Clinker Import Project: Owners Team Engineering Support

⁠⁠⁠Fremantle Port Authority (FPA) imports and exports bulk products at the Kwinana Bulk Terminal (KBT) via existing infrastructure including Kwinana Bulk Jetty No 2 (KBB2), various conveyor circuits and storage stockpiles. The facility is currently exporting bauxite and iron ore. Imports consist of cement clinker, nut coke, granulated slag, and gypsum. Clinker accounts for the majority of KBT's annual 1.1M tonnes of bulk imports.

The existing KBT import system contains the following assets for importing, stockpiling, and loading clinker.

• Kwinana Bulk Berth 2 (KBB2) Jetty
• Ship Unloader (AL05) situated on KBB2
• Reversable Jetty Conveyor 1 (JC01) situated on KBB2
• Import Conveyor 1 (IC01), Import Conveyor 11 (IC11) and Import Conveyor 2 (IC02)
• IC1-IC2-IC11 Transfer Station
• Twin Import Clinker Silos - 600 tonne capacity each
• Import Shed - 10,000 tonnes capacity
• Import Yard Stacker ICO3

The KBT import circuit requires an urgent upgrade to allow for the continued import of cement clinker and other products. The following import circuit assets have either reached the end or are fast approaching the end of their useful lives.

• Twin Import Clinker Silos - 600 tonne capacity each
• Import Shed - 10,000 tonnes capacity
• Import Yard Stacker ICO3
• Import Conveyor 11 (IC11)
• IC1-IC2-IC11 Transfer Station

Presently, FPA store clinker in the silos and import shed. However, a full shipment of clinker (40,000 tonnes) cannot be stored in the existing silos (1,200 tonnes) and import shed (10,000 tonnes). As a result, both clinker import customers utilise road transport to relocate the clinker by truck to their operational facilities. This causes the storage shed to overflow for later transport by truck and causes temporary ship unloading stoppages. Consequently, FPA intends to address the poor structural condition of existing assets and provide on-site storage capacity for a full 40,000 tonne clinker shipment.

In addition, one of FPA's customers provided notice that it intends to install a direct conveyor connection from its facility adjacent to KBT via an agreed lease corridor. The installation of the conveyor will abrogate the need for truck transport. FPA therefore also intends to install a future connection point between FPA's import system and its customers conveyor. FPA notes that it will still require a truck load-out hopper to supply clinker to its other customers.

FPA has received board approval to redevelop the import system to handle in excess of 1.4MTPA of clinker. The proposed project will involve the installation of a new 40,000 tonne storage shed, truck load-out hopper and a connection to the conveyor of FPA's customer. In addition, FPA will modify the existing Export Conveyor (EC01) so that it passes over the existing conveyance circuits to deliver product to either the new storage shed or the bypass conveyor. FPA will connect to the existing import system at IC01 with connection to EC01 via a new conveyor CC01.

To minimise the release of clinker dust to the environment, the redeveloped EC01 as well as all new conveyors will be covered with plastic conveyor covers that will be installed on all conveyors other than the shed stacking conveyor, CC02. All transfer points shall be enclosed, and dust proofed as much as possible with appropriate dust extraction. The new storage shed will require a dust extraction system and/or other innovative control mechanisms to limit dust emissions. Figure 2 provides an aerial overview of the proposed project.

FPA is seeking the services of an Owners Team Engineer to assist it throughout the execution of the project. FPA will require support per the following phased arrangement.

• Phase 1 Tender Preparation: Development of Design and Construction Tender Pack including as a minimum Scope of Work, Specifications, and Ready for Tender drawings.
• Phase 2 Tender: Provide engineering support and technical advice to review questions received during the tender period. Provide input to the review and evaluation of tenders.
• Phase 3: Delivery: Provide owners team engineering support during detailed design, fabrication, construction and commissioning.