INTERNATIONAL CASE STUDY: The Rail Capacity Enhancement project in the Pilbara/Western Australia
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Transcript of INTERNATIONAL CASE STUDY: The Rail Capacity Enhancement project in the Pilbara/Western Australia
Heavy Haul Rail Sao Paulo 2012
Rail Capacity Enhancement Projects in the Pilbara
– Western Australia
Overview
A leading provider of integrated engineering and project delivery services to the Resources and Infrastructure markets
Integrated project assessment, design and delivery management service offering across the mine, rail port and infrastructure asset lifecycles
Delivered or delivering, 45 projects for key blue chip clients, with combined capital value of $39bn
Market leader in the Australian heavy haul rail market
Leading mine site EPCM service provider to the Australian iron ore sector
Leader in remote operations enablement and technology integration in the resources sector
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Mine Rail Technology Infrastructure
Asset evaluation and consulting
Pre - feasibility studies Feas i bility studies
Detailed engineering design
Project delivery services Project construction
management Commissioning and
handover
Operations services
Maintenance services Continuous improvement
Environmental , health and safety management and training
Plant and mine closure and rehabilitation services
Optimis e Technology
enablement services
Sustaining capital works
The Calibre Service Continuum
Diversified integrated engineering and project delivery offering across the asset lifecycle
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Geological & Mining
Consulting
Mine-site Infrastructure
Rail Services
Industrial Technology
Sustainability Infrastructure Services
Port Services
Safety Training
• Track & civil
• Operations
• Signaling & communication
• Rail infrastructure
• Stockpile & blending
• Ship loading
• Infrastructure
• Simulation
• Design
• Delivery
• Optimisation
• Geological services
• Early stage mine design and consulting
• Corporate support
• Mine safety services
• Environmental management training
• Engineering solutions for sustainable environmental management
• Materials handling
• Mine infrastructure
• Minerals processing
• Industrial, commercial and retail structures
• Roads and bridges
• Urban development
• Safety & rescue training
• OSH consulting
• OSH compliance and documentation
Client deliverables by group businesses
The Calibre Group consists of complementary businesses providing integrated services across the asset lifecycle, to the resources and infrastructure sectors
Integrated services across the value chain Mine Rail Port Infrastructure
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Operations across Australia with an expanding geographical presence
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Enduring Value
Major Pilbara Players
BHP Billiton
Iron Ore
» 7 mining operations » 1000km track » 2 port facilities
» 14 iron ore mines » 1400+km mainline
track » 3 ports – Dampier
(East Intercourse and Parker Point), Cape Lambert
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Rio Tinto Iron Ore
Fortescue Metals Group
» 2 iron ore mines » 700+km track
Enduring Value
Rio Tinto Iron Ore – Expansion Projects
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» Services 14 mines via a mainline system of 1500km track
» First operated in 1966
» Investing US$15bn on Pilbara expansions between 2010 to 2015
» Targeting 353mtpa
» Additional 50% capacity to existing (225mtpa in 2011)
» 1 new mine – Hope Downs
» 3 mine expansions – Brockman 4, Western Turner Syncline, Nammuldi plus sustaining works at Marandoo to increase life of mine
Enduring Value
Rio Tinto Iron Ore – Expansion Projects
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Rail capacity expansions, technology and innovation
» Staged capacity upgrades to mainline targeting 353 mtpa by 2015
» Introduction of ECP (electronically
controlled pneumatic) braking systems on entire fleet
» Deployment of AutoHaul TM driverless
trains throughout the Pilbara Mine Location Map
Enduring Value
Fortescue Metals Group - Operations
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Enduring Value
Fortescue Metals Group - Overview
» Firmly established itself as one of the world's leaders in iron ore production and sea-borne trading.
» Tenements located throughout the resource rich Pilbara region of Western Australia » Construction of the initial mine, rail & port project commenced in 2006.
» 2008 - rail & port infrastructure were completed and operations were underway at their
flagship Cloudbreak mine
Production levels:
» FY10 = 27 million tonnes of iron ore » FY11 = 40 million tonnes of iron ore » FY12 = 55 million tonnes of iron ore » Expansion = 155 million tonnes of iron ore
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Enduring Value
Fortescue Metals Group - Port & Rail Infrastructure Continued
RAIL » First large-scale railway development undertaken in the Pilbara in more than 40 years » Currently the heaviest haul line in the world – 40 tonne axle load capacity » As of December 2012 total rail infrastructure = 700km, including 10 bridges » Current rolling stock includes:
– 43 locomotives – 3000 ore wagons – 30 fuel tanker wagons – 47 ballast wagons
» Each train carries up to 33,000 tonnes of iron ore, consists of 240 ore wagons and in 2.7kms long
» Train Control Centre located in Perth: FMG to introduce an Integrated Train Control System
Further Expansion Plans +155mtpa:
» Acquire two more trains » Operate 13 ore trains – each train to complete at least one trip per day
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Enduring Value
Fortescue Metals Group - Operations
CHICHESTER HUB » Designed to take capacity from 55Mtpa to 90Mtpa » Additional 5Mtpa capacity – JV with BC Iron
Cloudbreak:
» 40Mtpa since 2008 » Train load-out facility – capable of feeding 16,000 tonnes of ore per hour » 256km heavy heal railway from mine to Herb Elliot Port
Christmas Creek:
» Expansion underway to increase capacity » Ore processing plant operating at 18Mtpa » 50km rail extension to existing Port Hedland to Cloudbreak rail line
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Enduring Value
Fortescue Metals Group – Expansion Projects
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HERB ELLIOT PORT » Expand to 4 berths » A second and third train unloader » A third stacker » A second and third reclaimer » A third and fourth shiploading berth (AP3 and AP4) » A second and third shiploader
RAIL EXPANSION » Duplicating 120kms of the mainline from Port Hedland » New 130km rail spur to the Solomon Hub » Four new bridges » Two new rail loops to deliver iron ore to Herb Elliott Port
SOLOMON HUB » Large, low cost mining operation 120km west of the Chichester Hub » Maiden reserve of 716 million tonnes
– First stage to produce 60Mtpa of ore from the Firetail & Kings deposits
Enduring Value
BHP Billiton Iron Ore - Overview
» BHP Billiton Iron Ore is one of the world’s premier suppliers of iron ore, employing 13,000 people across the Pilbara.
» Mining operations are supported by the town of Newman while Port Hedland
houses the company’s port and rail facilities. » The massive Mt Whaleback mine, established in 1968, is the biggest single-
pit open-cut iron ore mine in the world being more than five kilometres long and nearly 1.5 kilometres wide.
» Adjacent are smaller deposits, Orebodies 29, 30 and 35. Smaller satellite
mines – Wheelarra and Orebodies 18, 23, 24 and 25 – are located outside the town of Newman.
» The Yandi and Area C mines are located about 100 kilometres north-west of
Newman. The Yarrie mine is 200 kilometres east of Port Hedland.
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Enduring Value
BHP Billiton - Operations
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Location of Operations
Enduring Value
BHP Billiton Iron Ore
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» 220 Mtpa combined capacity
» Port Hedland Inner Harbour Expansion commissioning scheduled for H2 CY12
» Jimblebar Mine Expansion delivers 35 Mtpa of mining capacity with larger processing
capacity, first production scheduled for Q1 CY14
» Rail Yard Facilities Expansion creates flexibility and increases our direct load capability
with commissioning expected in H2 CY14
Enduring Value
BHP Billiton Iron Ore – Utilisation of Dual Track
» Achieved 145 mtpa with single track infrastructure
» Single track operation required a large number of passing loops which created
inefficiency
» Dual track can deliver more than 300 mtpa of capacity with modest investment
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BHP Billiton Iron Ore Train
Enduring Value
Oakajee Port & Rail - Overview
» OPR established in 2007 – JV between Murchison Metals Ltd, Mitsubishi Development
Pty Ltd & Crosslands Resources Ltd » Deep water port 24km north of Geraldton » Will cater for the world’s largest ore carriers » 570km rail network to service operating & emerging projects » Project Value: $3.5bn » Currently on hold
OAKAJEE PORT:
» Site boasts a natural deep anchorage » Capacity to accommodate cape size vessels » State of art facilities
RAIL NETWORK:
» Strategic rail corridor from Oakajee to the North East at Weld range & Jack Hills » Heavy haul single track with passing loops – initial export capacity potential 45Mtpa
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Enduring Value
Oakajee Port & Rail - Operations
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Project Location
Enduring Value
Roy Hill - Overview
» 55Mtpa project – the next iron ore mining, rail & port project to be developed in the Pilbara
» Only independent iron ore project with West Australian majority ownership » Approx 115km north of Newman » Mine life of more than 20 years » Aiming to load it’s first shipment of ore for export by 2015
MINE
» Conventional open pit » Processing plant for the project will utilise low risk, proven technology - will be the
largest single feed processing plant in the region
RAIL
» 344km single line, heavy haul railway » Dedicated port stockyard facility located south of Port Hedland » Independently owned & operated » Operate 5 ore trains per day – total payload of 31,450 tonnes of ore
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Enduring Value
Roy Hill – Overview Continued…
PORT » Purpose built iron ore port facility at Port Hedland » Wharf designed to accommodate an average vessel size of 206,000
tonnes » Capable of handling larger 320,000 tonne cape size vessels
CORPORATE HEADQUATERS & REMOTE OPERATIONS CENTRE
» Construction of integrated Corporate Headquarters & Remote Operations Centre (ROC)
» Ability to integrate operations, marketing and corporate service functions » ROC will provide end-to-end integration of operations through state of the
art automation
ADDITIONAL INFRASTRUCTURE
» Construct & operate an airport » Workforce accommodation for over 5000 staff » Site access roads » Mining & processing support facilities
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Enduring Value
Roy Hill – Project Scale
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Enduring Value
Junior Miners – North West Infrastructure
NORTH WEST INFRASTRUCTURE
» Formally the North West Iron Ore Alliance » JV between Atlas Iron Ltd, Brockman Resources Ltd & FerrAus Ltd » Facilitate construction of port facility capable of exporting 50Mtpa » Two berths, stackers & loaders, conveyors, stockyard, rail car dumper & rail loop
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Enduring Value
Junior Miners – Atlas Iron Ltd
ATLAS IRON “The Pilbara’s Emerging Powerhouse”
» Operations: Pardoo Mine & Wodgina Mine » Expansion Projects (Horizon 1): Target production rate of 15Mtpa by 2015
» Development Projects (Horizon 2): Targeting up to 46Mtpa » Port Infrastructure: Utah Point & South West Creek » Rail: currently utilise road haulage – rail haulage will be prefered for future expansion &
development projects » Signed MoU in April 2012 with QR National – study the development of an independent
rail network
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Enduring Value
Atlas Iron – Project Area Map
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Enduring Value
Junior Miners – Brockman
BROCKMAN (RESOURCES) MINING Marillana Mine:
» Flagship project located 100km north-west of Newman » Located close to existing infrastructure – BHP’s railway traverses through the lease » Project requires rail infrastructure » August 2012 – Tripartite Alliance Study Agreement with QR National & Atlas Iron Ltd » Allocated 50Mtpa capacity at Port Hedland via North West Infrastructure set up » Progressing the development of an “independent” rail solution with QR National
Other Projects: Opthalmia Project & West Pilbara Project » Comprise of exploration tenements / prospects
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Enduring Value
Brockman – Project Area Map
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Flagship project location
Enduring Value
Junior Miners – BC Iron Ltd
BC IRON LIMITED “The Pilbara’s New Iron Ore Producer”
» 50/50 JV with FMG in 2009 – Nullagine Iron Ore Project » Mine life of 8.5 years » Annualised production rate of 5Mtpa » BC Iron is operator & manager of the project » Contracts FMG’s subsidiary, the Pilbara Infrastructure Company, to provide rail services » 100% owners of Bungaroo project: comprises of 5 Exploration Licences – close to
existing Rio Tinto rail system, the proposed rail & Anketell multi-user port
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Enduring Value
BC Iron Ltd – Project Area Map
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Enduring Value
Junior Miners – Aquila Resources
AQUILA RESOURCES LTD West Pilbara Iron Ore Project
» Projected Production rate: 30Mtpa from Stage 1 » Estimate mine life of 15 years » Significant infrastructure required e.g. airstrip » Heavy haul railway from the Central Processing Facility (CPF) to a port location at
Anketell Point (approximately 245km) » Train unloading, iron ore stockpiles, processing, blending and ship loading facilities at
the port location
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Enduring Value
Aquila Resources – Project Area Map
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calibregroup.com