Mining the Pilbara Presentation by Paul Toussaint-Jackson

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FLOATING DECK SOLUTIONS FOR CONVENTIONAL INFRASTRUCTURE CONSTRAINTS

AFD provides innovative maritime logistics solutions based on flexible, lightweight

and rapidly constructed infrastructure that is safe, robust and can be used for the

long-term. Our solutions are highly competitive in terms of both construction time

and cost compared to traditional infrastructure. Each solution is carefully tailored

for the client to complement core client business objectives. Our solutions are

systems that can be readily extended into landside logistics.

AFD can assist with the development of complete deal structures for the

establishment of the installations including regulatory approval, contract design,

contractor management, operations design, site management and financing. AFD

is uniquely placed to design deal structures that provide excellent return for

private proponents yet complement public policy objectives.

AFD has a contract with the new Pilbara Ports Authority for the facilitation of two

projects and is undertaking logistics infrastructure design work for clients in

Australia and overseas.

Australian Floating Decks

• Easily and rapidly scalar to suit developing trade;

• Uses shallow bathymetry (for the FDTS) as an asset rather than an obstacle: no

dredging is required. These facilities have minimal environmental impact;

• Rapidly constructed in a far shorter timeframe than conventional infrastructure;

• Far lower capital cost than conventional infrastructure of equivalent capability;

• Highly robust, safe and flexible and be highly suitable for use in cyclone prone areas;

• Readily handled by existing port services and operations;

• Completely privately funded but provide good revenue returns to the State, legacy

assets for the State and retain key controls for the State over the land or seabed

through lease/license instruments;

• Open access for general custom and have Customs and AQIS approved facilities.

• All types of project cargo handled including multi-thousand tonne pre-assembled

modules;

AFD Floating Deck System Design Elements

• The DFD (Dampier Floating Deck) and FDTS (Floating Deck Trans-shipment System)

are two projects that I have designed and developed on behalf of the Port of Dampier to

improve critical supply chain constraints affecting both the Port and the Pilbara region in

general.

• These projects are intended have the maximum trade facilitation impact at a fraction of

the cost of conventional infrastructure and with much shorter development times.

• The DFD I conceived as a forward floating supply base function to directly assist the

logistics of supplying offshore oil and gas platforms out of Dampier.

• The FDTS I designed as a land-backed facility with a moving floating deck that will allow

genuine international liner cargo shipping services to call at Dampier for the first time.

• Both the FDTS and DFD are designed as logistics systems rather than simple

infrastructure solutions and are highly adaptable including inwards supply for mine and

port construction and as platforms for conveyors and export facilities.

• These projects are game changers for logistics into the Northwest and are expected to

do much to fundamentally address some of the core logistics productivity issues we

have in that very important region for the Australian economy.

Case Study: New Floating Deck Projects for Dampier

Current logistics constraints • The Port of Dampier is one of the world’s largest bulk export ports and has excellent

private facilities for the export of LNG, condensate, iron ore and salt. These facilities are

profit-driven and fit for purpose.

• The principal import facility however, the Dampier Cargo Wharf (DCW), requires

expanded capacity to cope with the growth in trade. Congestion causes delays and

demurrage costs for project vessels, additional costs to projects and reinforces the use

of inefficient long-distance road-haul services to our region for large oversize and out of

gauge project cargo.

• In 2011 I undertook a study to find a solution to not only the constraints of the DCW

facility but also the wider logistics productivity issue for the Pilbara.

• From this study I identified two critical supply chains that conflict at Dampier:

- Critical Supply Chain 1 – The high cycle marine services supply to offshore oil and

gas installations; and,

- Critical Supply Chain 2 – The inwards industrial supply chain including mine supply.

• Both of these supply chains rely heavily on access to the DCW.

• Finally I recognised the advantages of enabling direct call international liner services.

GENERAL CARGO

VESSELS CAN BE

ALONGSIDE FOR A

WEEK TO SUIT CRANE

TO TRUCK

OPERATIONS

OFFSHORE SUPPLY

VESSELS NEED

RAPID CYCLE ACCESS

TO THE DCW.

THE DCW : DUE TO

WIDTH AND SWL LIMITS

CARGO CANNOT BE

STACKED ON THE WHARF

BUT MUST BE WORKED

TO TRUCK

• Critical Supply Chain 1 (high cycle offshore support) is constrained because its

vessels need frequent and ready access to the DCW. The development of trade

requires further berths: a general cargo vessel can occupy the existing western berths

for up to a week.

• Critical Supply Chain 2 (Inwards industrial supply) is constrained because the

development of trade requires further berths: project or general cargo exchange

requires extra time due to the need to work crane to truck.

• Both supply chains do not have stacking and handling areas available within the port

gates and must rely on private sites located elsewhere. Available land for private use in

the general port environs for cargo facilitation is in limited supply and in high demand.

The DCW cargo operations are therefore impacted by varying truck cartage cycle times,

the number of available trucks and the additional time required to stevedore oversize

and out of gauge cargo.

• By removing the constraints to both critical supply chains I realised that regular

internationally networked cargo liner shipping services to the Pilbara could be facilitated.

This would allow re-work of current supply networks through Eastern and Southern main

ports and reduce an over reliance on long-distance road-haul. To get genuine liner

services to call at the port would however require a complete re-think on infrastructure.

Legend

Current rail haul

Current road haul

East Coast liner route

Optional road haul

New West Coast liner options

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4

4

12

3

4

5

2

3

Currently China to Pilbara

supply chain takes 31 days

(red route)

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6

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FDTS supports China to

Pilbara supply chain of just

9 days 2

FDTS provides a general cargo

terminal function at Dampier

supporting the development of

new liner services.

DFD 3500 m2

25 tonnes/m2

2 x 100m berths

Drilling mud

Fuel

Fresh water

All hydraulic

Lateral movement <100mm

Demobilisation < 1 hour

• Directly addresses berth constraints for both OSV and general freight

and project tonnage into the Pilbara;

• Creates forward ‘supply base’ function to facilitate the service supply

chain for the oil and gas industry and to enable its re-design reducing

pressure on land close to the Port;

• Reduces cost to the oil and gas industry by improving cycle times for

OSVs and reducing overall charter requirements.

DFD: solution for critical supply chain 1

FDTS 3500 m2 floating decks

15000 tonne cargo dwt

Land-backed terminal

AQIS wash-down

Customs licensed

FDTS: the ‘shock absorber’ Trans-shipment in sheltered port anchorage

RORO or LOLO exchange

Deep water allows port access by large cargo liners

At Dampier floating deck will take 1.5 hours to shore

FDTS – The Logistics Game Changer

Enables for the first time a pure cargo liner service to operate to the Pilbara by acting as

a logistics ‘shock absorber’ thereby removing all current constraints to liner services.

Is ideally suited to a global RORO break-bulk service enabling realignment of major

industrial supply chains. This can include mine establishment, support and major

construction works such as the construction of wharves and loaders;

Has national supply chain ramifications including reducing supply chain times from

China by up to 70%;

Facilitates LOLO operations and relieves spot-chartered general cargo vessel

congestion;

Facilitates cold supply chain into the Pilbara;

Reduces oversize vehicle movements on the North West Coastal Highway;

Improves the economics and prospects for coastal shipping services.

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DFD and FDTS for Dampier 2014

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Dreams into reality

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First cargo handled 6 months after major

construction commenced

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Floating decks can work with high point loads, shear forces and

bending moments

Giant floating deck under construction in a foreign yard

FDTS Floating Deck Cargo Area Capacity

Sample cargo area capacity (theoretical tight stow only) based on 110m x 38m floating

deck (4180 m2 of useable area).

CAT 797 Mining Haul Trucks Largest

mechanical haul trucks in the world

(400 tonne payload)

CAT D9 Tractors

48.8 tonnes

TEU Sea Containers triple stacked or

560 double stacked Hammersley Iron Ore Rail Wagons

OR

OR

28 114

144 700+

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Floating decks de-mobilised to sheltered cyclone moorings

Floating Deck Systems: new RTP model

AFD has developed a new model for ore concentrate handling;

This is a fully self-contained floating base with an optional stockpile capability of up to

10000 tonnes;

Contains bulk fuel supply, maintenance workshops and amenities;

Berth space for up to 4 x 5000 tonne ore barges;

Rota box or bulk ship loader optional;

‘Pack away’ – can be demobilised in under an hour;

Can operate in bathymetry as shallow as 4 metres;

Far lower capital costs compared to conventional infrastructure;

Suitable for operations in cyclone prone areas

Floating Deck Systems – applications

Coastal topography, meteorological and environmental conditions need to be carefully

assessed for each new development;

The real solution for each site is not as infrastructure alone but as a logistics system if

the full value of the installation is to be realised.

The many attributes of these systems including lower capital cost make them attractive

to the private sector.

The systems are designed to be complementary to traditional infrastructure and can be

applied to developed ports or greenfield sites.

Low environmental impact makes the systems ideal for environmentally sensitive sites.

Floating Decks – stability, flexibility, strength

The floating decks are very stable allowing structure of very large weight and weight to

be located on an otherwise very shallow draught platform. This can include loaders and

conveyors in various forms, stockpiles, workshops and berth space;

The floating decks can be easily modularised to create greater working area;

Floating decks allow shallow bathymetry to be used as an opportunity rather than as a

problem – they can be used to bridge to deeper water either as a static or moving

installation;

The simplicity of floating deck installations makes them easy to work within the normal

colour and movement of a port;

Floating decks can be easily fit to simple shore-side construction to provide the option of

legacy (shore land) assets that may be important in achieving permission from the State.

The Floating decks can be readily transferred to other sites or sold.

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FDTS first stage development –

Dampier, WA

Thank you