Total Systemcycle time
Time +/- 64 Hours(Loading to loading)
Halfweg – Re-manning of trains
Crew book off
Source: Iron Ore Line Production and Investment teams
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Operational re-design
Assessment of infrastructure
Efficiency improvement
New technologies
Rail infrastructure establishment
New rolling stock
New design: Focus areas
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Operational Re-design
• Present infrastructure and train design limited capacity to 37 mtpa• Various configurations of train consists and lengths were investigated for
the way forward• Basic principles of capacity
– Distance between crossing loops– Speed of trains– Train lengths
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Infrastructure Configuration
• Single line track layout–Crossing loop spacing and train speed determine number of slots
• Higher throughput volumes:–Single line with limited slots
• More slots * More crossing loops• More tonnage per slot * Longer trains
* Longer crossing loops–Double line
• Run more trains
• Longer trains with less infrastructure vs Short trains with double line
11TRANSNET freight rail
Train Configuration
• Spoornet solution–Longer trains
• Presently–2 by 108 = 216 wagon trains with headend locomotives
• Planned–3 by 114 = 342 wagon trains with distributed power–40 slot grid with 28 trains/week Even loops–72 slot grid with 44 trains/week All loops
• Future–3 by 140 = 420 wagon trains with distributed power–72 slot grid with 44 trains per week All loopsOr–40 loops with 2 by 114 = 228 wagon trains
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Distributed Power (DP)
• Distributed Powered (DP) trains to be deployed
• Locomotives are distributed through the train
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Distributed Power
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Distributed Power (DP)
• Distributed Powered (DP) trains to be deployed
• Locomotives are distributed through the train
• Locomotives in train are remote controlled by radio
• Train forces and train dynamics significatly improved
• Braking improved, shorter stopping distances
• Enables longer trains with one crew
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Train Operations• Train unit = 114 wagons with a locomotive attached at each end
114 wagons
Unit
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Train Operations• Train unit = 114 wagons with a locomotive attached at each end
• Main line train = 3 independent units complete with locomotives
Units controlled with DP from crew in leading cab
114 wagons
Unit
114 wagons
Unit
114 wagons
Unit
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Train Operations• Train unit = 114 wagons with a locomotive attached at each end
• Main line train = 3 independent units complete with locomotives
Units controlled with DP from crew in leading cab
114 wagons
Unit
114 wagons
Unit
114 wagons
Unit
• Main line train can run with 1, 2 or 3 units and improves flexibility
• Main line train decompiled for loading and off loading at terminals
• Locomotives remained coupled to units at terminals
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Design Parameters
Present 47 mtpa 61/90 mtpa
Wagons/train 216 342 420
Train length 2 430 3 850 5 020m
Wagon payload 100/85 100/85 100
Net ton/train 20 000/21 600
34 200/29 070 42 000
Slots per week 28 28/44 44
Distributed power none Electric/diesel mixed Electric
Train loading time 8 hours 8 hours 6:45 hours
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Changes to increase capacity
Increase the length of ALL loops (odd & even) to accommodate the
342 wagon trains
Build new loop (7A) to replace loop 7
Upgrade yard capacity to operate 342 wagon trains in Salkor yard,
link line to the port and at loading sidings
Install 1:20 crossing at loops to decrease the cycle times on the line
Increase energy supply from Eskom to accommodate 9 active
locomotives in a sub-section (feeder lines, sub-station, etc)
Build feeder substations
Build Eskom transmission lines & substations
20TRANSNET freight rail
Changes to increase capacity
Change rolling stock maintenance facilities to in-yard maintenance
Replace the signaling system with electronic switching
Upgrade and new equipment at Saldanha Port and loading sidings
Upgrade 1000 85 ton payload wagons to 100 ton
Purchase 1070 new 100 ton payload wagons
Purchase new electric locomotives
Install DP in existing and new locomotives
Electric brakes in all electric and some diesel locomotives
Repeater stations along railway line to relay DP signals.
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Volume Demand Scenarios
25
35
45
55
65
75
85
95
Jul-0
5
Jan-
06
Jul-0
6
Jan-
07
Jul-0
7
Jan-
08
Jul-0
8
Jan-
09
Jul-0
9
Jan-
10
Jul-1
0
Jan-
11
Jul-1
1
Jan-
12
Jul-1
2
Jan-
13
Jul-1
3
Jan-
14
Jul-1
4Months
Mill
ion
ton
per Y
ear
Customersoptimistic scenario
Customer confirmeddemand
Planned for 41 Mtpa
Opportunity
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Capacity Build-up
25
30
35
40
45
50
55
60
65
70
75
Jul-0
5
Jan-
06
Jul-0
6
Jan-
07
Jul-0
7
Jan-
08
Jul-0
8
Jan-
09
Jul-0
9
Jan-
10
Jul-1
0
Months
Mill
ion
ton
per Y
ear
Customersoptimistic scenarioCustomer confirmeddemandPlanned for 41 Mtpa
Maximum RailCapacitySAPO/NPA Capacity
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Critical Assumptions
• Wagon turnaround time from Sishen - 56 hours (currently 64 hours)
• Wagon turnaround time from Beeshoek - 72 hours (currently 84 hours)
• Operational efficiency of line 93%
• Locomotives remain on train during loading
• Train follow-up time 4 hours 12 mins
• Load-out rates at loading stations 5400 tonnes/hour
• Dual tippling of wagons
24TRANSNET freight rail
Thank you