Ongoing global demand, driven by emerging economies, is pressuring the resources industry to mine, process and export commodities quicker than ever, but still at a competitive cost.
Khumani Iron Ore Mine Expansion South Africa
As the demand for resources booms, our clients are faced with the challenge of maximising returns from resources of reducing grade in competitive, fast paced world markets. Seeking to optimise yields and capital investment while minimising operational costs, they also face the challenges of a skilled worker shortage, higher extraction and haulage costs of remote locations and the increasing political influences on the industry.
Accountability is the foundation of Aurecon’s client promise. We take responsibility for the projects in which we are involved and maintain open relationships with our clients to ensure our services meet and evolve with their needs, without compromising on innovation, cost or deadlines.
With resources knowledge developed over 50 years in the industry, Aurecon offers global experience in engineering, management and technical services across the entire project life cycle.
At Aurecon, we understand that amidst these industry-wide issues, the goals and challenges of each of our clients are different. So, we work closely with each client to tailor innovative solutions that increase direct operating hours and asset longevity, improve reliability and reduce maintenance. We do not compromise on Health & Safety; it comes first in everything we do and is a core value for Aurecon. We foster this by appointing experienced teams who combine a deep understanding of the management of Health & Safety with that of our clients.
“Our key strength is our constant focus on our clients’ needs and drivers. Our clients rely on our demonstrated ability to be flexible and work with them to deliver facilities and services that are functional, economic, sustainable and on budget.“ Ross Nugent Industry Director - Resources
Ross Nugent Ross has gained broad experience through his previous roles as Project Director for a major EPCM project and as Global Research and Engineering Manager for the development of a new technology project. His experience covers research, engineering, product and project development, technology commercialisation, business plan development, project management and manufacturing management.
Technical specialties Aurecon offers global resources industry experience, working with our clients on innovative and cost-effective solutions for projects ranging from feasibility studies and small start up facilities to complex engineering, procurement and construction management (EPCM) projects.
Heavy haul rail
Resource project development
Aurecon offers a comprehensive EPCM service geared to the development and expansion of mine, rail, seaboard import and export terminals, and associated mine, port and marine facilities. Our specialities range from feasibility studies to delivery, including detailed design, procurement and management of all requisite materials, equipment and contracting services, and construction.
As an international leader in developing and managing heavy haul railways and rail operations for bulk materials, our specialist knowledge covers the full spectrum of rail engineering and development, as well as bulk transport chains and interfaces. Our specialist services range from studies and estimating to master planning, simulation and asset management.
Bulk materials handling
Our market leading expertise in mine infrastructure draws on a large cross section of our capabilities – civil, transport, geotechnical, structural, mechanical and electrical engineering – to deliver comprehensive pit to port solutions. Aurecon offers a full range of end to end mine infrastructure services including roads, buildings, construction management, energy, water, control systems, airstrips, waste and environmental management.
We have developed seven of the world’s ten largest coal port terminals and have more than 50 years’ experience in this highly specialised field, developing and implementing advanced technical designs for all aspects of major materials handling systems. Our cost-effective designs focus on individual system components operating cohesively together, which maximises productivity and reduces operational delays for our clients.
Industry data shows that enabling infrastructure now dominates the cost profile for new resource developments. A new partnership, the JK Aurecon Alliance, offers a fresh resource project development approach that links expert assessment of mine and metal extraction with enabling infrastructure. Specialising in resources studies, reviews throughout the project life cycle and the role of owner’s engineer, the Alliance delivers a ‘new generation’ of resource project development solutions by thinking outside the box to incorporate infrastructure design into the geometallurgy and mine design process.
Asset management Aurecon develops and implements robust asset management plans that maintain the performance, continuity and profitability of our clients’ assets, helping optimise returns throughout the asset’s life cycle. Our experience covers the full spectrum of asset management, ranging from life cycle costing to facilities management and strategic advice on asset acquisition, rationalisation and disposal.
Aurecon’s key areas of resource industry expertise include:
Feasibility studies Ports and marine Roads and bridges Rail infrastructure and operations Controls and instrumentation Health, safety, environment and community management Electrical and mechanical Structural Geotechnical Mine services Accommodation and buildings Operations maintenance Water Power generation, supply, transmission and distribution Supply chain logistics Mine surface infrastructure design Bulk materials handling, storage and transport Fuel supply and storage
NCIG Coal Export Terminal Australia
Dalrymple Bay Australia
Jilalan Rail Yard Upgrade Australia
Rรถssing Uranium Mine Expansion Namibia
Abbot Point Australia
A tailored services mix As clients move through the project life cycle, we offer a range of multidisciplinary capabilities, enabling us to tailor a service mix for each individual client.
Strategy and planning
Health & Safety
Capital investment studies
Risk assessment and management
Social licence to operate
Project and programme delivery
Industrial and administration buildings
Fuel supply, storage and distribution 6
Environment and community
Operation and maintenance
Dalrymple Bay Australia
Controls and instrumentation
Airports airside and landside
Ports and coastal
Health & Safety
Roads and bridges
Dams and reservoirs
Pumps and pipelines
Water planning and management
Infrastructure advisory services
Software and database development
Information communication technology infrastructure
Land development infrastructure
Water quality Aurecon Resources
Global success stories Our expertise and industry knowledge have been developed on projects around the world, allowing our teams to develop detailed localised knowledge of the 80 plus countries in which we have worked.
“Aurecon has a flexibility that you don’t usually associate with a large engineering firm and this has been critical in the design of the Albion Process Plant within a large brownfields complex.” Mike Hourn Albion Process Manager to Xstrata Technology
Dalrymple Bay Coal Terminal Australia
Khumani Iron Ore Mine Expansion South Africa
Client DBCT Management Pty Ltd
Client Assmang Limited
Aurecon has been integrally involved in the ongoing planning, design and project delivery of the Dalrymple Bay Coal Terminal over its 30 year development history. We undertook the design and project management of the initial development, commissioned in 1983 as the first common user coal export terminal in Queensland. This engagement continued through subsequent development, as additional inloading, stockyard and outloading capacity has been progressively added.
Aurecon provided engineering services for both Phase 1 and Phase 2 of the Khumani Expansion Project. The Khumani iron ore mine was expanded to replace the tonnage of Assmang’s Beeshoek mine, which had reached the end of its economic life and was unable to sustain production.
The most recently completed Stage 7 expansion (DBCT7X) provides a terminal with three rail receival facilities and three shiploaders at berths located four kilometres offshore. It increases the terminal’s capacity by 50 per cent to a nameplate rating of 85 million tonnes per annum (Mtpa), making it the third largest terminal in the world. Aurecon, in a joint venture with Hatch, integrated full (EPCM) services for this seventh expansion which was delivered in three phases and required careful integration of multiple disciplines and stakeholder requirements.
The main components of Aurecon’s scope of work included: bulk earthworks and layer works for the crusher tip terrace, workshop platform design, overland conveyor terrace/road design, stacker and reclaimer bunds for the run of mine (ROM) and product load out, bulk water supply, provision of access roads and onsite roads, civil engineering services and stormwater management and attenuation dams design.
GAP 50 Rail Project Australia
Cigading International Bulk Terminal Indonesia
Moatize Coal Mine Phase I Mozambique
Client Queensland Rail
Client PT Cigading International Bulk Terminal
Part of the Goonyella to Abbot Point (GAP) Expansion Project was an upgrade designed to boost the system’s capacity to handle increased traffic generated by the ongoing growth in coal exports from the Bowen Basin region. The system maintains and services selected trains from both the Goonyella and Newlands coal systems. Working as part of the Coal Stream Alliance (CSA), comprising QR National, Macmahon, MVM Rail, Aurecon, Parsons Brinckerhoff and Hatch, we were engaged to deliver the project in stages to meet the predicted increase in export demand for coal through the Abbot Point port. The upgrade was undertaken in two phases, with the CSA delivering the total scope of the Abbot Point to Bogie River section of the project, from detailed engineering to construction and commissioning of all civil works. The civil works were successfully installed on time and within budget and increased the system’s coal handling capacity to 50 Mtpa.
Aurecon provided conceptual design, bid document evaluation, design audit and employer’s representative services for the Cigading International Bulk Terminal. Stage 1 of the project provides the coal terminal with an initial capacity of 4.5 Mtpa, which will be increased to 7.5 Mtpa during Stage 2. Stage 1 consists of two phases for Aurecon, including provision of design audit and employer’s representative services during construction stage. It incorporates nine flights of belt conveyors, two barge unloaders, three stockpiles of 130 000 tonnes and one shiploader. Aurecon developed the conceptual design which formed the base of the owner’s tender package, and assisted the owner in bid evaluation and design review for all disciplines (excluding geotechnical), the preparation of regular progress reports and chairing monthly stakeholder meetings.
Aurecon provided a conceptual design for the mine, followed by detailed design of the mine infrastructure components, including maintenance and administration facilities, bulk water and electrical supply, new access roads, water treatment and rail loading facilities. Aurecon’s responsibilities also included geotechnical investigations and project management, with a core team of specialists assigned to assist the client in the implementation of the project. Aurecon had previously provided extensive feasibility studies and options analysis for transporting 12 Mtpa of coal to the Port of Nacala. Following Vale’s acquisition of an additional coking coal mine with a capacity of 14 Mtpa (Moatize II), Aurecon was again engaged to consider the transportation of additional tonnage and prepared a master plan for a 40 Mtpa port terminal facility.
Award-winning innovation We strive for excellence in our client relationships and our project delivery, working in partnership with our clients to deliver innovative solutions. While our results and client satisfaction speak for themselves, we are proud to receive international industry recognition for our achievements.
“Despite the fast track delivery schedule we requested, and the volatility of the construction industry at the time, the exceptional commitment of the Aurecon design team, together with the contracting strategy adopted, ensured that the X50 expansion was completed to a high quality, within budget and on schedule.” Brad Fish N orth Queensland Bulk Ports Chief Executive Officer
Winner Consult Australia Awards for Excellence 2011 Category: Project of the Year Gold Award Consult Australia Awards for Excellence 2011 Category: Resources and Mining Winner Australian Bulk Handling Awards 2011 Category: Facility of the Year
Abbot Point Coal Terminal X50 Expansion Australia The X50 expansion effectively duplicated the entire terminal, with the construction of a second rail unloading station and inloading conveyor stream to the stockyard, a stockyard expansion to more than two million tonnes storage capacity, four additional stacker/reclaimer machines, construction of a second outloading stream including a 1 700 tonne capacity surge bin, sample plant, 2.85 kilometre long jetty conveyor and shipping gallery, and construction of a second berth and ship loader capable of loading at 7 200 tonnes per hour. Aurecon was responsible for all engineering design and procurement contracts for all equipment and machines, calling of tenders and contracting of all site construction works, technical support and site supervision. We also developed all the control system software and assisted in the plant’s commissioning. Our recommended contracting strategy saved six months and produced a time– and cost-effective outcome. The Abbot Point Ship Loader No 2 has become a benchmark for future machine designs.
Joint winner Australian Bulk Handling Awards 2010 Category: Bulk Handling Facility of the Year (Resources and Infrastructure) NCIG Coal Export Terminal Australia The Newcastle Coal Infrastructure Group (NCIG), comprising a consortium of six coal companies in the Hunter Valley region, successfully tendered to the New South Wales Government to develop a greenfield coal export terminal at the Port of Newcastle. With a start up capacity of 30 Mtpa, the project was the worldâ€™s largest initial build for a coal export terminal. Aurecon, in joint venture with Hatch, provided full EPCM services for this Phase 1 development, which has been specifically designed for staged expansion from 30 Mtpa to 66 Mtpa, with further expansions possible. The USD 1 billion project was delivered six weeks ahead of schedule and within budget.
Contact us Registered office, Singapore 152 Beach Road #22-02 Gateway East Singapore 189721 T +65 6256 6188 E email@example.com Registered office, Australia Melbourne Aurecon Centre Level 8, 850 Collins Street Docklands VIC 3008 Australia T +61 3 9975 3000 E firstname.lastname@example.org Registered office, South Africa Tshwane Aurecon Centre Lynnwood Bridge Office Park 4 Daventry Street Lynnwood Manor 0081 South Africa T +27 12 427 2000 E email@example.com About Aurecon Aurecon provides engineering, management and specialist technical services for public and private sector clients globally. The group, with an office network extending across 25 countries, has been involved in projects in over 80 countries across Africa, the Americas, Asia Pacific and the Middle East and employs around 7 500 people throughout 11 industry groups. We seek to foster human achievement in all aspects of our work. Aurecon offices are located in: Angola, Australia, Botswana, China, Ethiopia, Ghana, Hong Kong, Indonesia, Lesotho, Libya, Malawi, Mozambique, Namibia, New Zealand, Nigeria, Philippines, Qatar, Singapore, South Africa, Swaziland, Tanzania, Thailand, Uganda, United Arab Emirates, Vietnam. For more information please visit www.aurecongroup.com Join us on www.facebook.com/Aurecon Follow us on www.linkedin.com/company/Aurecon Follow us on www.twitter.com/Aurecon Watch us on www.youtube.com/user/AureconGroup Aurecon South Africa (Pty) Ltd is a certified Level 3 BBBEE contributor. The Aurecon Group is made up of a number of separate legal entities operating across diverse jurisdictions. Not all those entities provide services to clients. ÂŠ2013 Aurecon V1_20130320
Abbot Point Australia