Automated stockyard

system cuts
operational costs

CASE: BlueScope Steel Limited, Australia

FLSmidth BulkExpert technology provides unmanned and
optimised operation of dry bulk equipment.
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BlueScope Steel
virtually doubles
reclaiming throughput
Unique combination
of a 3D laser scanning
system and dedicated
RTK GNSS receivers
provides real-time,
full terrain stockyard
information.
Early phase overview picture
of the raw materials stockyard
BulkExpertTM Unmanned Control.
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The background
BlueScope Steel Limited is one of two steel mills located in
Australia. It operates one blast furnace and supplies steel
products mainly to the Australian market. For iron ore
and additives for steel production, the company operates
a primary stockyard for ship unloading and a secondary
stockyard for material blending and sorting. These compact,
high-utilisation stockyards are equipped with three ship
unloaders and two bucket-wheel stacker/reclaimers, which
were commissioned in the 1970s and converted in 2014
from relay control to PLC.
The objective
BlueScope wanted a stockyard automation solution to cut
operational costs, maximise stockyard area utilisation and
boost reclaiming throughput.
Defining the project
FLSmidth performed an initial feasibility study. From which
BlueScope looked into other alternatives, but concluded
that FLSmidths patented technology was superior, chiefly
because it allows for fully automated unmanned operation
and provides constantly updated real-time stockyard
inventory information. The FLSmidth solution also offered
custom site-specific stacking patterns and the ability to
perform in-stockyard blending by operating two reclaimers
on the same conveyor. Additionally, simulation capability
would allow BlueScope to predict precisely how upcoming
bulk deliveries could be stacked and reclaimed.
The solution
The stockyards two stacker/reclaimers were equipped
FLSmidths BulkExpert unmanned control system, consisting
of high-precision RTK GPS receivers and 3D laser scanners,
which were ideal to meet the compact stockyards need for
greater accuracy.
Rapid delivery was part of the package. The order was
placed in January 2014. Working together with BlueScope,
FLSmidth completed installation within two months; the
system was operational in October and performance tests
were conducted successfully in November.
Challenges
In addition to meeting the main project goals of cutting
operational costs and maximising available space and
throughput in a compact stockyard, the FLSmidth and
BlueScope teams worked closely together to identify and
meet on-site challenges that arose in the course of the
project. For example, a supply road had to be factored
into the automated system design to ensure that one of
the stacker/reclaimers did not intrude upon road traffic.
In addition, while implementing the system, FLSmidth
and BlueScope teams realised and corrected the fact
that the stacker/reclaimer buckets were subject to an
excessive amount of carry back and material spillage.
Inspection of raw materials stockyard
while Stacker/reclaimer is positioning
itself getting ready for the new order
scheduled from the Central Control.

Using this system, only one central-control-room operator

is required to control a complete stockyard. The system
complements the conventional PLC control on the stacker/
reclaimer with an additional dedicated industrial control
computer that continuously executes advanced mathematical
algorithms to calculate operating commands for the stacker/
reclaimers. This enables BlueScope not only to operate the
machines in an unmanned mode, but also to achieve the
highest possible utilisation of machines and stockyard area
with centimetre-level accuracy and efficiency far beyond the
capability of a human stacker/reclaimer operator.

The BulkExpert solution also includes a collision avoidance

safety component. Every moving piece of equipment including
three ship-unloaders is fitted with a GPS receiver, so the system
can automatically alert the central operator if machines are
within the vicinity of outer-limit operations and perform a
machine shutdown if there is danger of collision.
Results
The BulkExpert system has nearly doubled reclaiming
throughput for BlueScope, from 10-12,000 to 19,000 tpd,
a very difficult rate to reach with human operators or
conventional PLC automation solutions.

The system uses advanced mathematical modelling to predict

the stacking pattern, which not only ensures maximum
pile footprint utilisation but it also contributes to a reduced
material segregation. Furthermore, the stable reclaiming feed
improves the quality of material fed through the mill and
makes it easier to achieve precise blending from different
stacks by following a desired blending ratio more accurately
than would be possible using an operator. The system
reduces flow rate variances by more than 40%, which for Stacker/Reclaimer working in close vicinity of the Grab
the first time enables the two machines to work together unloader. Stacker/Reclaimer operation is made safer by
to create the ideal blending result on the outgoing belt. removing the onboard operator.

Much of the existing hardware was revitalised, many of

which were more than 30 years old. Space utilisation and
operational efficiency have been improved by the systems
simulation capability, which significantly improved planning,
WITH STACKER/RECLAIMER
allowing management to plan days ahead and decide exactly
how incoming material will be stacked and reclaimed. AUTOMATION AND ANTI-COLLISION
Efficiency and safety have also been increased because the SYSTEMS, WE CAN INCREASE
unmanned BulkExpert system allows stockyard machinery THROUGHPUT AND STILL ACHIEVE
to operate consistently close to operational limits without SAFE MACHINE INTERACTION
exceeding them. The system has also significantly reduced
maintenance costs by reducing machine movements. Derek Sheppard
All of which is expected to add up to a full ROI within Ore Preparation Maintenance and
two years. Asset Development Manager

M 05-16 800-166-LANG V1

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brochure are for general reference only and may change at any time. www.flsmidth.com/bulkexpert