Client

Lyttelton Port Company

Budget

$20 million

Contract Type

Design & Construct

Completed

Nov 2004

Location

South Island

Lyttelton Port Company Fast Coal Project

New Zealand’s largest coal terminal, Lyttelton Port receives coal from the West Coast, where it is aggregated and loaded on to vessels for export. With coal trains arriving four to five times per day, and ships leaving approximately every 12 days, an efficient coal handling system is essential to keep pace with demand.

To increase through put of coal we undertook a major upgrade to the coal handling facility and expansion to the coal storage yard. Our work included:

  • Construction of a new 2000 tph rail unloader system 
  • Installation of a new 1000 tonne staker / reclaimer system. The stacker takes the coal dumped from rail wagons and stacks it in huge piles, then the reclaimer picks it up with a bucket wheel to transfer by conveyor to waiting ships.
  • Installation of a new jet slinger (a conveyor belt which carries coal and stacks it into ships for export)
  • Extension and reconfiguration of the coal processing yard 
  • Installation of new control systems
  • Upgrade of the coal dust suppression system and stormwater collection & treatment systems. 

To increase through put of coal we undertook a major upgrade to the coal handling facility and expansion to the coal storage yard. The coal-stacker and reclaim system was purchased second-hand by Lyttelton Port Company from the United Kingdom. Our team travelled to Port of Tyne, Newcastle to decommission and disassemble the reclaimer, before shipping it to Lyttelton, where it was recommissioned and upgraded.

we undertook a major upgrade to the coal handling facility and expansion to the coal storage yard.

The challenging working environment added significantly to the complexity of the project – the coal facility remained fully operational while the upgrade was undertaken, and all works had to be undertaken around the daily coal trains and the shipping cycle. With offshore customers waiting for coal, any disruption to coal train or shipping schedules was simply not an option.

The new machinery, along with reconfiguration of the storage yard and improved coal train retrieval facilities, increased the Port’s ship loading capability by 35% - from 18,000 tonnes per day to 25,000 tonnes per day. The new dust suppression and stormwater systems significantly reduced the facility’s environmental footprint, while the control systems enabled operations staff to better track its functioning and performance, controlling all aspects of the yard centrally.

Project Partners

Name Opus International

Role Civil consultant

Name Carson Group (SI) Ltd

Role Project Manager

Name Soros Associates Australia

Role Mechanical Consultant