New Developments in Heavy Haul in South Africa Heavy Haul Rail Africa 2014 March 2014 W C Kuys: Project Director, TFR
Willem Kuys, TFR - New Developments in Heavy Haul in South Africa
Jan 21, 2015
Willem Kuys, Project Director at TFR delivered the presentation at the 2014 Heavy Haul Rail Africa Conference.
The Heavy Haul Rail Africa Conference 2014 covers all the relevant issues including government and resource sector perspectives on future developments in heavy haul rail infrastructure, opportunities to source relevant funding, regulatory progress, challenges in planning and construction, rolling stock requirements, maintenance and capacity enhancement.
For more information about the event, please visit: http://www.railconferences.com/hhrafricaconference
The Heavy Haul Rail Africa Conference 2014 covers all the relevant issues including government and resource sector perspectives on future developments in heavy haul rail infrastructure, opportunities to source relevant funding, regulatory progress, challenges in planning and construction, rolling stock requirements, maintenance and capacity enhancement.
For more information about the event, please visit: http://www.railconferences.com/hhrafricaconference
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New Developments in Heavy Haul in South Africa
Heavy Haul Rail Africa 2014
March 2014
W C Kuys: Project Director, TFR
2
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
8 Future Capacity Expansions
9 Heavy Haul: Concluding Remarks
3
Introduction
o Coal and Ore Lines heavy haul operations
o Lessons and technology developments
o Application of some heavy haul principles on GF
o Building blocks to support GF higher tonnages
o Concluding remarks
4
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
8 Future Capacity Expansions
9 Heavy Haul: Concluding Remarks
5
Transnet Freight Rail Network
Sishen
Saldanha
Cape Town
East London
Port Elizabeth
Hotazel
Durban
Musina
Kimberley
Lephalale Polokwane
De Aar
Richards Bay
Johannesburg
Ngqura
Core Freight Lines
Branch lines
Not active
Picked up Lines
Heavy Haul Coal Export Line
Ermelo
30t/axle 26t/axle
Heavy Haul Iron Ore Export Line
1067mm Gauge
2ND Longest Heavy Haul line in the world @ 861 km
7% of route kilometre
588 km from Mpumalanga Coalfields
6
o 60% of present Volumes generated from coal and iron ore exports
o Renewed effort to regain revenue and volumes.
o Emphasis on General freight growth that is critical for viability. Grow to 50% of total volumes
Heavy Haul Iron Ore line
Heavy Haul Coal line
General Freight
Transnet Freight Rail: Market Demand Strategy (Mt)
7
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line o Profile
o Operating Philosophy
o Technology
o Technologies embedded
o Future Challenges/Strategy
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
The Coal Line: Profile Distance +/- 580km from Blackhill to Richards Bay
Topography o Descends from 1700 meters altitude to sea level
o Undulating topography and high rainfall
Axle loads 26 t/axle on heavy haul and some feeder lines
Ruling Gradient 1:100 North of Ermelo 1:160 for loaded trains South of Ermelo on one of the two tracks, and 1:66 for empties
Traction 3kV DC: North of Ermelo 25kV AC: South of Ermelo
Civil 137 bridges, 37 tunnels Overvaal tunnel = 4 km (single)
# of lines Double, 3rd line on some feeder sections
Authorisation Colour light signalling with CTC
Locomotives o 7E/11E on AC, 10E on DC sections o 110 new AC/DC 19E in commissioning
Wagons CCL gondola: max payload of 84 tons
Gross tons per train 22 000 tons at 2,2km in length
Volumes in 2012/13 63 mt export coal, 11 mt general freight
Capacity 74 mt export coal; 14 mt general freight
Competitiveness Most affordable global coal transporter
9
Coal line: Complexity of Operations o Operating Philosophy
100 wagon trains on the feeder line ; train sets combined at Ermelo as 200 wagon trains to RBCT
Loaded coal trains are run separately from general freight trains
o Richards Bay is developing as a mega bulk port
o Coal line is becoming a multi-product bulk export line Coal export and general freight
‘systems’ evident
General freight potential in excess of 30mt
o Shifting of coal sources to Waterberg and Botswana Longer haul distance
Longer trains north of Ermelo
Interim sourcing over GF lines
Ermelo
General Freight Source Areas
Rustenburg
Lephalale
Richards Bay Coal
Source Areas
Steelpoort
Soutpansberg
Phalaborwa
Extension of the ‘pipe’ from 600km to 1200km Increase in length of haul warrants review of longer trains
10
Coal line: Major Technologies Embedded
o Increases capacity: Higher speeds & improved braking
o Improves train handling - related derailments and train breaks
o Improves turnaround time
o Increase Safety margins
o WDP being deployed
o Utilised on AD & DC powered sections or run
through
o Reduces cycle times in change over yards
o Improved energy efficiency of 18%
o Regen capability
o Increase reliability and availability of the
locomotive fleet – AC traction motors
o Freeing up of class 7E and 10E locomotive
fleet to address the GFB growth requirement
ECP/WDP
BEN
EFIT
S
New 19 AC/DC
Locomotives
11
The 19E AC/DC Locomotive
12
Coal Export line: Future Challenges/Strategy
13
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
o Profile
o Operating Philosophy
o Technologies Embedded
o Future Strategy
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
8 Future Capacity Expansions
14
Iron Ore Line: Profile
Distance 861 km
Topography Semi-desert, descending to the coast from 1 295 m above sea level at the Sishen mines.
Axle loads Operated at 30 t/axle
Ruling Gradient 1:250 loaded trains 1:100 empty trains
Traction 50kV AC
Civil Olifantsrivier Bridge
# of lines Single line with crossing loops at 40km intervals
Train Authorisation SIMS-S colour light signalling
Locomotives o Class 9E and 34 Class Diesels o Class 15 E locomotives being commissioned
Wagons CR type: max payload of 100 tons
Gross tons per train 41 000 tons @ 4km train length
Volumes in 2010/11 55 mt export iron ore, 1 mt general freight
Capacity 60 mt infrastructure capacity
Competitiveness Longest heavy haul production trains in the world
15
Iron Ore Line: Operating Philosophy
To Saldanha Steel
KUMBA/ASSMANG/BURK/Small loaders Loading Stations
Port Terminals Tippler, Stacking/
Reclaiming
Port Terminals Reclaiming & Ship Loading
SALKOR Compiling/De-compiling trains, Shunting, NTG, Wagon & Locomotive maintenance
Rail operations Train operations, Crews, Traffic Control, Per way, Communication, Signalling, Power supply, Infrastructure- and Rolling Stock maintenance Haul distance of 860 km
Beeshoek
New Kolomela
link ERTS
Khumani
National Ports Authority Berth capacity, Berths,
Marine services
Halfweg – Re- manning of trains Crew book off
342 wagon RDP Trains – total mass 41 000 tons 114 wagon rakes – total mass 13 667 tons
System 1: Mines System 2: Rail System 3: Stockpile System 4: Ship-loading
1 2
4 3
16
Iron Ore Line: Technologies Embedded
o DP (RDP) Longest operational trains in the world RDP – Quickly implementation on new routes
o DP with mixed locomotive fleet 9E electric locomotives
Old Class 34 diesel locomotives
New 15E electric locomotives
New Class 43 diesel locomotives
Complex: Non homogeneous tractive effort
o Train dynamics Long train over various grades
Complements: Technical team AND Train Drivers
Train over various grades
17
0
1
2
3
4
5
6
7
8
9
1 6 11 16 21 26 31 36 41 46 51 56 61 66 71
Gradient
Gradient
18
Iron Ore Line: Technologies Embedded
o DP (RDP) Longest operational trains in the world RDP – Quickly implementation on new routes
o DP with mixed locomotive fleet 9E electric locomotives
Old Class 34 diesel locomotives
New 15E electric locomotives
New Class 43 diesel locomotives
Complex: Non homogeneous tractive effort
o Train dynamics Long train over various grades
Complements: Technical team AND Train Drivers
o Energy efficient locomotives Power Factor close to 1 - 18 % energy saving
Regen capability of locomotives – 20% to 30% of trip power returned to grid
o AC traction motors Maintenance
Adhesion
Minimal overheating at low speeds
o Supporting infrastructure
19
Iron Ore Line: Supporting Infrastructure
Wayside Monitoring o VIS Vehicle Identification System o Hot Box Detector o Dragging Equipment Detectors o Wheel Impact Monitoring System o Wheel profile monitoring system o Skew bogie detector o BAM- Bearing Acoustic Measuring System for wheels
o WILMA - Wayside Intelligent Long-stress Management system. o UBRD – Ultrasonic Brocken Rail Detector system
Signalling
o Electronic interlocking
o Saldanha CTC via microwave communication/fibre
Telecommunications Telecommunication system is being upgraded to TCS-R and GSM train communication Constrained by SKA (Square Kilometer Array radio telescope)
20
342 Wagon RDP Train
End of train @ 4 kilometres
21
Iron Ore Line: Future Strategy
o Upgrading of capacity on the Ore line is crucial
for:
the development of the mineral rich Northern
Cape
Retaining a competitive export channel
Supporting sustainable development of
emerging and junior miners
o Expansion Challenges for Ore Line Electric Traction Power Incremental infrastructure steps high GF Traffic
o Expansion of the corridor to 82mt of iron ore
being investigated Third tippler in Saldanha Port
Additional infrastructure capacity – GF Trains
Present Port capacity 58 mtpa – Major expansion required
Sishen
Saldanha
22
Salkor Office block
Ore Yard
General freight yard
Work-shops
Port of Saldanha Ship Loader
Saldanha: Infrastructure
23
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
8 Future Capacity Expansions
9 Heavy Haul: Concluding Remarks
24
Challenge: Apply HH Technology on GF
o Options to increase rail capacity are: Increase train speeds
Increase axle loads of wagons
Increase the train lengths
Additional crossing loops to run more trains at shorter intervals
Clever signalling to increase slot utilisation
o Longer trains the most attractive in the short term Long hauls
Set-up time
Terminals and yards
Incremental roll-out
Short hauls
25
Challenge: Apply HH Technology on GF
o Distributed Power Long trains – Joining short trains
One crew
RDP and ECP/WDP - Both technologies operational in TFR
o Modern locomotives opens new opportunities Energy savings – Efficient and regen
Maintenance & reliability – Better scheduled railway
Better adhesion – Creep over steep hills
Locomotives must work hard!
o Simulations Operations
Yards
Look into the future
Assume a scheduled railway
26
Operational Slot Design
o Empiric rule: Practical train plan only 66% of maximum slots o 34% for Catch-up/Recovery and
Infrastructure maintenance
o Recovery implies bunching: Power peaks Terminal block-out
Less maintenance time
Slots
27
Operational Slot Design
o Empiric rule: Practical train plan only 66% of maximum slots o 34% for Catch-up/Recovery and
Infrastructure maintenance
o Recovery implies bunching: Power peaks Terminal block-out
Less maintenance time
Slots
o Integrate the following requirements:
Balanced operations
Operational efficiency – Old unreliable equipment
Infrastructure Maintenance – Accommodate special requirements
Character of line – Long single line/Double line
Capacity level of line – Construction requirements before capacity
increase
o Do not steal slots! Deny maintenance justifiable time on track
Operational
Designs
28
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
o Manganese Corridor
o Waterberg Corridor
7 Processes to be developed
8 Future Capacity Expansions
9 Heavy Haul: Concluding Remarks
29
Development of the Manganese Corridor
o Manganese presently being exported from the Northern Cape to Port Elizabeth with 104 wagon GF trains at 20 ton per axle
o This corridor is being developed using heavy haul principles to:
Expand capacity to 16mtpa
Retain the exports in the Eastern Cape with economic benefits for Ngqura
harbor and the Coega IDZ
The manganese channel investment allows TFR to:
Diversify overall network investment;
Densify this critical GF corridor, and
The flexibility to utilise rolling stock elsewhere in commodity downturns
8
4 x 104 (1:80)
22 19 16
4 x 183 (1:80)
4 x 246 (1:100)
4 x 200 (1:80)
4 x 216 (1:100)
Million tons per annum
Op=
ons Develop
men
t
20 ta
l 26 ta
l
Manganese Corridor: Volume Ramp-up Strategy
• Optimal (overall system cost) short term ramp-up in line with demand is 16Mtpa with logical capacity
breakpoints at 8 and 16Mtpa
• Significant capital cost increase beyond 19Mtpa due to Eskom upgrade
• Concurrent conversion of corridor to 26t/axle through sustaining capex will allow future operation of
integrated heavy haul system
Train configura>on Development path
Manganese Corridor: Systems Solution
Mamathwane Compila>on Yard
Coega Compila>on Yard
100 wagons
100 wagons
200 wagon
trains
Operating Philosophy
• 16Mtpa solution based on heavy
haul principles (long trains and
operations)
• 200 wagon + 9 dual voltage loco
RDP trains between compilation
yards
• 100 wagon unit train distribution
to mines and tippler yard with
diesel locos
• Main line & distribution operated
by TFR
• 4 x 200 wagon trains / day, 350
days/annum
32
Development of the Waterberg Corridor
o Augment coal for the Witbank basin Eskom coal requirements for power stations
Domestic coal
Export coal
o Long Term: New heavy haul line Lephalale-Thabazimbi-Ermelo Long new line, 558km
All or nothing
o Interim: Develop existing line to 25mtpa Schedule & Costs
33
Development of the Waterberg Corridor
o Augment coal for the Witbank basin
o Long Term: New heavy haul line Lephalale-Thabazimbi-Ermelo
o Interim: Develop existing line to 25mtpa
o Thinking: Long DP trains on existing GF line – 200 wagons
Incremental development – 3 short trains, 3 long trains, 6 long trains
Technologies DP – ECP/WDP (Mixed locomotives, later all electric)
AC/DC locomotives – Run through AC/DC sections
DP train know how
Challenges
Traction Power
Gradients
Compiling and splitting of 200 wagon trains
o Processes to develop
Lephalale (Ellisras)
Atlanta
Matlabas
Thabazimbi
Pendoring Pyramid Pyramid South
Ogies
Witbank Greenview
Vaalwater
Springs Welgedag
Trichardt
Modimolle (Nylstroom) Naboomspruit
Rustenburg
Polokwane
Roossenekal
Belfast Boshoek
Steelpoort
Groenbult
Blackhill
Gaborone
Wonderfontein
Hamelfontein ERMELO
Bela-Bela (Warmbaths)
BOTSWANA RSA Maha
lapye
34
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
8 Future Capacity Expansions
9 Heavy Haul: Concluding Remarks
35
Processes to be Development for long GF DP trains
o Longer trains on existing GF infrastructure is the future to successfully enhance volumes at reasonable costs.
o Long trains work well over long haul distances
The set-up time to compile and decompile long DP trains
Dual voltage electric locomotives increases haul distances.
Diesel powered trains
Mixed traction (Dual voltage locomotives combination with diesel locomotives)
o The OHTE power supply a constraint with all electric powered long heavy DP trains
o The key lever in running long trains is the DP technology. DP trains the platform to
launch long trains in GF
o Five supporting sub-processes to be develop and refine to enhance the efficiency of
long DP trains
36
Five Processes to Develop
1. On the Fly AC/DC changeover points
The On the Fly AC/DC changeover points to be tested soon.
The AC/DC technology on 19E locomotives will then also be tested thoroughly.
2. Compiling and Decompiling DP trains
Presently DP trains are compiled and decompiled in a yards
Develop processes to couple/split DP train outside yards on a single loop
Reduce setup time and yard infrastructure
3. Brake Test Requirements
Reducing the brake test time of coupling and splitting DP trains to less than 10 minutes.
Do not compromise safety
4. Crawling of trains over steep inclines
Negotiate trains over inclines at less than the balancing speed of the locomotives.
Especially possible with locomotives fitted with AC traction motors with higher adhesion levels
5. Telemeters for DP Trains
Telemeters required for all trains
Develop a telemeter that is attached on the last wagon, but not fitted on the buffer.
Join and split DP trains without removing the telemeter.
37
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
8 Future Capacity Expansions
9 Heavy Haul: Concluding Remarks
Saldanha
Cape Town
East London
Durban
Richards Bay
De Aar
Ngqura
Botswana
Zimbabwe
Namibia
Maputo
Swaziland
Mozambique
Future Developments
• Due to the interfaces and dependencies, work packages need to be progressed within a holistic Coal Strategy.
Coal Backbone
Swazi link
Techobanine
23
4
1
SA-Botswana link
1 2 3 4
Central Basin Waterberg Fields Botswana South Fields Soutpansberg/ Limpopo
Lephalale
Ermelo
List Projects Waterberg Upgrade existing line
New heavy haul
Manganese
Ore Line 82mtpa
Maputo link Coal 81/91mtpa
39
Presentation Outline
1 Introduction
2 Heavy Haul in South Africa: Context
3 The Richards Bay Coal Export line
4 The Sishen – Saldanha Iron Ore Export line
5 Challenge: Apply HH Technology on GF Lines
6 Practical Application of HH Technology in GF
7 Processes to be developed
8 Future Capacity Expansions
9 Heavy Haul: Concluding Remarks
40
Concluding Remarks
o Heavy Haul operations provides a commercial, competitive advantage in economies with vast mineral resources
o Heavy haul operations in South Africa are at the cutting edge of technology on a 1067mm gauge rail system
o The heavy haul technologies and heavy haul principles can be implemented in GF to:
Enhance MDS volumes
Develop GF corridors in semi-heavy haul operations
o Five processes must be further developed for the flexible implementation of long trains on GF lines
o Operational staff to be developed to operate these sophisticated system
Thank You
42
43
Ore line: 1:250
Mn: 1:80
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