Dalrymple Bay Terminal (DBT), located in Queensland, Australia, ranks as one of the world’s three largest coal export facilities. The coal is brought by train from mines in the Central Bowen Basin area and is loaded onto bulk carrier vessels for transportation to the world markets.
Conveyors play a central part in coal handling at the terminal. Each conveyor pulley is powered by one or two motors mounted at the ends of the pulley shaft. Fluid couplings are used for starting. ABB has supplied a number of AXR HV rib cooled induction motors for the conveyors, with powers ranging from 560 to 840 kW and a voltage rating of 3.3 kV. The latest motors to be delivered have an IE4 super premium efficiency’ rating – following publication of a new efficiency standard – and could well be the first HV IE4 motors installed anywhere in Australia.
IE4 efficiency supports sustainability
“We are very pleased to pioneer the use of IE4 HV motors in Australia,” says Eric Doumergue, Maintenance Manager of Dalrymple Bay Coal Terminal Pty Ltd (DBCT P/L). “Highly efficient motors use less energy, which means reduced carbon dioxide emissions. This is a great fit with our corporate sustainability strategy – we operate within the Great Barrier Reef World Heritage Area, and we take our responsibility to protect the environment very seriously.”
“Efficiency classes are very new for high voltage motors – they were introduced through an IEC standard published in February 2024,” explains Rory Paltridge, Local Division Manager – Motors, of ABB in Australia. “The new standard means we now have a set of globally harmonized efficiency classes for HV motors, and motors will show the rated efficiency value and class on their rating plate. This will make it easy for customers to select the high-efficiency products they need to reduce their energy consumption, operation costs, and carbon footprint.”
The new IEC standard, 60034-30-3, defines four efficiency classes from IE1 up to IE4. It covers HV induction motors rated up to 2 MW and 11 kV for direct-on-line connection. ABB has long been committed to helping customers maximize the efficiency of motor-driven applications, and a review of motors supplied during 2023 showed that more than 95% of relevant HV motors already complied with IE4, the highest efficiency class under the new standard.
Flexibility and reliability
In addition to providing IE4 efficiency, AXR rib cooled motors are engineered to order (ETO) and offer great flexibility. The main terminal box can be mounted on either the left or right side, or at either end. DBCT P/L utilizes this feature to change the placement of the terminal box, so motors can be installed on either side of the conveyor. As a result, they have been able to reduce the number of spare motors they keep in stock.
“Our AXR motors also have a good track record for reliability, thanks to their rigid frame and stable running temperatures,” Rory Paltridge adds. “Reliability is essential in an operation that runs 24/7, like DBT. The motors’ high reliability and an on-site stock of spare units that can be quickly modified for installation minimize unscheduled downtime, helping ensure that vessels are loaded on time.”
DBT is located around 40 km south of Mackay on the Queensland coast. It has been in operation since 1983 and has a nameplate capacity of 85 million tonnes per year. As a major facility for the export of metallurgical coal, it is an important element in the global steel supply chain. DBCT P/L holds the operating and maintenance contract on the terminal.
For more information on IEC Standard 60034-30-3 and ABB HV motors, click here.
